Consumables for use with aerosol supply devices

Abstract

A consumable (24) is described for use with an aerosol delivery device (2). The consumable (24) includes a substrate (28), an aerosol-generating material (26), and a delivered substance (40) that can be volatilized, where the substrate (28) supports the aerosol-generating material (26) and the delivered substance (40) volatilizes upon heating of one or both of the substrate (28) or the aerosol-generating material (26).

Description

[Technical Field]

[0001] This disclosure relates to a non-flammable aerosol supply system, in particular to consumables for use with an aerosol supply device, a method for manufacturing consumables for use with an aerosol supply device, and an aerosol supply system comprising the consumables and the aerosol supply device. Background

[0002] Smoking products such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Alternatives to these types of articles release inhalable aerosols or vapors by heating a substrate material without combustion, thereby releasing compounds from the substrate. These can be called non-combustible smoking articles, aerosol generating assemblies, or aerosol supply devices.

[0003] One example of such a product is a heating device that releases compounds by heating an aerosolizable material, which can be called a solid aerosol-generating material, without combustion. This solid aerosol-generating material, in some cases, includes tobacco material. Upon heating, at least one component of the material volatilizes, usually forming an inhalable aerosol. These products can be called non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations for volatilizing at least one component of the solid aerosol-generating material are known.

[0004] Another example is the existence of hybrid devices. These hybrid devices include a liquid source (which may or may not contain nicotine) that vaporizes upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-generating material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce an inhalable medium.

[0005] According to a first aspect of the present disclosure, a consumable for use with an aerosol supply device is provided. The consumable comprises a support, an aerosol-generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol-generating material, and the deliverable substance volatilizes upon heating of either or both of the support or the aerosol-generating material.

[0006] A second aspect of the present disclosure provides a method for manufacturing a consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and at least one volatile substance. The method is a) The step of preparing a support, b) A step of applying a slurry of aerosol-generating material to the surface of a consumable, c) A step of drying the applied aerosol-generating material, d) The step of applying at least one substance to the surface of the consumable, Includes.

[0007] According to a third aspect of the present disclosure, an aerosol supply system is provided, comprising an aerosol supply device and consumables according to a first aspect of the present disclosure.

[0008] A fourth aspect of the present disclosure provides a method for generating an aerosol from a consumable according to the first aspect of the present disclosure using an aerosol generating device, the aerosol generating device having at least one heat source arranged to heat the consumable without burning it during use, the at least one heat source being a resistance heating element.

[0009] Further features and advantages of this disclosure will become apparent from the following description of embodiments of this disclosure, given by reference to the accompanying drawings, for example. [Brief explanation of the drawing]

[0010] [Figure 1] This disclosure shows schematic diagrams of embodiments of an aerosol supply device and consumables. [Figure 2]Shows a first embodiment of the consumable of FIG. 1 along the cross-section line AA'. [Figure 3] Shows the second surface of the support of the first embodiment of the consumable of FIG. 1. [Figure 4] Shows a second embodiment of the consumable of FIG. 1 along the cross-section line AA'. [Figure 5] Shows a perspective view of the second consumable of FIG. 4. [Figure 6] Shows a third embodiment of the consumable of FIG. 1 along the cross-section line AA'. [Figure 7] Shows a fourth embodiment of the consumable of FIG. 1 along the cross-section line AA'. [Figure 8] Shows a fifth embodiment of the consumable of FIG. 1 along the cross-section line AA'. [Figure 9] Shows a schematic first example of a method for manufacturing a consumable according to the present disclosure. [Figure 10] Shows a schematic second example of a method for manufacturing a consumable according to the present disclosure. [Figure 11] Shows a schematic third example of a method for manufacturing a consumable according to the present disclosure. Detailed description

[0011] The consumable in this specification may alternatively be referred to as an article.

[0012] In some embodiments, the consumable contains an aerosol-generating material. The consumable can include an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol modifier, one or more active ingredients, one or more fragrances, one or more aerosol-forming agent materials, and / or one or more other functional materials.

