Composite aerosol-generating materials

Abstract

A composite aerosol-generating material (530) comprising two sheets of carrier material (522A, 522B) with a gel (544) disposed therebetween. A method and apparatus for producing a composite aerosol-generating material (530) comprising a gel (544) disposed between two sheets of carrier material (522A, 522B). The gel (544) may carry an aerosol-generating substance, such as nicotine.

Description

[Technical Field]

[0001] The present disclosure relates to composite aerosol-generating materials, methods for manufacturing such composite aerosol-generating materials, and apparatuses for such manufacturing. Additionally, the present disclosure relates to aerosol-generating rods comprising composite aerosol-generating materials, methods for manufacturing such rods, and apparatuses for manufacturing such rods. The aerosol-generating rods may be for use in aerosol-generating articles. The aerosol-generating articles may be for use with aerosol-generating devices. The present disclosure particularly, but not exclusively, relates to applications in sandwich configurations of a gel between aerosol-generating materials or carrier materials. The gel preferably includes an active agent, such as a flavorant, a humectant, a plasticizer, or nicotine. The gel preferably includes a combination of active agents. [Background technology]

[0002] To manufacture an aerosol-generating rod, the procedure typically involves the following steps: A flat sheet of aerosol-generating material is unwound from a bobbin of aerosol-generating material. The aerosol-generating material is then typically sprayed with a liquid or powder ingredient, such as glycerin or flavor. Finally, the aerosol-generating material is pulled through a funnel-shaped device that collects the sheet into a continuous cylindrical rod of the desired diameter. The continuous rod is wound and cut to the desired length before being combined with other rods in a line to form the aerosol-generating article.

[0003] However, spraying a liquid or powder component onto a sheet can lead to certain drawbacks: for example, in a spraying process, typically only a portion of the material is sprayed and fixed onto the sheet of aerosol-generating material.

[0004] It would therefore be desirable to provide improved application of flavors and other ingredients that overcome these drawbacks. It would also be desirable to provide an aerosol-generating material for use in an aerosol-generating rod, and to provide an apparatus and method for producing the aerosol-generating material that reduces the amount of ingredients that are wasted, thereby reducing production costs and saving time by reducing the amount of cleaning required. Summary of the Invention

[0005] According to one aspect of the present invention, - providing a first continuous sheet of carrier material; - dispensing a gel onto a surface of a first continuous sheet of carrier material; - providing a second continuous sheet of carrier material and positioning the second continuous sheet of carrier material against the gel to form a composite material having the gel disposed between the first continuous sheet of carrier material and the second continuous sheet of carrier material; - Further provided is a method for producing a composite aerosol-generating material, comprising the step of dispensing a greater amount of gel into a central region proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel dispensed into lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material.

[0006] According to another aspect of the present invention, - a sheet of a first carrier material; - a sheet of a second carrier material; - a gel disposed between a first sheet of carrier material and a second sheet of carrier material, with a greater amount of gel disposed in a central region proximal to the longitudinal axis of the first continuous sheet of carrier material than in lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material.

[0007] The composite aerosol-generating material of the present invention may be suitable for use in an aerosol-generating rod, or aerosol-generating article. In some embodiments, the composite aerosol-generating material is for use in an aerosol-generating rod.

[0008] The present invention provides a method for producing a composite aerosol-generating material for use in an aerosol-generating rod, comprising the steps of providing a first continuous sheet of carrier material, dispensing a gel onto a surface of the first continuous sheet of carrier material, and providing a second continuous sheet of carrier material and positioning the second continuous sheet of carrier material against the gel to form a composite material having the gel disposed between the first continuous sheet of carrier material and the second continuous sheet of carrier material. The precise positioning of the first continuous sheet and the second continuous sheet of carrier material allows for consistent production of the composite aerosol-generating material.

[0009] The method for manufacturing a composite aerosol-generating material preferably further includes a crimping step. This can be crimping the first continuous sheet of carrier material, the second continuous sheet of carrier material, or both the first and second continuous sheets of carrier material. The crimping facilitates fabrication by facilitating assembly of the sheet in subsequent fabrication steps, since the crimping action weakens the elasticity of the sheet of carrier material and provides multiple ridges and corrugations on the sheet. The ridges and corrugations are regularly distributed at predetermined locations and extend substantially the entire length of the sheet. Thus, the crimping helps to assemble the sheet in a more defined manner. Additionally, the crimping also allows a greater amount of sheet material to be pulled through a funnel-shaped device to form an aerosol-generating rod, compared to an uncrimped sheet. Furthermore, the crimping helps to create a uniform distribution of flow channels and maintain the flow channels by weakening the elasticity of the sheet of aerosol-generating material. The crimping rate and the size and pattern of the grooves or indentations can vary. Thus, a large number of different aerosol flow conditions can be generated for specific desired draw resistance characteristics. The crimping step is preferably performed before dispensing the gel onto the first continuous sheet of carrier material or onto a surface portion of the first continuous sheet of carrier material. Crimping before dispensing the gel facilitates manufacturing rather than crimping after dispensing the gel. This helps prevent the gel from being squeezed during crimping, thus reducing the risk of the gel coming into contact with manufacturing equipment. Crimping before dispensing also advantageously allows for crimping only one of the sheets of first or second carrier material, instead of crimping a composite aerosol-generating material comprising at least two sheets of carrier material.

[0010] In certain embodiments, the method for producing a composite aerosol-generating material further includes providing a first continuous sheet of carrier material and a second continuous sheet of carrier material from respective sources of different carrier materials. Having the first continuous sheet of carrier material and the second continuous sheet of carrier material from different sources of carrier material, or being different carrier materials, allows for the use of a large number of different materials and combinations of different carrier materials. Thus, a variety of different composite aerosol-generating materials with different carrier materials or combinations of aerosol-generating materials (or both different carrier materials and aerosol-generating materials) deliver a large number of different aerosols.

[0011] In certain embodiments, the method of manufacturing a composite aerosol-generating material further includes providing both the first continuous sheet of carrier material and the second continuous sheet of carrier material from a single source of carrier material, which can simplify the manufacturing process by having only one source of carrier material for producing the first continuous sheet of carrier material and the second continuous sheet of carrier material.

[0012] In certain embodiments, the method for producing a composite aerosol-generating material further includes folding a single continuous source sheet of carrier material to form both the first continuous sheet of carrier material and the second continuous sheet of carrier material, such that the first continuous sheet of carrier material and the second continuous sheet of carrier material are integral with each other via a fold. Folding the source sheet of carrier material to form the first continuous sheet of carrier material and the second continuous sheet of carrier material allows for ease of manufacture and efficient use of the material. It also prevents dispensed gel from being squeezed to one side.

[0013] Folding the sheet of source support material can be by any suitable means known in the art, including the use of a guide. Certain embodiments include folding the sheet of source support material using a guide. In certain embodiments, the guides used in the present invention can be roller-type guides, such as directional rollers, or positioning rollers, or static curved guides, or any combination of the types of guides described. Movement of the sheet of source support material toward the folding means causes the sheet of source support material to bend onto itself until the folding process is complete, with one side section of the continuous sheet of support material completely folded upward and in contact with the gel already dispensed onto the other side section of the sheet of source support material.

[0014] In certain embodiments, the method for producing a composite aerosol-generating material further includes cutting a continuous single source sheet of carrier material to form both a first continuous sheet of carrier material and a second continuous sheet of carrier material. Cutting the source sheet of carrier material to form the first continuous sheet of carrier material and the second continuous sheet of carrier material ensures that the materials of the first continuous sheet of carrier material and the second continuous sheet of carrier material are the same, for example, with respect to composition or thickness. Furthermore, providing both sheets of carrier material from a single source ensures that the material properties of the first continuous sheet of carrier material and the second continuous sheet of carrier material are consistent.

[0015] Typically, the width of the carrier material to be cut may range from 5 centimeters to 50 centimeters wide, preferably from about 20 to 40 centimeters wide, and more preferably about 25 centimeters wide.

[0016] The cutting of the sheet of source support material is typically performed using a cutting means, such as one or more of a cutter, knife, blade, or saw, or a jigsaw-type cutter, or a circular knife, to cleanly cut the sheet of source support material and form both a first continuous sheet of support material and a second continuous sheet of support material. The cutting blade is typically directed toward the approaching source support material. Typically, the cutting means is an in-line system, cutting the source support material into two sections along the longitudinal axis of the sheet of source support material, but this is not necessarily the case. The cutting means may cut the source support material into three or more sections depending on requirements. The first continuous sheet of support material and the second continuous sheet of support material are formed separately. In embodiments in which the second continuous sheet of support material is positioned in contact with the gel, guiding and conveying means are required to position the second continuous sheet of support material at the desired location, ideally above the gel already dispensed on the first continuous sheet of support material. In this way, the gel is embedded in a sandwich configuration between the two continuous sheets of support material. Typically, the first continuous sheet of carrier material formed from cutting the carrier material continues in the same or similar path or direction as the cut carrier material. The second continuous sheet of carrier material is guided by a guide means so as to be positioned in contact with the gel dispensed onto the first continuous sheet of carrier material. The sheet of carrier material is preferably cut longitudinally in the sheet transport direction before the gel is dispensed onto the first continuous sheet of carrier material. Cutting the sheet of source carrier material before dispensing the gel reduces the risk of the gel coming into contact with the cutting means, e.g., a cutter. It also reduces the risk of dust from the cutting means coming into contact with the gel or the gel nozzle. Preferably, there is a distance between the cutting stage and the gel dispensing stage to prevent dust generated in the cutting stage from interfering with gel dispensing.If the aerosol-generating material is cut into three or more sections or sheets of carrier material, each section or sheet can be used or removed in a manner similar to that described for the first continuous sheet of carrier material or the second continuous sheet of carrier material. A single cutting means can supply multiple devices with first and second continuous sheets of carrier material to produce a composite aerosol-generating material. The composite aerosol-generating material is then assembled together to produce an aerosol-generating rod. The sheet cutting means can have dust protection means, such as a vacuum source, to collect dust from the cutter. Having a dust protection means can shorten the distance between the cutter and the gel application step, thereby speeding up the production of the composite aerosol-generating material and subsequent aerosol-generating rods. The order of cutting and gel dispensing is not essential to the practice of the present invention; in principle, each cutting and gel dispensing step can occur before, after, or simultaneously with the other, depending on the embodiment. In some embodiments of the present invention, the gel is dispensed by a gel dispensing means including at least one nozzle. The use of nozzles aids in accurate dispensing of the gel, both in terms of the amount of gel dispensed and the positioning of the dispensed gel. In some embodiments, in combination with other processes, the method for producing a composite aerosol-generating material further includes regulating the gel output by a control system. The control system may aid in accurate dispensing of the gel, both in terms of the amount of gel dispensed and the positioning of the dispensed gel. The gel dispensing means may have multiple nozzles that produce multiple gel strips on the first continuous sheet of carrier material. In some embodiments, not all nozzles dispense gel at the same time. Alternatively, in some embodiments, all nozzles may dispense gel at the same time. The control system may also record the dispensing of the gel, including both the amount of gel dispensed and the positioning of the dispensed gel, so that the total amount of any component in the gel can be calculated and tracked. The gel dispensing means, e.g., a dispenser, may also have a temperature control system that controls the temperature of the gel. Ideally, the gel dispensing means includes a heater or a thermal sensor, or both.Such a system also preferably includes a feedback loop for processing information. The system can make necessary changes, for example, to the heat required or the dispensing speed of the gel. Typically, increasing the temperature reduces the viscosity of the gel, making it easier or faster to dispense. Some gels may require a temperature for optimal dispensing and storage. Bringing the gel to the required temperature before it reaches the nozzle can aid in consistent dispensing of the gel. The heater may be a resistive heater, but any suitable heater may be used. The dispensing means, e.g., a dispenser, may also include cooling means, e.g., a chiller. The cooling means can assist in hardening the gel once it is in the correct position, thus reducing the risk of leakage. Alternatively, or additionally, depending on the type of gel used, the cooling means can assist in holding the first continuous sheet of carrier material and the second continuous sheet of carrier material together. In some examples, the cooling means reduces the viscosity of the gel so that it remains in the same position once hardened. In other examples, the cooling means accelerates hardening of the gel. The gel dispensing means may also include one or more of a flow meter, a pump, and an actuation tap to allow fine adjustment to the flow of gel dispensed. This has the advantage of allowing fine adjustments to be made to maintain a consistent gel flow. This is important because the gel may change over time during the manufacturing process. Many factors, such as humidity and ambient temperature, as well as variations in the supplied gel, can lead to changes in the gel. In preferred embodiments, each nozzle has a flow meter and an actuation tap to allow independent adjustment of the flow of gel dispensed from the nozzle. In some embodiments, the nozzles used to dispense gel onto the first continuous sheet of carrier material dispense the same type of gel onto each sheet of carrier material. Alternatively, the nozzles dispensing gel onto the first continuous sheet of carrier material may dispense different types of gel. For example, in some embodiments, when the nozzles dispense different types of gel, one or more nozzles may dispense a flavor-containing gel. Alternatively, one or more nozzles may dispense a nicotine-containing gel.Alternatively, one or more nozzles may dispense a glycerin-containing gel. Alternatively, one or more nozzles may dispense a propylene glycol-containing gel. Alternatively, one or more nozzles may dispense any combination of the listed types of gels. Having different nozzles for different types of gels allows for fine-tuning and varying the composition of the gel. For example, more flavor may be required for different end products, or certain ingredients may be preferred in certain locations on the sheet of aerosol-generating material.

[0017] In a preferred embodiment, the gel dispensing means dispenses gel onto the same side of the first continuous sheet of carrier material, preferably the upper side of the sheet, so that the dispensed gel easily rests and secures on the sheet of carrier material due to gravity for transport to a subsequent manufacturing process.

[0018] In some embodiments, the method of making a composite aerosol-generating material further comprises dispensing a gel non-uniformly onto one surface of a first continuous sheet of carrier material.

[0019] In some embodiments, the method for producing a composite aerosol-generating material further comprises dispensing a greater amount of gel into a central region proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel dispensed into lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material.

[0020] In some embodiments, the method for producing a composite aerosol-generating material further comprises dispensing at least 10 percent more gel mass into a central region proximal to the longitudinal axis of the first continuous sheet of carrier material than into lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material. Alternatively, the method may comprise dispensing at least 15 percent more gel mass into the central region. In other embodiments, the method comprises dispensing at least 20 percent more gel mass into the central region, or at least 25 percent more gel mass into the central region.

[0021] Controlling the amount and location of gel on the first continuous sheet of carrier material or the second continuous sheet of carrier material, or within the composite aerosol-generating material, can reduce the risk of gel leakage from the composite aerosol-generating material. Avoiding gel leakage can also aid in the uniform production of the composite aerosol-generating material and therefore ensure uniformity of performance in the final product produced.

[0022] In certain embodiments, the method for producing a composite aerosol-generating material further includes providing a continuous band of susceptor material. Preferably, the method for producing a composite aerosol-generating material includes positioning the continuous band of susceptor material relative to the gel. The continuous band of susceptor material is preferably positioned relative to the gel after the gel has been dispensed onto a first continuous sheet of carrier material. In certain embodiments, the composite aerosol-generating material comprises a susceptor material. The susceptor material allows for induction heating. When the susceptor material is positioned within an alternating electromagnetic field, eddy currents are induced within the susceptor material, and hysteresis losses occur, causing the susceptor material to heat. In embodiments where the susceptor material is in thermal contact or close thermal proximity with the aerosol-generating material or gel, the aerosol-generating material or gel is heated. Upon heating, the aerosol-generating material or gel can assist in the emission or generation of aerosols. Preferably, the susceptor material is in direct physical contact with the gel. However, in alternative embodiments, the susceptor material may be positioned between sheets of carrier material without being in direct physical contact with the gel.

[0023] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate or release an aerosol from, for example, a gel or aerosol-generating material, or from an aerosol-generating substrate or carrier material carrying the gel. In some embodiments, the susceptor comprises carbon. Preferred susceptors may comprise or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel or stainless steel. Preferred susceptor materials include metals, such as aluminum. Preferred susceptors can be heated to temperatures above 50°C. More preferably, the susceptor may be heated to temperatures between about 40°C and about 500°C, particularly between about 50°C and about 450°C, and preferably between about 100°C and about 400°C. The susceptor may also comprise a non-metallic core having a metallic layer disposed thereon (e.g., a metallic track formed on the surface of a ceramic core).

[0024] The susceptor may include a protective outer layer, such as a protective ceramic or glass layer, that encapsulates the susceptor. The susceptor may also include a protective coating formed of glass, ceramic, or an inert metal formed over a core of susceptor material.

[0025] The susceptor may be a multi-material susceptor. In particular, the susceptor may include a first susceptor material and a second susceptor material. The first susceptor material is preferably optimized for heat loss and therefore heating efficiency. For example, the first susceptor material may be aluminum or a ferrous material such as stainless steel. In contrast, the second susceptor material is preferably used as a temperature marker. For this purpose, the second susceptor material is selected to have a Curie temperature corresponding to a predetermined heating temperature of the susceptor assembly. At that Curie temperature, the magnetic properties of the second susceptor change from ferromagnetic to paramagnetic, accompanied by a temporary change in its electrical resistance. Therefore, by monitoring the corresponding change in the current absorbed by the induction source, it is possible to detect when the second susceptor material reaches its Curie temperature, and therefore, when the predetermined heating temperature is reached. The second susceptor material preferably has a Curie temperature below the ignition point of the aerosol-forming substrate, i.e., preferably below 500°C. Suitable materials for the second susceptor material may include nickel and certain nickel alloys. Nickel has a Curie temperature in the range of approximately 354°C to 360°C, depending on the nature of impurities. This Curie temperature range is ideal because it is approximately the same temperature to which the susceptor must be heated to generate an aerosol from the aerosol-forming substrate, yet is still low enough to avoid localized overheating or combustion of the aerosol-forming substrate.

[0026] When the susceptor is in the form of a strip, particularly a blade, plate, sheet, strip, or foil, the susceptor preferably has a substantially rectangular cross section. In this case, the susceptor preferably has a width dimension greater than its thickness dimension (e.g., twice the thickness dimension). Advantageously, strip-shaped susceptors preferably have a width of about 2 to about 8 mm, more preferably about 3 to about 5 mm, and a thickness of about 0.03 to about 0.15 mm, more preferably about 0.05 to about 0.09 mm.