[0013] The device for heating the aerosol-generating material used with the consumable is part of a non-combustible aerosol supply system. The non-combustible aerosol supply system releases compounds from the aerosol-generating material without burning the aerosol-generating material, such as an e-cigarette, a tobacco heating product, and a mixing system, etc., which use a combination of aerosol-generating materials to generate an aerosol.

[0014] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating constituent materials (or components thereof) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0015] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a power-supplied non-combustible aerosol supply system.

[0016] In some embodiments, the non-flammable aerosol supply system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0017] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustible heating system. An example of such a system is a cigarette heating system.

[0018] In some embodiments, a non-flammable aerosol supply system is a mixing system for generating an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, be tobacco or a non-tobacco product.

[0019] Typically, a non-flammable aerosol supply system may comprise a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0020] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. These consumables are, in some cases, referred to as articles throughout the disclosure.

[0021] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device for a non-combustible aerosol supply system, may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be excited to disperse power in the form of heat to an aerosol-generating material or heat transfer material in the vicinity of the heat source.

[0022] In some embodiments, the non-flammable aerosol supply device may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0023] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0024] According to a first aspect of this disclosure, a consumable for use with an aerosol supply device is provided. The consumable comprises a support, an aerosol-generating material, and a deliverable substance that can be volatilized. The support supports the aerosol-generating material, and the deliverable substance volatilizes when the support or the aerosol-generating material is heated.

[0025] The advantage of the consumables of this disclosure is that the aerosol-generating material and the delivered substance are distinct from each other, even though they may be physically close to each other, although this is not essential. They can be located in different places on or within the consumable and can be treated or behave differently during the manufacture, storage, and / or use of the consumable. The aerosol-generating material and the delivered substance can be different from each other and may possess different properties such as the optimal temperature range for vaporization or aerosol formation, the chemical composition of the vapor or aerosol produced from the aerosol-generating material and the delivered substance, storage characteristics, volatilization rate, and rate of volatilization. This can be advantageous during the use of the consumable, during storage of the consumable before use, and / or during the manufacture of the consumable.

[0026] References to the substance to be delivered in this disclosure are understood to include references to a single substance or a mixture of two or more substances.

[0027] In some of the embodiments described above, the support comprises an adsorbent material, and the adsorbent comprises the substance to be delivered.

[0028] In this disclosure, any discussion of an sorbent containing the delivered substance refers to the absorption or adsorption of the delivered substance onto the sorbent material. A situation in which the delivered substance enters a pore or cavity in the sorbent material but does not chemically interact with the sorbent material. The situation in which the delivered substance enters the sorbent material and chemically interacts with the sorbent material. A situation in which the delivered substance forms a film of the delivered substance on the sorbent material, but does not chemically interact with the sorbent material, or A situation in which the delivered substance forms a film of the delivered substance on the sorbent material and chemically interacts with the sorbent material to form an adsorbate. Includes.

[0029] In some embodiments of any of the above embodiments, the delivered substance is located within one or more distinct zones of the sorbent material, or is absorbed / adsorbed within these zones and is not located outside these distinct zones. In other embodiments, the delivered substance is located within one or more distinct zones of the sorbent material at a higher concentration than the delivered substance is located in the portion of the sorbent material not within these distinct zones, or is absorbed / adsorbed within these zones.

[0030] In some embodiments, the absorption or adsorption of the delivered substance onto the sorbent material is achieved by coating the delivered substance onto the surface of the sorbent material, thereby enabling the absorption or adsorption of the delivered substance onto the sorbent material. This coating may, but is not limited to, be by spraying, brushing, roller coating, or known printing techniques such as inkjet or valvejet printing.

[0031] The use of separate aerosol-generating materials and delivered substances offers one or more advantages. One such advantage is that the delivered substance can be selected to form aerosols faster and / or at a lower temperature than aerosol formation from the aerosol-generating material alone. This allows the user to receive a puff of aerosol more quickly than they would from a consumable containing only the aerosol-generating material.