[0027] In certain embodiments, the method for producing a composite aerosol-generating material further includes repeating the steps of producing a composite aerosol-generating material and layering the composite aerosol-generating materials one on top of the other. Thus, the composite aerosol-generating material includes multiple layers, producing a multi-layer composite aerosol-generating material. Each component layer of the composite aerosol-generating material can be the same or different in terms of composition or structure. Numerous combinations using different composite aerosol-generating materials, and additionally, in some embodiments, different carrier layers, can be performed to produce the final composite aerosol-generating material. This allows for the production of many different composite aerosol-generating materials, potentially with many different aerosol qualities and characteristics. In certain embodiments, the method for producing a composite aerosol-generating material includes layering one composite aerosol-generating material on top of another composite aerosol-generating material. In certain embodiments, the method for producing a composite aerosol-generating material includes layering one composite aerosol-generating material on top of the other and inserting a susceptor material between the two layers of composite aerosol-generating material. The composite aerosol-generating material or multi-layer composite material may be assembled and preferably wound to form a composite aerosol-generating rod.

[0028] In certain embodiments, the apparatus or manufacturing method further comprises a layering system. The layering system allows the composite aerosol-generating materials to be layered, preferably one on top of the other. The description and given examples only exemplarily refer to a vertical orientation of the top and bottom of the composite aerosol-generating materials on top of each other; other orientations having composite aerosol-generating materials adjacent to each other are also functional and within the scope of the disclosure herein. In preferred embodiments, the composite aerosol-generating materials are stacked such that the top and bottom surfaces of the stacked layers of composite aerosol-generating materials are gel-free. In these particular embodiments, the outward-facing surfaces of the individual composite aerosol-generating materials are preferably gel-free.

[0029] In some embodiments, the susceptor is positioned between layers of composite aerosol-generating material. In embodiments where there is no gel between the layers of composite aerosol-generating material (meaning there is no gel on the outer surfaces of the composite aerosol-generating material) and the susceptor is positioned between the outer sides of the layers of composite aerosol-generating material, the susceptor may not be adjacent to the gel. However, the susceptor may still be able to heat the gel through the layers of composite aerosol-generating material. Advantageously, having a susceptor between the outer surfaces of the composite aerosol-generating material is easy to manufacture. In alternative embodiments, the gel is positioned or dispensed on the outer surfaces of the layers of composite aerosol-generating material; therefore, in these embodiments, the susceptor is adjacent to the gel when the susceptor is positioned between the outer surfaces of the composite aerosol-generating material.

[0030] Other embodiments may include gel between composite aerosol-generating materials, but ideally there is no gel on the outer surface that is not adjacent to another composite aerosol-generating material. Preferably, the gel is only on the inner surface, and therefore the outer surface is gel-free. Advantageously, this avoids gel contamination by reducing the risk of the gel coming into contact with the packaging material or with the surfaces of machinery, such as guide means for positioning the sheets and funnel-shaped devices to assemble the sheets into a continuous cylindrical rod.

[0031] In certain embodiments, the layering system includes at least one lateral movement system. Such a lateral movement system can move one material, e.g., one sheet of one carrier material or composite aerosol-generating material, from one side to the top (or bottom) or parallel to another material, e.g., another sheet of another carrier material or composite aerosol-generating material. A manufacturing process, apparatus, or layering system may have numerous lateral movement systems. Typically, the number of lateral movement systems in an apparatus, layering system, or manufacturing process is equal to the number of sections minus one. Ideally, each lateral movement system serves a different source section. For example, if a carrier material is cut into two parts to form a first sheet of carrier material and a second continuous sheet of carrier material, there is one lateral movement system that moves one sheet, e.g., the second continuous sheet of carrier material, on top (or bottom) of the other. Preferably, the lateral movement system(s) places all of the materials, e.g., the sheets of carrier material and composite aerosol-generating material, in vertical piles, one on top of the other. As described, other orientations are possible in other embodiments.

[0032] In some preferred embodiments, the method for manufacturing a composite aerosol-generating material further includes pressing the composite aerosol-generating material in a direction perpendicular to its plane. For example, in a vertical stack of layers of composite aerosol-generating material, pressure from a pressing system is applied along the height of the stack. Different pressures may be applied to the stack of materials. The pressing system may have variable pressure application depending on the desired effect or the size of the stacked materials. In certain embodiments, the manufacturing apparatus or manufacturing system includes two pressing rollers that cooperate to apply pressure to the composite aerosol-generating material as it passes through the rollers. In certain embodiments, the manufacturing apparatus or manufacturing system includes a single pressing roller. Ideally, the pressure of the pressing system is high enough to bond the material to the gel strips, but low enough to avoid causing structural damage to the sheet. Ideally, the gel strips are not pressed to the point where there is no airflow path between the continuous sheets of carrier material or layers of composite aerosol-generating material.

[0033] The present invention further provides a composite aerosol-generating material comprising a sheet of a first carrier material, a sheet of a second carrier material, and a gel, the gel being disposed between the first sheet of carrier material and the second sheet of carrier material.

[0034] In a preferred embodiment, the composite aerosol-generating material further comprises a susceptor material positioned between the first and second sheets of carrier material, the susceptor material being capable of being heated by induction heating, such that when the susceptor material is placed in an alternating electromagnetic field, eddy currents are induced in the susceptor material and hysteresis losses occur, causing the susceptor material to heat up.

[0035] In producing the composite aerosol-generating material, the sheet of the first carrier material and the sheet of the second carrier material are preferably continuous sheets, although continuous sheets may be cut to length as needed and therefore no longer continuous.

[0036] In a preferred embodiment, the gel comprises one or more of a flavor, an active agent, a plasticizer, a humectant, nicotine, glycerin, or propylene glycol.

[0037] In a preferred embodiment, the sheet of carrier material comprises tobacco material.

[0038] The present invention also relates to a composite aerosol-generating rod comprising a composite aerosol-generating material described herein or produced by the process described herein.

[0039] An apparatus for producing a composite aerosol-generating material for use in an aerosol-generating rod includes means for supplying a first continuous sheet of carrier material, means for dispensing a gel onto a surface of the first continuous sheet of carrier material, and a layering system for providing a second continuous sheet of carrier material and positioning it against the gel to form the composite aerosol-generating material.

[0040] An example of a means for supplying is a supply device.

[0041] In certain embodiments, in combination with other features, the apparatus further comprises a cutter located upstream of the layering system for cutting the sheet of source support material along the longitudinal axis of the sheet of source support material to form a first continuous sheet of support material and a second continuous sheet of support material.

[0042] In certain embodiments, in combination with other features, the apparatus further comprises folding means, e.g., a folding device adapted to fold at least a portion of the sheet of source support material along the longitudinal axis of the sheet of source support material to form a first continuous sheet of support material and a second continuous sheet of support material.

[0043] In certain embodiments, in combination with other features, the apparatus further comprises a crimping system, preferably located upstream of the gel dispensing and layering system.

[0044] The first continuous sheet of carrier material, or the second continuous sheet of carrier material, or both the first continuous sheet of carrier material and the second continuous sheet of carrier material may be crimped. If the composite aerosol-generating material is multi-layered, any combination of crimped and uncrimped sheets of carrier material may be used to construct the multi-layer composite aerosol-generating material.

[0045] The present invention also discloses an apparatus further comprising a layering means configured to layer composite materials to form a multi-layer composite aerosol-generating material. This can be layering of the same composite aerosol-generating material on itself, or layering of different composite aerosol-generating materials one on top of the other. An example of a layering means is an apparatus for layering.

[0046] In certain embodiments, the apparatus further comprises a press system, and the composite aerosol-generating material, the multi-layer composite aerosol-generating material, or both, are pressed by at least one press roller. In preferred embodiments, the apparatus further comprises a means for assembling the composite aerosol-generating material, the multi-layer composite aerosol-generating material, or both. In preferred embodiments, the apparatus further comprises a means for winding the composite aerosol-generating material or the multi-layer composite aerosol-generating material after it has been assembled. The packaging means allows the composite aerosol-generating material to be cut into aerosol-generating rods. In some embodiments, the apparatus comprises a cutter for cutting a continuous length of wound composite aerosol-generating material to a desired length. Thus, the wound composite aerosol-generating material can be easily transported during the manufacturing process. The apparatus of the present invention may include any of the features described herein for manufacturing a composite aerosol-generating material, such as a gel dispensing means, a nozzle, a control means, a guide, a roller, a press system, or any combination thereof.

[0047] In certain embodiments, the sheet of carrier material comprises a porous material. In certain embodiments, the sheet of carrier material may be made of a porous material. Porous materials have the advantage that the material can firmly hold the gel. Advantageously, porous carrier materials can firmly hold the gel to a greater extent than non-porous carrier materials. The pores of the porous material can absorb the gel, thereby allowing the gel to be easily placed on the sheet of porous carrier material and resulting in rapid adhesion. The porous material can strongly fix the gel to the surface of the carrier sheet by absorption through its pores. Thus, the porous material can prevent migration of the gel adjacent to the porous material. The porous material used in the present invention helps reduce leakage of gel from the composite aerosol-generating material. Composite aerosol-generating materials made from porous materials help reduce leakage of gel, thereby reducing contamination of machine parts during manufacturing, for example, reducing contamination of the cutting blade of a cutter when cutting a continuous length of wound composite aerosol-generating material to the desired length.

[0048] The porous material may be any suitable porous material capable of holding or retaining the gel. Ideally, the porous material allows the gel to move within. In certain embodiments, the porous material comprises a natural, synthetic, or semi-synthetic material, or a combination of the materials described. In certain embodiments, the porous material comprises a sheet material, a foam, or a fiber, e.g., loose fiber, or a combination thereof. In certain embodiments, the porous material comprises a woven fabric, a nonwoven fabric, or an extruded material, or a combination thereof. Preferably, the porous material comprises, for example, cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. Preferably, the porous material comprises a sheet material, e.g., cotton or cellulose acetate. An advantage of porous materials is that the gel is retained within the porous material, which may aid in the manufacture, storage, or transportation of the gel. This may help maintain the desired shape of the gel, particularly during manufacture, transportation, or use. The porous materials used in the present invention may be crimped or shredded. In certain embodiments, the porous material comprises a crimped porous material.

[0049] In some embodiments, the gel is at least partially absorbed into the porous material. In the sandwich arrangement of the present invention, using two porous carrier materials has the advantage that the two porous materials hold the gel in place, thus providing improved or stronger gel fixation compared to using only one porous material. Therefore, using two porous materials in a sandwich-type arrangement according to the present invention is advantageous for providing improved gel retention. Improved gel retention allows for improved control of gel dispensing and reduced waste due to reduced gel migration and leakage. The gel can be precisely positioned with reduced migration or loss of the gel and additives or materials therein. Therefore, improved control of the amount of gel and additives therein can be achieved. Furthermore, reduced gel leakage reduces machine contamination, thus reducing downtime for cleaning or repairing machines in manufacturing.

[0050] In certain embodiments, the carrier material comprises an aerosol-generating material. The carrier material may comprise, for example, tobacco, tobacco material, powdered tobacco, tobacco stems, nicotine, tobacco leaves or cast leaf tobacco, or any combination of the aerosol-generating materials described. The aerosol-generating material may also be a porous material, which has the advantage of retaining the gel. In certain embodiments, the carrier material may comprise an aerosol-generating material, and the gel may also comprise an aerosol-generating substrate. In alternative embodiments, either the gel or the carrier material may comprise the aerosol-generating substrate.

[0051] In combination with certain embodiments, the gel comprises a gelling agent, hi certain embodiments, the gel comprises agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0052] In certain embodiments, the gel comprises water, e.g., the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

[0053] Preferably, the gel includes an active agent. In combination with certain embodiments, the active agent includes nicotine. In certain embodiments, the nicotine is included in the gel along with an aerosol former for the desired nicotine delivery. Securing the nicotine within the gel at room temperature is desirable to prevent leakage.

[0054] In certain embodiments, the gel includes a solid tobacco material that releases flavor compounds when heated. Depending on the particular embodiment, the solid tobacco material may be one or more of a powder, granules, pellets, pieces, spaghetti, strips, or sheets, including one or more plant materials such as herb leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0055] The gel may contain a suitable gelling agent. For example, the gelling agent may contain one or more biopolymers, such as two or three biopolymers. When the gel contains multiple biopolymers, the biopolymers are preferably present in substantially equal amounts by weight. The biopolymer may be formed of a polysaccharide. Suitable biopolymers for use as gelling agents include, for example, gellan gum (natural, low-acyl gellan gum, high-acyl gellan gum, with low-acyl gellan gum being preferred), xanthan gum, alginate (alginic acid), agar, guar gum, etc. Preferably, the gel contains agar. Preferably, the gel contains only a single gelling agent. Preferably, the single gelling agent is agar or guar.

[0056] As used herein, the term "aerosol-generating article" is used to describe an article that is capable of generating or emitting an aerosol.

[0057] As used herein, the term "aerosol-generating device" refers to a device used in conjunction with an aerosol-generating article, typically enabling the generation of an aerosol from the aerosol-generating article. Aerosol-generating devices often include a heater.

[0058] As used herein, the term "aerosol-generating material" is used to describe a material that supports the generation of an aerosol or has the ability to generate an aerosol, such as cast tobacco leaf. The term also includes materials that support the release of an aerosol from an aerosol-generating substrate, such as an aerosol former.

[0059] As used herein, the term "aerosol-generating substrate" is used to describe a substrate that has the ability to generate an aerosol, such as cast leaf tobacco or nicotine.

[0060] As used herein, the term "carrier material" is used to describe a material that aids in carrying, storing, or supporting an element, or that has the ability to carry, store, or support an element. In the present invention, this includes carrying a gel, particularly when the gel comprises the aerosol-generating substrate. The term "carrier" also includes aerosol-generating material, tobacco, cotton, or any material capable of carrying an aerosol-generating substance, such as a gel. For example, the aerosol-generating material can absorb the gel and / or is not destroyed by the gel.

[0061] As used herein, the term "composite aerosol-generating material" is used to describe a material that includes two or more components, at least one of which includes an aerosol-generating substrate or aerosol-generating material. A composite aerosol-generating material does not require that two or all of the components generate an aerosol.

[0062] As used herein, the term "crimped" refers to a material having a plurality of substantially parallel ridges or corrugations. It also includes the process of crimping a material. The ridges may be longitudinal, transverse, angular, straight, wavy, continuous, interrupted, or any combination thereof. The longitudinal ridges may improve the formation of flow channels that extend substantially the entire length of the sheet when assembled. Furthermore, compared to uncrimped or crimped sheets, the longitudinal ridges formed by crimping aid in forming airflow channels at designated locations and in ensuring that each airflow channel has a relatively similar cross-sectional size, thereby achieving a uniform distribution of flow channels across the cross-section of the formed aerosol-generating rod. Therefore, a relatively consistent resistance to withdrawal (RTD) for the aerosol-generating rod may be achieved.

[0063] For purposes of this disclosure, as used herein, the term "diameter" or "width" refers to the largest transverse dimension of a composite aerosol-generating material, or a first continuous sheet of carrier material and a second continuous sheet of carrier material, a portion or component thereof, an aerosol-generating article, or an aerosol-generating device. As an example, "diameter" refers to the diameter of an object having a circular transverse cross-section, or the diagonal width of an object having a rectangular cross-section.

[0064] As used herein, the term "aggregated" is used to describe a sheet, or a sheet of a first continuous carrier material or a sheet of a second continuous carrier material, or a composite aerosol-generating material that is rolled, folded, or otherwise compressed or constricted substantially transverse to the longitudinal axis of the composite aerosol-generating material.

[0065] As used herein, the term "gel" is used to describe a solid, jelly-like, semi-rigid material or mixture of materials with a three-dimensional network that can hold other materials and has the ability to release materials into an aerosol.

[0066] As used herein, the term "longitudinal direction" is used to describe the direction between a downstream or proximal end and an opposing upstream or distal end of an aerosol-generating article or aerosol-generating material, or a composite aerosol-generating material, or a sheet of carrier material.

[0067] As used herein, the term "outer" in relation to a sheet of carrier material is used to describe a portion of the sheet of carrier material that is more toward a longitudinal side of the sheet of carrier material than toward the middle of the cross-sectional portion of the sheet of carrier material. Similarly, the terms "inner" or "center" (in relation to a sheet of carrier material) are used to describe a portion of the material that is more central in the cross-sectional portion of the sheet of carrier material than toward a longitudinal side of the sheet of carrier material.

[0068] As used herein, the term "plasticizer" is used to describe a substance, typically a solvent, that is added to create or promote plasticity or flexibility and reduce brittleness.

[0069] As used herein, the term "rod" is used to describe a component, segment, or element for use in an aerosol-generating article. A "continuous rod" is a precursor to a rod before cutting to a desired length.

[0070] As used herein, the term "porous material" is used to describe any material that has the ability to hold, retain, or support a gel. Typically, porous media have channels within their structure that can be filled to retain or hold a fluid or semi-solid, for example, to retain a gel. Preferably, the gel will also be able to pass or move (to some extent) along and through the channels within the porous material.

[0071] As used herein, the term "susceptor" is used to describe an element including a material capable of being inductively heated in an alternating electromagnetic field. This can be the result of at least one of hysteresis loss or eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material. Hysteresis loss occurs in ferromagnetic or ferrimagnetic susceptors due to magnetic domains in the material being switched under the influence of the alternating electromagnetic field. Eddy currents may be induced if the susceptor is conductive. In the case of a conductive ferromagnetic susceptor or a conductive ferrimagnetic susceptor, heat can be generated due to both eddy currents and hysteresis loss. Thus, a susceptor can include a material that is at least one of conductive and magnetic.

[0072] As used herein, the term "resistance to draw" (RTD) is used to describe the resistance to drawing a fluid, e.g., gas, through a material. As used herein, resistance to draw is expressed and measured in accordance with ISO 6565:2002.

[0073] As used herein, the term "sheet" or "sheet material" is used to describe a generally planar, laminar element whose width and length are substantially greater than its thickness.