[0032] A further advantage is that the aerosol-generating material and the delivered substance can be selected to give the user a puff with the same flavor throughout, or to give a puff with a first flavor from the delivered substance followed by a second flavor from the aerosol-generating material.

[0033] A further advantage is that the delivered substance can have a sufficiently low aerosol formation temperature, which is achieved by heat radiated from the aerosol-generating material, or by heat that is not directed towards / absorbed by the aerosol-generating material while it is being heated. This increases the total amount or volume of aerosol (from the delivered substance and the aerosol-generating material) that can be generated per unit of thermal energy applied to the consumable compared to a consumable containing only the aerosol-generating material.

[0034] The support may consist of a material suitable for forming the substrate. The support may be, for example, paper, cardboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy, or may include these. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material of the support. In some alternative embodiments, the susceptor is on or attached to one or both sides or surfaces of the material.

[0035] The sorbent material is either an absorbent or an adsorbent related to the substance being delivered, and is a material suitable for use in non-flammable aerosol delivery systems. Suitable materials for the sorbent material include, but are not limited to, porous materials, dry gels (aerogels, xerogels, cooling gels), fibrous materials (natural or synthetic), paper, cardboard, ceramics, wood, aerogels, activated carbon, porous polymers, and sponges. In the consumables of this disclosure, the sorbent material has a desired object to be delivered that is absorbed or adsorbed by the structure of the sorbent material.

[0036] The sorbent material can be heated so that the delivered substance is absorbed or adsorbed onto the sorbent material and aerosolized. The sorbent material can be selected for its electrothermal properties and the rate at which the delivered substance can be aerosolized and the aerosol leaves the sorbent material.

[0037] In some embodiments of any of the embodiments described above, the at least one substance absorbed or adsorbed by the sorbing material includes one or more flavorings, active substances, mixtures of flavorings, mixtures of active substances, mixtures of one or more flavorings and one or more active substances, one or more solvents, and / or one or more aerosol generating agents or aerosol forming agent materials.

[0038] In some of the embodiments described above, the delivered substance may have an aerosolization temperature of 60 degrees Celsius or higher.

[0039] In some of the embodiments described above, the support may include an adsorbent material. In some of the embodiments described above, the support may be formed from an adsorbent material.

[0040] An aerosol-generating agent or aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0041] In some embodiments of any of the embodiments described above, the support comprises an adsorbent material. In some embodiments, the support is a lamination, the lamination comprising at least first and second substrates, at least one of which is formed from the adsorbent material. In some embodiments, another substrate of the lamination may be present for structural purposes, in particular to provide desired handling characteristics to the consumable, for example, to provide some degree of elastic restorative force against deformation of the consumable and / or to provide stiffness.

[0042] In some embodiments of any of the embodiments described above, the adsorbent material forms one or both of the first or second surfaces of the support. In some embodiments, one surface of the support is composed of the adsorbent material, and the other surface of the support is composed of a material that is not the adsorbent material.

[0043] In some of the embodiments described above, the surface of the support is formed from an impermeable material.

[0044] In some embodiments of any of the above embodiments, one of the surfaces of the support is formed from a susceptor.

[0045] In some embodiments of any of the above embodiments, the support is a lamination comprising at least three substrates, wherein the substrate not forming the first or second surface of the support is a susceptor.

[0046] A susceptor is a material that can be heated by the penetration of a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and the penetration of a fluctuating magnetic field into the conductive material causes inductive heating of the susceptor through resistive heating resulting from eddy currents. The susceptor may also be a magnetic material, and the penetration of a fluctuating magnetic field into the magnetic material causes magnetic hysteresis heating of the susceptor. The susceptor may be both conductive and magnetic, and can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is called a magnetic field generator.

[0047] The susceptor may contain a ferromagnetic metal such as iron, or an iron alloy such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steels such as Grade 410 stainless steel, Grade 420 stainless steel, Grade 430 stainless steel, or similar grades of stainless steel. Alternatively, the susceptor may contain a suitable non-magnetic, particularly paramagnetic, conductive material such as aluminum. In paramagnetic conductive materials, induction heating occurs only by resistance heating due to eddy currents. Alternatively, the susceptor may contain a non-conductive ferrimagnetic material such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated only by hysteresis loss. The susceptor may contain commercially available alloys such as Phytherm230 (having a composition of 50 wt% Ni, 10 wt% Cr and the remainder Fe in wt% units) or Phytherm260 (having a composition of 50 wt% Ni, 9 wt% Cr and the remainder Fe).

[0048] In some embodiments of any of the embodiments described above, the susceptor may be a metal foil, optionally an aluminum foil, or an iron foil. Alternatively, in some embodiments of any of the embodiments described above, the susceptor may be any conductor that can be sprayed, or vapor deposited on a material forming a support.

[0049] In some embodiments of any of the above embodiments, the adsorbent material forms both of the first and second surfaces of the support.

[0050] In some of the embodiments described above, the support is formed entirely from an adsorbent material.

[0051] In one embodiment of any of the embodiments described above, the support includes a substrate of support material, the support material includes one or more of paper, card, cardboard, cardboard, reconstructive material, plastic material, ceramic material, composite material, glass, metal, or metal alloy.

[0052] In one embodiment of any of the embodiments described above, the support comprises a plastic material capable of withstanding temperatures typically encountered in non-flammable aerosol supply devices. In some embodiments, the support comprises polyetheretherketone (PEEK). Such embodiments have the advantage that the support can be reused and the consumable is less susceptible to any condensation in the non-flammable aerosol supply device than consumables comprising a support that includes the use of an adsorbent material for structural purposes.

[0053] In some embodiments of any of the embodiments described above, the aerosol-generating material is supported on the surface of a support that is not an adsorbent material. Such a configuration has the advantage that, during the manufacture of the consumables, subsequent storage, and use, the aerosol-generating material or any component of the aerosol-generating material is not adsorbed / absorbed onto the support or adsorbent material.

[0054] In some of the embodiments described above, the aerosol-generating material is supported on the surface of a support formed from an adsorbent material.

[0055] In some of the embodiments described above, the delivered material is supported on the surface of a support.

[0056] In some embodiments of any of the above embodiments, the consumable further includes an adsorbent material which contains a substance that is not part of the support but is supported and delivered on the support.

[0057] In some embodiments of any of the above embodiments, the aerosol-generating material is supported on a first surface of the support, and the sorbent material is supported on one or both of the first and second surfaces of the support. In these embodiments, the sorbent material is supported on the surface of the support, not as part of the support. Such a configuration has the advantage that the sorbent material can be supported on the support only in the location where it is desirable to be located.

[0058] In some embodiments of any of the embodiments described above, the aerosol-generating material and the sorbent material are both positioned on a consumable such that heating of the aerosol-generating material to aerosolize at least one component of the aerosol-generating material also heats at least a portion of the sorbent material. This heating of at least a portion of the sorbent material may be due to heat conduction from a portion of the aerosol-generating material and / or the support supporting the aerosol-generating material. Such heating of the sorbent material can be considered indirect heating.

[0059] As a result of such indirect heating, the adsorbent material may be heated to a temperature lower than the temperature at which the aerosol-generating material is heated, but still sufficient to volatilize the delivered substance. In some embodiments, the heating profile of the adsorbent material may be influenced by the shape of the adsorbent material and its proximity to the aerosol-generating material.

[0060] In some embodiments of any of the embodiments described above, the support may include or support means for regulating or facilitating the conduction of heat from the aerosol-generating material and / or a portion of the support supporting the aerosol-generating material to the adsorbent material.

[0061] In some embodiments of any of the embodiments described above, the sorbent material includes at least one separate zone. Each separate zone is a volume of the sorbent material that can be positioned relative to the aerosol-generating material such that, as a result of heating the aerosol-generating material to aerosolize at least one component of the aerosol-generating material, the sorbent material in the separate zone is heated to a temperature high enough to volatilize or aerosolize at least one substance absorbed or adsorbed therein. The sorbent material may include one or more separate zones.