[0074] Any of the features or steps described herein in relation to one embodiment, aspect or example of a composite aerosol-generating material, a multi-layer composite aerosol-generating material, or an aerosol-generating rod, or any of their manufacture (including apparatus) may be equally applicable to any other embodiment, aspect or example of a composite aerosol-generating material, a multi-layer composite aerosol-generating material, an aerosol-generating article or an aerosol-generating rod, their method of manufacture, or apparatus for manufacture. [Example]

[0075] Example 1 1. A method of making a composite aerosol-generating material for use in an aerosol-generating rod, comprising: - providing a first continuous sheet of carrier material; - dispensing a gel onto a surface of a first continuous sheet of carrier material; - providing a second continuous sheet of carrier material and positioning the second continuous sheet of carrier material against the gel to form a composite material having the gel disposed between the first continuous sheet of carrier material and the second continuous sheet of carrier material. Example 2 A method for producing a composite aerosol-generating material according to example Ex1, further comprising the step of crimping at least one of the first continuous sheet of carrier material and the second continuous sheet of carrier material. Example 3 A method for producing a composite aerosol-generating material according to embodiment Ex1 or Ex2, further comprising providing a first continuous sheet of carrier material and a second continuous sheet of carrier material from respective sources of different carrier materials. Example 4 A method for producing a composite aerosol-generating material according to example Ex1 or Ex2, further comprising providing both the first continuous sheet of carrier material and the second continuous sheet of carrier material from a single source of carrier material. Example 5 A method for producing a composite aerosol-generating material according to Example Ex4, further comprising the step of folding a continuous single sheet of carrier material source to form both a first continuous sheet of carrier material and a second continuous sheet of carrier material, so that the first continuous sheet of carrier material and the second continuous sheet of carrier material are integral with each other via a fold. Example 6 A method for producing a composite support material according to example Ex4, further comprising cutting a continuous single source sheet of support material to form both a first continuous sheet of support material and a second continuous sheet of support material. Example 7 A method for producing a composite aerosol-generating material according to any of Examples Ex1 to Ex6, further comprising the step of dispensing a greater amount of gel into a central region proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel dispensed into lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material. Example 8 A method for producing a composite aerosol-generating material according to any of Examples Ex1 to Ex7, further comprising providing a continuous band of susceptor material and positioning the continuous band of susceptor material against the gel after the gel has been dispensed onto the sheet of first continuous carrier material. Example 9 A method for producing a composite aerosol-generating material according to any of Examples Ex1 to Ex8, further comprising pressing the composite aerosol-generating material in a direction perpendicular to the plane of the composite aerosol-generating material. Example 10 A method for producing a composite aerosol-generating material according to any of Examples Ex1 to Ex9, wherein the gel comprises a flavor, or an activator, or a plasticizer, or a humectant, or nicotine, or glycerin, or propylene glycol, or any combination thereof. Example 11 A method for producing a composite aerosol-generating material according to any of Examples Ex1 to Ex10, wherein the composite aerosol-generating material comprises tobacco material. Example 12 1. A composite aerosol-generating material comprising: - a sheet of a first carrier material; - a sheet of a second carrier material; a gel disposed between the sheet of first carrier material and the sheet of second carrier material. Example 13 A composite aerosol-generating material according to example Ex12, further comprising a susceptor material positioned between the sheet of first carrier material and the sheet of second carrier material. Example 14 A composite aerosol-generating material according to example Ex12 or Ex13, wherein the first continuous sheet of carrier material, or the second continuous sheet of carrier material, or both the first sheet of carrier material and the second sheet of carrier material comprise an aerosol-generating material. Example 15 A composite aerosol-generating rod comprising a composite aerosol-generating material according to Examples Ex12 to Ex14 or produced as in any of Examples Ex1 to Ex11.

[0076] Reference will now be made to the drawings, which depict one or more embodiments described in the present disclosure. However, it will be understood that other embodiments not shown in the drawings are within the scope of the present disclosure. Like numbers used within the figures refer to like components, steps, and the like. However, it will be understood that the use of one number to refer to a component in a given figure is not intended to limit the same numbered component in another figure. Additionally, the use of different numbers to refer to components in different figures is not intended to indicate that the differently numbered components may not be the same or similar to other numbered components. The figures are presented by way of illustration and not by way of limitation. Schematic diagrams presented in the figures are not necessarily drawn to scale. [Brief explanation of the drawings]

[0077] [Figure 1] FIG. 1 is a schematic perspective view of a cutting system for cutting sheets of source support material. [Figure 2] FIG. 2 is a schematic perspective view of one embodiment of a gel dispensing system with several nozzles for a sheet of source carrier material. [Figure 3] FIG. 3 shows a schematic top view of a layering system for producing an aerosol-generating material stack. [Figure 4] FIG. 4 shows a schematic side view of the layering system of FIG. [Figure 5] FIG. 5 is a schematic perspective view of a system for manufacturing aerosol-generating rods. [Figure 6] FIG. 6 is a schematic cross-sectional view of a composite aerosol-generating material according to one embodiment. [Figure 7] FIG. 7 is a schematic cross-sectional view of a composite aerosol-generating material according to another embodiment. [Figure 8] FIG. 8 is a schematic cross-sectional view of a composite aerosol-generating material according to a further embodiment. [Figure 9] FIG. 9 is a schematic cross-sectional view of a composite aerosol-generating material according to a further embodiment. [Figure 10] FIG. 10 is a schematic cross-sectional view of a composite aerosol-generating material including a susceptor material according to one embodiment. [Figure 11] FIG. 11 is a schematic cross-sectional view of a composite aerosol-generating material including a susceptor material according to a further embodiment. [Figure 12] FIG. 12 is a schematic diagram of a cross-section of a susceptor between two composite aerosol-generating materials. [Figure 13] FIG. 13 is a cross-sectional view of an aerosol-generating rod with a susceptor positioned between the composite aerosol-generating materials prior to assembly. DETAILED DESCRIPTION OF THE INVENTION

[0078] FIG. 1 illustrates one example of a cutting system 10. A source sheet 12 of carrier material is initially unwound from a bobbin (not shown) and transported in the direction generally indicated by the arrow. The source sheet 12 of carrier material has a longitudinal axis extending longitudinally and has a particular width and a particular thickness. In certain embodiments, the source carrier material 12 is preferably tobacco cast leaf (TCL), although in other embodiments, the source carrier material 12 comprises other materials, such as cotton. The cutting system 10 preferably includes a cutter 20, which in this example takes the form of an in-line knife 10. In certain embodiments, other cutters 20, such as a circular knife or a rotary cutter, are used.

[0079] The in-line knife 20 has a longitudinal axis perpendicular to the longitudinal axis of the sheet of source support material 12, such that the sharp edge of the knife 20 faces the incoming sheet of source support material 12. The sheet of source support material 12 is cut by the knife 20 into two sections 22A, 22B along a cutting line 24. In certain embodiments, the sheet of source support material 12 is cut along its longitudinal axis so that both the first section 22A and the second section 22B have the same width. In other embodiments, the sheet of source support material 12 is cut along a cutting line 24 offset from the longitudinal axis so that the first section 22A has a larger width relative to the second section 22B, or so that the second section 22B has a larger width relative to the first section 22A. In other examples, the sheet of source support material 12 is cut into three or more sections 22A, 22B, for example, using two or more cutters 20 or using the same cutter 20. Because the cutting process typically generates dust, in some embodiments, the cutting system 10 also includes dust protection within the cutting system 10. For example, the dust protection may take the form of an air suction system (not shown) so that generated dust is at least partially exhausted in a controlled manner. The inclusion of the dust protection prevents a high percentage of dust from contacting the gel 144 (see FIG. 2) or the source support material 12, which could otherwise cause contamination and quality issues. The two sections 22A, 22B form a first continuous sheet of support material and a second continuous sheet of support material.

[0080] FIG. 2 illustrates one example of a gel dispensing system 100. The gel dispensing system 100 includes a gel dispensing station 140 having three gel dispensing nozzles 142. Each nozzle 142 dispenses gel 144 onto a surface portion of a section 122 of a first continuous sheet of carrier material 12. Three gel strips 144 are applied to the section 122 of the first continuous sheet of carrier material. The section 122 of the first continuous sheet of carrier material is transported along a direction generally indicated by an arrow in this example. In certain embodiments, a different number of gel dispensing stations 140 or nozzles 142 are used. In such embodiments, a different number of gel strips 144 are produced. In this example, the gel strips 144 dispensed from the nozzles 142 are preferably parallel to one another; however, in other examples, the gel strips 144 are not parallel to one another, e.g., wavy, offset along the longitudinal axis of the section 122 of the first continuous sheet of carrier material, or looped.

[0081] In some embodiments, the amount of gel 144 applied per strip and per dispensing system is calculated so that the gel 144 does not spread beyond the surface of the section 122 of the first continuous sheet of carrier material during the layering and pressing processes (both as described), thereby preventing the gel 144 from contacting (and therefore contaminating) the inner surface of the funnel-shaped device 490 (see FIG. 5 ) during the gathering or pressing or packaging process (not shown).

[0082] In some examples, the gel dispensing system 100 includes a temperature control system (not shown) having a heater (not shown) and a thermal sensor (not shown) coupled through a feedback loop. The temperature control system heats the gel 144 and controls its temperature so that it remains within a target temperature range before reaching the gel dispensing station(s) 140. Optionally, the gel dispenser station 140 additionally includes a flow meter, pump, or actuation tap (not shown) or the like that allows the flow of each nozzle 142 to be independently adjustable or that allows different types of gel 144 to be delivered by different nozzles 142, e.g., onto different locations on the section 122 of the first continuous carrier sheet. This is particularly advantageous because it facilitates applying different amounts of gel 144 and therefore producing different composite aerosol-generating materials. The amount of gel 144 dispensed can be varied, for example, by changing the nozzle flow rate or the length of time the gel 144 is dispensed from the nozzle. In certain embodiments, the variation in the amount of gel 144 can be independently varied from nozzle to nozzle. This also allows the flow of gel 144 from each nozzle 142 to be adjusted depending on the position of the nozzle 142; for example, a nozzle 142 located near the longitudinal axis of the section 122 of the first continuous sheet of carrier material is adapted to dispense a larger amount of gel 144 relative to the amount dispensed by the nozzle 142 near the edge of the section 122 of the first continuous sheet of carrier material to prevent the gel 144 from spreading beyond the surface of the section 122 of the first continuous sheet of carrier material during the pressing process. The flow rate of the dispensed gel 144, the duration for which the gel 144 is dispensed, or the pattern formed by the dispensed gel 144 may be varied in different embodiments. Of course, the order of the cutting step (of the source carrier material 12) and the gel application step is not related. While the cutting step of the source carrier material 12 is preferably performed before the gel dispensing step, in certain embodiments, the cutting step is performed after the gel dispensing step or simultaneously with the gel application step.

[0083] 3-4 illustrate one embodiment of a layering system 250, 350 for producing an aerosol-generating rod. The layering system 250, 350 places two sections 222A, 222B, a first continuous sheet of carrier material 222B and a second continuous sheet of carrier material 222A, on top of each other to form a composite aerosol-generating material 530 (better shown in FIG. 6). The first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A each have a specified width. The first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A each have a specified thickness. The composite aerosol-generating material 530 comprises the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A, and a gel 244 disposed between the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A. The layering system 250, 350 includes a lateral movement system that places the second continuous sheet of carrier material 222A on top of the first continuous sheet of carrier material 222B. In this example, the second continuous sheet of carrier material 222A is on top and the second continuous sheet of carrier material 222B is on the bottom. In other embodiments, the composite aerosol-generating material 530 is configured in another manner, for example, so that the second continuous sheet of carrier material 222A is placed below the first continuous sheet of carrier material 222B. The lateral movement system places the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A in a vertical pile, one on top of the other, with the second continuous sheet of carrier material 222A directly above and parallel to the first continuous sheet of carrier material 222B. In other embodiments, the second continuous sheet of carrier material 222A and the first continuous sheet of carrier material 222B are offset from each other. 3-4 show a single lateral movement system for placing the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A on top of each other. In other embodiments, the layering systems 250, 350 include multiple lateral movement systems, allowing for the production of stacks of three or more sheets of carrier material 222A and 222B.3-4, first continuous sheet of carrier material 222B and second continuous sheet of carrier material 222A are unwound from separate bobbins (not shown) onto the lateral movement systems of layering systems 250, 350, while in other embodiments, a single source sheet of carrier material 222 is unwound from a bobbin and then cut into separate sections, first continuous sheet of carrier material 222B and second continuous sheet of carrier material 222A. Rollers 252, 254, 256, and 258 assist in orienting the first continuous sheet of carrier material, or the second continuous sheet of carrier material, or both the first continuous sheet of carrier material and the second continuous sheet of carrier material.

[0084] As best seen in FIG. 4 , the lateral movement system includes a transport roller 352, a directional roller 354, and a pair of positioning rollers 356. The first continuous sheet of carrier material 322B is transported onto the transport roller 352. The second continuous sheet of carrier material 322A is contacted by the directional roller 354 from the side not receiving the gel 344 to avoid contamination. The directional roller 354 is angled so that the movement of the second continuous sheet of carrier material 322A is redirected toward the first continuous sheet of carrier material 322B. The angle of the directional roller 354 is selected to conserve manufacturing space while avoiding applying too much strain to the second continuous sheet of carrier material 322A, which could otherwise alter the structure of the second continuous sheet of carrier material 322A. Both the second continuous sheet of carrier material 322A and the first continuous sheet of carrier material 322B are then directed through a positioning roller 356 positioned so that the second continuous sheet of carrier material 322A is positioned adjacent to the first continuous sheet of carrier material 322B. The distance from the first continuous sheet of carrier material 322B to the surface of the positioning roller 356 is approximately equal to the thickness of the second continuous sheet of carrier material 322A. This arrangement allows the two continuous sheets of carrier material 322B, 322A to come into contact as they pass through the positioning roller 356. The axis of rotation of the positioning roller 356 is perpendicular to the direction of transport of the first sheet of aerosol-generating material 322B. This aligns the second continuous sheet of carrier material 322A with the first continuous sheet of carrier material 322B, as can be seen in FIG. 3 .

[0085] In certain embodiments, the layering system also includes a press system having two press rollers 358 through which the second continuous sheet of carrier material 322A and the first continuous sheet of carrier material 322B additionally pass. As the first continuous sheet of carrier material 322B and the second continuous sheet of carrier material 322A are conveyed through the press rollers 358, the pressure exerted by the press rollers 358 allows the second continuous sheet of carrier material 322A, the first continuous sheet of carrier material 322B, and the intervening gel 344 to adhere together. The pressure is high enough to promote adhesion between the first and second continuous carrier material sheets 322B, 322A and the gel 344, but low enough so that the first and second continuous carrier material sheets 322B, 322A are not structurally damaged and the gel strips 344 are not pressed to the point that no airflow path exists between the first and second continuous carrier material sheets 322B, 322A. In such cases, the first and second continuous carrier material sheets 322B, 322A with the gel 344 create an airtight block through which aerosols or air cannot flow, which may affect the draw resistance characteristics in some cases. In certain embodiments, the positioning roller 356 takes the form of a single positioning roller acting on the surface. In certain embodiments, the press roller 358 takes the form of a single press roller acting on the surface.

[0086] FIG. 5 illustrates one embodiment of a layering system 450 for manufacturing aerosol-generating rods. A tobacco cast leaf (TCL) sheet 412 (also an example of a source carrier material, which is an aerosol-generating material) is unwound from a bobbin (not shown) and crimped by a pair of crimping rollers 470A, 470B to create ridges and grooves in the sheet 412 of source carrier material. The crimped sheet 412 of source carrier material is then cut into two sections by a cutter 420 to form a first continuous sheet 422B of carrier material and a second continuous sheet 422A of carrier material. In this example, the cutter 420 is an in-line cutter, more specifically, a circular knife. It should be understood that the crimping step is optional. In certain embodiments, the cutting step is replaced by providing the first continuous sheet 422B of carrier material and the second continuous sheet 422A of carrier material from different bobbins or sources. The cutting process is provided to reduce the storage space required for multiple bobbins of first continuous sheet of carrier material 422B and second continuous sheet of carrier material 422A. Gel 444 is applied by a gel dispensing system 440 having three nozzles 442, each of which dispenses a strip of gel 444 onto the surface of first continuous sheet of carrier material 422B. Second continuous sheet of carrier material 422A is directed by a redirecting fork 452 toward the gel-dispensed surface of first continuous sheet of carrier material 422B to form a composite aerosol-generating material or "sandwich" having first continuous sheet of carrier material 422B and second continuous sheet of carrier material 422A with gel 444 disposed between them. A detailed cross-sectional view of the composite aerosol-generating material is shown in Figure 5, in which three gel strips 444 of approximately equal width are disposed between a second continuous sheet of carrier material 422A and a first continuous sheet of carrier material 422B. The composite aerosol-generating material of the first continuous sheet of carrier material 422B and the second continuous sheet of carrier material 422A, with the gel 444 in its core, is then directed toward the input end of a funnel 490 and compressed into the shape of a continuous rod 492 at the output end of the funnel 490.

[0087] FIG. 6 shows a schematic cross-sectional view of a composite aerosol-generating material 530 according to one embodiment. The composite aerosol-generating material 530 includes a sheet of first carrier material 522B and a sheet of second carrier material 522A. Three gel strips 544 are disposed between the first and second carrier material sheets 522B, 522A. The central gel strip 544B is located in a central region proximal to the longitudinal axis, and the gel strips 544A and 544C are spaced apart in lateral regions on either side of the central gel strip 544B. In this embodiment, the gel strips 544A, 544B, and 544C have the same width. Therefore, the gel strips 544A, 544B, and 544C can be said to be uniformly disposed. The gel strips 544A, 544C are preferably positioned inward from the outer edges of the first sheet of carrier material 522B and the second sheet of carrier material 522A to avoid gel staining on the machine, e.g., to avoid contamination of a funnel (not shown) due to leakage of gel 544. In other embodiments, the gel strips 544 are dispensed unevenly (see FIG. 7). The composite aerosol-generating material 530 is produced using a layering system 450, as described with reference to FIG. 5. In certain embodiments, the first continuous sheet of carrier material 522B and the second continuous sheet of carrier material 522A are provided from the same sheet 512, e.g., on a single bobbin (not shown), and then cut in two via a cutting system 420 to form the first continuous sheet of carrier material 522B and the second continuous sheet of carrier material 522A. In other embodiments, the first continuous sheet of carrier material 522B and the second continuous sheet of carrier material 522A are each provided from different sources, for example, the first continuous sheet of carrier material 522B is provided on a first bobbin (not shown) and the second continuous sheet of carrier material 522A is provided on a different bobbin (not shown).