[0062] In some embodiments of any of the above embodiments, the delivered substance is volatilized a period PS after the start of heating of the support or aerosol-generating material, and the aerosol-generating material is configured to release an aerosol a period PA after the start of heating of the support or aerosol-generating material, where the period PS is less than or equal to PA. In some embodiments, the period PS is less than PA.

[0063] In some embodiments of any of the embodiments described above, the adsorbent material comprises one or more distinct zones, and the concentration of the delivered substance in the adsorbent material within the distinct zones can be higher, and in some embodiments significantly higher, than the concentration of the delivered substance in the portion of the adsorbent material not within the distinct zones. The relative concentrations of the delivered substance in the distinct zones and outside the distinct zones can be determined by the location of absorption / adsorption of the substance delivered to the adsorbent material.

[0064] In some embodiments of any of the above embodiments, the separate zones can be identified only by the relative position of the consumables and / or by the concentration of the substance delivered in the adsorbent material within the separate zone.

[0065] In other alternative embodiments, the separate zone has a shape and size, which is at least partially defined by an adsorbent material surrounding the separate zone, which has a capacity for the adsorption of at least one delivered substance into the adsorbent material that is reduced to the capacity for the adsorption of at least one substance into the adsorbent material in the separate zone.

[0066] In some embodiments, the capacity of the adsorption of the delivered substance into the adsorbent material surrounding the separate zone may be affected by the adsorption / absorption of nonvolatile substances into the adsorbent material surrounding the separate zone. In some other embodiments, the surface of the adsorbent material surrounding the separate zone may be treated to limit the permeability of the surface of the delivered substance to less than the permeability of the surface in the separate zone. In some embodiments, this is at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% lower than that of the separate surface.

[0067] By blocking or limiting the adsorption of a substance delivered to an sorbent material in areas of the sorbent material where the delivered substance is not desired, the adsorption of the delivered substance is likely to result in a reduction of the delivered substance used in the manufacture of the consumable, along with associated cost savings. Furthermore, such blocking or limiting allows for more uniform utilization of the consumable of this disclosure than would be achieved if the location of the delivered substance in the sorbent material were not controlled.

[0068] In some embodiments of any of the embodiments described above, there are at least two distinct zones, at least two of which contain different delivered substances or different mixtures of delivered substances.

[0069] In some embodiments of any of the embodiments described above, the aerosol-generating material is supported on a support in one or more distinct parts, and at least one distinct zone is associated with each distinct part of the aerosol-generating material.

[0070] In some embodiments of any of the above embodiments, the surface of a support on which a separate portion of the aerosol-generating material is supported includes or supports an sorbent material, which includes a separate zone, the separate zone substantially surrounding the separate portion of the aerosol-generating material. This configuration has the advantage that when the separate portion of the aerosol-generating material is heated, the sorbent material in the separate zone is indirectly heated by the separate portion of the aerosol-generating material.

[0071] In some embodiments of any of the embodiments described above, the consumable includes a separate portion of aerosol-generating material on a first surface of a support, a separate zone of sorbent material on a second surface of the support, and the separate portion and zone of the aerosol material are in corresponding positions on their respective surfaces. By corresponding positions, it should be understood that when one of the separate portion and zone of the aerosol-generating material is viewed from a position perpendicular to the surface on which it is located, one of the separate portion and zone of the aerosol-generating material substantially overlaps the other of the separate portion and zone of the aerosol-generating material.

[0072] In some embodiments of any of the above embodiments, the shapes of the distinct portions and distinct zones of the aerosol-generating material on the planes of the first and second surfaces of the support are substantially the same.

[0073] In some embodiments of any of the embodiments described above, a separate portion of the aerosol-generating material covers a first area on the surface of a support on which the separate portion is supported, and a separate zone covers a second area on the surface of the support on which the separate zone is supported, wherein one of the first and second areas is larger than the other of the first and second areas.