[0088] FIG. 7 shows a schematic cross-sectional view of a composite aerosol-generating material 630 according to another embodiment. The composite aerosol-generating material 630 includes a sheet of a first carrier material 622B, a sheet of a second carrier material 622A, and a sheet of a third carrier material 622C. Three gel strips 644 are disposed between the first and second carrier material sheets 622B, 622A. The central gel strip 644B is located in a central region proximal to the longitudinal axis, and the gels 644A, 644C are spaced apart in side regions on either side of the central gel strip 644B. ​​In this embodiment, three additional gel strips 644 are disposed between the first and third carrier material sheets 622B, 622C. The gel strip 644B in the central region has a greater width than the gel strips 644A, 644B in the side regions. Thus, gel strips 644A, 644B, 644C can be said to be non-uniformly distributed. In other examples, the distribution of gel 644A, 644B, 644C between first sheet of carrier material 622B and second sheet of carrier material 622A is different from the distribution of gel 644A, 644B, 644C between first sheet of carrier material 622B and third sheet of carrier material 622C. In some examples, gel 644 is uniformly distributed between first sheet of carrier material 622B and second sheet of carrier material 622A, and gel 644 is non-uniformly distributed between first sheet of carrier material 622B and third sheet of carrier material 622C. The gel strips 644A, 644C are preferably positioned inward from the outer edges of the first sheet of carrier material 622B and the second sheet of carrier material 622A to avoid contamination of the machine due to gel staining, e.g., leakage of gel 644 into a funnel (not shown). Specifically, in this embodiment, more gel 644 is dispensed into a central region proximal to the longitudinal axis of the second sheet of carrier material 622A relative to the amount of gel 644 dispensed into lateral regions distal to the longitudinal axis of the second sheet of carrier material 622A. Thus, the central gel strip 644B has a greater width than the gel strips 644A, 644C. This reduces the risk of contamination, e.g., leakage of gel 644 into a funnel (not shown).In certain embodiments, 10 percent (%) more gel 644 mass is dispensed into the central region than into the side regions, and in other embodiments, 20 percent (%) more gel 644 mass is dispensed into the central region than into the side regions of the sheet of aerosol-generating material.

[0089] The composite aerosol-generating material 630 is produced using a layering system 450, as described with reference to Figure 5. In certain embodiments, the first sheet of carrier material 622B, the second sheet of carrier material 622A, and the third sheet of carrier material 622C are preferably provided from the same carrier material source, for example, on a single bobbin (not shown), and then cut into three sections 622A, 622B, and 622C via a cutting system 420. In certain embodiments, gel 644 is placed on both sides of the first continuous sheet of carrier material 622B, and the second continuous sheet of carrier material 622A and the third continuous sheet of carrier material 622C are placed on the first sheet of carrier material 622B via the layering system 450. In certain embodiments, the composite aerosol-generating material 630 is constructed by providing a first continuous sheet of carrier material 622B and a third continuous sheet of carrier material 622C and applying gel strips 644 to the top of each of the first continuous sheet of carrier material 622B and the third continuous sheet of carrier material 622C. The first continuous sheet of carrier material 622B is placed on top of the third continuous sheet of carrier material 622C, and then the second continuous sheet of carrier material 622A is placed on top of the first continuous sheet of carrier material 622B. The top and bottom surfaces of the composite aerosol-generating material 630 are preferably free of gel 644. In certain embodiments, two of the first continuous sheet of carrier material 622A, the second continuous sheet of carrier material 622B, or the third continuous sheet of carrier material 622C are provided on a single bobbin (not shown) from the same carrier material source and cut into two sections via the cutting system 420. In certain embodiments, each of the first continuous sheet of carrier material 622A, the second continuous sheet of carrier material 622B, and the third continuous sheet of carrier material 622C are each provided from a different source. That is, the sheets 622A, 622B, and 622C are unwound from different respective bobbins. In alternative embodiments, manufacturing the composite aerosol-generating material involves repeatedly manufacturing the composite aerosol-generating materials and layering the composite aerosol-generating materials one on top of the other.This provides composite aerosol-generating materials with additional layers and / or different numbers of layers.

[0090] The composite aerosol-generating material 630 is produced by an apparatus (not shown) having a means for supplying a first continuous sheet of carrier material 622A. In one embodiment, the means for supplying the first continuous sheet of carrier material 622A is a bobbin (not shown). The apparatus has a nozzle that dispenses a gel 644 onto the surface of the first continuous sheet of carrier material 622A, and a layering system that provides a second continuous sheet of carrier material 622B and positions the second continuous sheet of carrier material 622B on the gel 644 to form the composite aerosol-generating material 630. In another embodiment, the first continuous sheet of carrier material 622A is supplied by a cutter. The cutter is located upstream of the layering system. The cutter cuts a source sheet of carrier material along its longitudinal axis to form the first continuous sheet of carrier material 622A and the second continuous sheet of carrier material 622B. Additionally, in some embodiments, the apparatus further comprises folding means for folding a portion of the source support material along its longitudinal axis to form a first continuous sheet of support material 622A and a second continuous sheet of support material 622B.

[0091] FIG. 8 shows a schematic cross-sectional view of a composite aerosol-generating material 730 according to a further embodiment. The composite aerosol-generating material 730 includes a first sheet 722A of carrier material, a second sheet 722B of carrier material, a third sheet 722C of carrier material, and a fourth sheet 722D of carrier material. Three gel strips 744 are disposed between the first sheet 722A of carrier material and the second sheet 722B of carrier material. The central gel strip 744B is located in a central region proximal to the longitudinal axis, and the gel strips 744A, 744C are spaced apart in lateral regions on either side of the central gel strip 744B. In this embodiment, no gel is disposed between the second sheet 722B of carrier material and the third sheet 722C of carrier material. Instead, three additional gel strips 744 are disposed between the third sheet 722C of carrier material and the fourth sheet 722D of carrier material. The composite aerosol-generating material 730 includes two composite aerosol-generating materials, 722A, 722B, and 722C, 722D. The gel strip 744B in the central region has a larger width than the gel strips 744A, 744C in the side regions. Therefore, the gel strips 744A, 744B, 744C can be said to be unevenly arranged. The gel strips 744A, 744C are preferably positioned inward from the outer edges of the first sheet of carrier material 722A, the second sheet of carrier material 722B, the third sheet of carrier material 722C, and the fourth sheet of carrier material 722D to avoid contamination of the machine, such as leakage of gel 744 into a funnel (not shown). Specifically, in this embodiment, more gel 744 is dispensed into the central region, proximal to the longitudinal axis of the section 722, relative to the amount of gel 744 dispensed into the side regions, distal to the longitudinal axis of the section 722. Thus, the central gel strip 744B has a greater width than the gel strips 744A, 744C, which reduces the risk of contamination, for example the risk of the gel 744 leaking into the funnel (not shown).

[0092] The composite aerosol-generating material 730 is produced using the layering system 450, as described with reference to FIG. 5. In certain embodiments, a single sheet is preferably provided from a single source, e.g., on a single bobbin (not shown), and then cut into four sections via the cutting system 420 to form a first continuous sheet of carrier material 722A, a second continuous sheet of carrier material 722B, a third continuous sheet of carrier material 722C, and a fourth continuous sheet of carrier material 722D. The top and bottom surfaces of the composite aerosol-generating material 730 are preferably free of gel 744. In certain embodiments, at least two of the first continuous sheet of carrier material 722A, the second continuous sheet of carrier material 722B, the third continuous sheet of carrier material 722C, or the fourth continuous sheet of carrier material 722D are preferably provided from the same source sheet of carrier material, e.g., on a single bobbin (not shown), and then cut into two sections via the cutting system 420. In certain embodiments, each of the first continuous sheet of carrier material 722A, the second continuous sheet of carrier material 722B, the third continuous sheet of carrier material 722C, and the fourth continuous sheet of carrier material 722D are each provided from a different source, i.e., sheets 722A, 722B, 722C, 722D are unwound from different respective bobbins.

[0093] 9 shows a schematic cross-sectional view of a composite aerosol-generating material 830 according to a further embodiment. In this embodiment, gel 844 is deposited on sheet 812 (carrier material), and then sheet 812 is folded back onto itself. As shown, this prevents gel 844 from being squeezed from one side. The folding of sheet 830 produces two layers, a first continuous sheet of carrier material and a second continuous sheet of carrier material, that are operably bonded or integrated with each other. The two layers, the first continuous sheet of carrier material and the second continuous sheet of carrier material, are connected by a fold (not shown).

[0094] FIG. 10 shows a schematic cross-sectional view of a composite aerosol-generating material 930 according to one embodiment. The composite aerosol-generating material 930 includes a sheet of first carrier material 922B and a sheet of second carrier material 922A. Two gel strips 944 are disposed between the first carrier material sheet 922B and the second carrier material sheet 922A. The centrally positioned susceptor material 900 is located in a central region proximal to the longitudinal axis, and the gel strips 944 are located in lateral regions on either side of the centrally positioned susceptor material 900, with gaps between them. In this embodiment, the gel strips 944 have the same width. The gel strips 944 are preferably positioned inward from the outer edges of the first carrier material 922B and the second carrier material 922A to prevent leakage of gel from the composite aerosol-generating material 930. The composite aerosol-generating material 930 is produced using the layering system 450 described with reference to FIG. 5 and an additional susceptor material 900 insertion mechanism. In the embodiment of FIG. 10, the first continuous sheet of carrier material 922B and the second continuous sheet of carrier material 922A are provided from the same sheet 512, for example, on a single bobbin (not shown), and then cut in two to form the first continuous sheet of carrier material and the second continuous sheet of carrier material. In manufacturing the embodiment of FIG. 10, the susceptor material 900 is inserted onto the first continuous sheet of carrier material 922B before dispensing gel onto the surface of the first continuous sheet of carrier material 922B. The susceptor material 900 is shown without direct contact with the gel strips 944. However, the embodiment of FIG. 10 shows the composite aerosol-generating material 930 before it is pressed. When pressed, the gel strips 944 may extend laterally between the first carrier material 922B and the second carrier material 922A and come into direct contact with the susceptor material 900.

[0095] FIG. 11 shows a schematic cross-sectional view of a composite aerosol-generating material 930 according to another embodiment. The composite aerosol-generating material 930 includes a first sheet 922B of carrier material, a second sheet 922A of carrier material, and a third sheet 922C of carrier material. Two gel strips 944 are disposed between the first sheet 922B of carrier material and the second sheet 922A of carrier material. A centrally positioned susceptor material 900 is located between the two gel strips 944 in a central region proximal to the longitudinal axis of the composite aerosol-generating material 930. In this embodiment, three additional gel strips 944 are disposed between the first sheet 922B of carrier material and the third sheet 922C of carrier material. When the composite aerosol-generating material 930 of the embodiment of FIG. 11 is pressed, the susceptor material 900 preferably comes into direct contact with the gel 944.

[0096] 12 shows a schematic side view of a composite aerosol-generating material 1030 comprising two layers of composite aerosol-generating material. The first composite aerosol-generating material comprises two continuous sheets of carrier material 1022A and 1022B, with a gel 1044A between the two continuous sheets of carrier material 1022A and 1022B. The second aerosol-generating material comprises two continuous sheets of carrier material 1022C and 1022D, with a gel 1044B between the two sheets of carrier material 1022C and 1022D. A susceptor or continuous susceptor band 1000 is positioned between the two layers of composite aerosol-generating material. In this illustrated embodiment, the susceptor 1000 is not in direct contact with the gels 1044A and 1044B. During use, heat from the susceptor 1000 or continuous susceptor band 1000 can still reach the gel through the carrier materials 1022B and 1022C. In this embodiment, the carrier material is all cotton, the gel contains nicotine, and the susceptor strip is aluminum.

[0097] FIG. 13 shows a cross-sectional view along the longitudinal axis of the aerosol-generating rod 1130. As with the embodiment of FIG. 12, the susceptor band 1100 is positioned between the continuous carrier materials 1122A and 1122B, not adjacent to the gels 1144, 1044A, and 1044B. In the embodiment of FIG. 13, the continuous susceptor band 1100 is placed between the composite aerosol-generating materials just prior to assembling the composite aerosol-generating materials and the continuous susceptor band 1100. The assembled materials are wound to produce the continuous aerosol-generating rod 1130. In this embodiment of FIG. 13, the carrier material is linen. The susceptor band is carbon. The gel includes nicotine. The gel further includes glycerin.

[0098] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are provided to facilitate understanding of certain terms used frequently herein.

[0099] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0100] As used in this specification and the appended claims, the term "or" is generally used in its sense to include alternatively or additionally, unless the context clearly dictates otherwise.

[0101] As used herein, the words "have," "having," "include," "including," "comprise," "comprising," and the like are used in an open-ended sense and generally mean "including, but not limited to." It should be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0102] The words "preferred" and "preferably" refer to embodiments of the invention that may offer certain advantages, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Moreover, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure, including the claims.

[0103] Any directions referred to herein, such as "up," "down," "left," "right," "upper," "lower," and other directions or orientations, are described herein for clarity and brevity and are not intended to limit the actual device or system. The devices and systems described herein may be used in numerous directions and orientations.

[0104] The above illustrated embodiments are not limiting, and other embodiments consistent with those described above will be apparent to those skilled in the art.

Claims

1. 1. A method for producing a composite aerosol-generating material, comprising: - providing a first continuous sheet of carrier material; - dispensing a gel onto the surface of said first continuous sheet of carrier material; - providing a second continuous sheet of carrier material and positioning said second continuous sheet of carrier material against said gel to form a composite material having a gel disposed between said first continuous sheet of carrier material and said second continuous sheet of carrier material; - further comprising the step of dispensing a greater amount of gel into a central region of the first continuous sheet of carrier material that is proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel dispensed into lateral regions that are distal to the longitudinal axis of the first continuous sheet of carrier material.

2. 10. The method of claim 1, further comprising the step of crimping at least one of the first continuous sheet of carrier material and the second continuous sheet of carrier material.

3. 3. The method of claim 1 or claim 2, further comprising providing the first continuous sheet of carrier material and the second continuous sheet of carrier material from respective sources of different carrier materials.

4. 3. The method for producing a composite aerosol-generating material of claim 1 or claim 2, further comprising providing both the first continuous sheet of carrier material and the second continuous sheet of carrier material from a single source of carrier material.

5. 5. The method for producing a composite aerosol-generating material of claim 4, further comprising the step of folding the continuous single sheet of carrier material source to form both the first continuous sheet of carrier material and the second continuous sheet of carrier material so that the first continuous sheet of carrier material and the second continuous sheet of carrier material are integral with each other via folds.

6. 5. The method of claim 4, further comprising cutting the continuous single source sheet of support material to form both the first continuous sheet of support material and the second continuous sheet of support material.

7. 7. The method for producing a composite aerosol-generating material according to claim 1, further comprising the step of pressing the composite aerosol-generating material in a direction perpendicular to the plane of the composite aerosol-generating material.

8. 8. The method for producing a composite aerosol-generating material according to claim 1, wherein the gel comprises a flavoring, an activator, a plasticizer, a humectant, nicotine, glycerin, propylene glycol, or any combination thereof.

9. The method for producing a composite aerosol-generating material according to any one of claims 1 to 8, wherein the composite aerosol-generating material comprises tobacco material.

10. A method for producing a composite aerosol-generating material, comprising: - providing a first continuous sheet of carrier material; - dispensing a gel onto the surface of said first continuous sheet of carrier material; - providing a second continuous sheet of carrier material and positioning said second continuous sheet of carrier material against said gel to form a composite material having a gel disposed between said first continuous sheet of carrier material and said second continuous sheet of carrier material; the gel is dispensed as a central strip along a central region proximal to a longitudinal axis of the first continuous sheet of carrier material and as a plurality of side strips along lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material, the central strip containing a greater amount of gel than each of the plurality of side strips; method.

11. A method for producing a composite aerosol-generating material, comprising: - providing a first continuous sheet of carrier material; - dispensing gel onto a surface of said first continuous sheet of carrier material in a plurality of lateral strips along lateral regions distal to the longitudinal axis of said first continuous sheet of carrier material; providing a continuous band of susceptor material and positioning said continuous band of susceptor material between said plurality of lateral strips after said gel has been dispensed onto said first continuous sheet of carrier material; - providing a second continuous sheet of carrier material and positioning said second continuous sheet of carrier material against said gel to form a composite material having a gel disposed between said first continuous sheet of carrier material and said second continuous sheet of carrier material; method.

12. 1. A composite aerosol-generating material comprising: a sheet of a first carrier material; a sheet of a second carrier material; a gel disposed between the first sheet of carrier material and the second sheet of carrier material, the gel being arranged as a central strip along a central region proximal to a longitudinal axis of the first continuous sheet of carrier material and as a plurality of side strips along lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material, the central strip comprising a greater amount of gel than each of the plurality of side strips; A composite aerosol-generating material comprising:

13. 13. The composite aerosol-generating material of claim 12, wherein the first continuous sheet of carrier material, or the second sheet of carrier material, or both the first and second sheets of carrier material comprise an aerosol-generating material.

14. A composite aerosol-generating rod comprising the composite aerosol-generating material of claim 12 or 13.

15. A composite aerosol-generating material, comprising: a sheet of a first carrier material; a sheet of a second carrier material; a gel, the gel being disposed between the first sheet of carrier material and the second sheet of carrier material, the gel being disposed as a plurality of lateral strips along lateral regions distal to the longitudinal axis of the first continuous sheet of carrier material; a susceptor material positioned between the first sheet of carrier material and the second sheet of carrier material and between the plurality of lateral strips; A composite aerosol-generating material comprising:

Images