[0074] In some embodiments of any of the embodiments described above, the consumable includes one or more perforations extending at least between the first and second surfaces of the support. This configuration has the advantage that when the consumable is in use, aerosols generated on or from the first side of the support pass through the perforations to reach the other side or second surface of the support. This is advantageous because, in some embodiments, it allows aerosols generated from an aerosol-generating material on one side or surface of the support to mix with aerosols generated from an sorbent material on the other side or surface of the support. This has the result that the two aerosols can be mixed before they are passed to the mouthpiece before they are inhaled by the user.

[0075] In this disclosure, the term “number” is intended to mean 0, 1, or 2 or more.

[0076] In some embodiments of any of the embodiments described above, one or more perforations extend between one of the first sides or surfaces of the support and the adjacent surface of the consumable to the other side or surface of the support. In such embodiments, the perforations extend through the support, for example, a portion of the aerosol-generating material supported on the surface of the support, or, in alternative embodiments, through the support and a portion of the sorbent material supported on the surface of the support.

[0077] In some embodiments of any of the embodiments described above, one or more perforations extend between a surface of the consumable adjacent to a first side or surface of the support and a surface of the consumable adjacent to a second side or surface of the support. In such embodiments, the perforations may extend through the support, a portion of the aerosol generation, and a portion of the sorbent material.

[0078] In some embodiments of any of the embodiments described above, at least one of the perforations has a first dead-end end within the consumable, and the other end is open through one of the surfaces of the support, the delivered substance, the aerosol-generating material, or the surface of the consumable. The dead-end end is the end within the material, and therefore the end of the perforation is closed by that material.

[0079] In some of the embodiments described above, the perforations are at least 0.01 mm 2 at least 0.05 mm 2 at least 0.1 mm 2 at least 0.5 mm 2 at least 1 mm 2 , at least 2mm 2 , or at least 3 mm 2 It has the following cross-sectional area.

[0080] In one embodiment of any of the above embodiments, the aerosol-generating material supported on the support is positioned such that there is a band of the support on both surfaces of the support, extending a predetermined distance on the support from the edge of the support where there is no aerosol-generating material. The band can extend the same distance from the edge of the support along the entire length of the edge of the support. The band can assist in handling the consumables during use or packaging. The band may be continuous or discontinuous along the entire length of the edge of the support. The band can extend different distances on the surface of the support at different locations around the edge of the support.

[0081] A second aspect of the present invention provides a method for manufacturing a consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and at least one substance. This method is a) The step of preparing a support, b) A step of applying a slurry of aerosol-generating material to the surface of a consumable, c) A step of drying the applied aerosol-generating material, d) The step of applying at least one substance to the surface of a consumable within the adsorbent material, Includes.

[0082] An advantage of the method according to the second aspect of this disclosure is that the coating of the aerosol-generating material and the substance to be delivered onto the support can be carried out separately in both time and space. Such capability overcomes known challenges relating to the manufacture of consumables for use with aerosol-delivering devices.

[0083] In the manufacture of consumables for use with aerosol supply devices, it is known that a slurry of aerosol-generating material is formed, and the slurry comprises a solvent that causes the aerosol-generating material to form a slurry, and one or more different substances or groups of substances (e.g., one or more physiologically active materials and one or more fragrances or flavorings) that will form part of the aerosol when the consumable is used and the aerosol-generating material is aerosolized. However, the solvent and these substances may have different evaporation rates at any given temperature.

[0084] In the manufacture of consumables, aerosol-generating material slurry is applied to the surface of a support or to a sheet of material, which is then cut to form multiple supports. The slurry is then dried to form aerosol-generating material of approximately fixed dimensions on the surface on which the slurry is supported. In some embodiments, the aerosol-generating material is dried to form an aerosol-generating gel or aerosol-generating film. During the drying process, the solvent for the slurry evaporates, as do some of the substances that will form part of the aerosol when the consumable is used. During the slurry drying process, the different evaporation rates of the solvent for the aerosol-generating material and the various substances that will be aerosolized have been shown to have an effect that can make it difficult to precisely control the amount of substance that will form part of the aerosol in the dried aerosol material. As a result, it can be difficult to achieve a consistent, predictable, and repeatable commercial product. A further effect is that a large amount of active material incorporated into the slurry is lost before the slurry is sufficiently dried to form aerosol-generating material, aerosol-generating gel, or aerosol-generating film of approximately fixed dimensions.

[0085] The method of this disclosure enables the slurry to be formulated to contain only substances that do not evaporate in undesirable amounts during the drying of the slurry. These substances may have an evaporation rate higher or significantly higher than the evaporation rate of the solvent under the conditions under which the slurry is dried.

[0086] In some embodiments of any of the embodiments described above, substances that have previously evaporated in undesirable amounts during slurry drying may include all or some of the substances delivered by this disclosure. This reduces the amount of substances lost by evaporation during the manufacturing process, thereby increasing the efficiency of use of these substances and reducing the environmental problems associated with the evaporation of these substances during the consumable manufacturing process.

[0087] A further advantage of the method of this disclosure may be that the slurry can undergo a drying process at a higher temperature than previously possible, thereby reducing the manufacturing time of the consumables.

[0088] In some of the embodiments described above, step (b) is performed at any point after step (a), step (c) follows step (b), and step (d) is performed at any point after step (c). For example, there may be a gap of several days, several weeks, or several months between steps (a) and (b) and / or between steps (c) and (d).

[0089] In some embodiments of any of the above embodiments, the method further includes step (e), which includes preparing an adsorbent material.

[0090] In some embodiments of any of the above embodiments, step (e) is performed before step (d), and step (d) includes coating the substance to be delivered onto an sorbent material to form an sorbent material containing the substance to be delivered, and, if the support does not contain an sorbent material, coating the consumable with the sorbent material containing the substance to be delivered.

[0091] In some embodiments of any of the above embodiments, the sorbent material can be fixed to a consumable at any point in the manufacturing process. It will be understood that the sorbent material can be made unaffected by exposure to the drying process for the aerosol-generating material slurry. In some embodiments, the sorbent material is fixed to a support.

[0092] In some of the embodiments described above, the support in step (a) includes an adsorbent material.

[0093] In some embodiments of any of the above embodiments, step (e) includes applying a paste to a consumable and then drying the paste so that it dries to form an adsorbent material. Such a method step can allow the adsorbent material to be applied only to a predetermined portion of the support. In some embodiments, the drying of the paste is simultaneous with step (c).

[0094] In some embodiments of any of the embodiments described above, step (e) includes forming a desired shape of the adsorbent material and fixing this shape of the adsorbent material in a desired position on a consumable. This method of shaping the adsorbent and then fixing it to a support allows the adsorbent material to be molded or cut from a larger unit of adsorbent material, such as a sheet of adsorbent material.

[0095] In some embodiments of any of the above embodiments, steps (e) and (d) include preparing a sheet of sorbent material, applying an adhesive to the first surface and covering the adhesive with a removable carrier sheet, applying the substance to be delivered to the other surface of the sorbent material, enabling the substance to be delivered to be absorbed or adsorbed by the sorbent material, and cutting the sorbent material into one or more desired shapes.

[0096] The adhesive may be a peelable adhesive, a repositionable adhesive, a low-tack adhesive, or any other suitable adhesive.

[0097] Next, the sorbent material can be stored or transferred to the consumable, the carrier sheet can be peeled off from the sorbent material, and then the sorbent material can be adhered to the consumable at the desired position. The sorbent material can be adhered to the consumable during the manufacture of the consumable. Alternatively, the user of the consumable can adhere the sorbent material to the consumable before use. This allows the user to take one or more portions of the sorbent material containing different delivered substances, such as fragrances, select the fragrance they wish to use, and apply that fragrance to the consumable. This embodiment has the advantage to the user of choice and control over the experience, and to the manufacturer the advantage of being able to manufacture a limited range of consumables that can be used with a much wider variety of delivered substances.

[0098] In some embodiments of any of the embodiments described above, step (d) is performed before the sorbent material is fixed to the consumable. This has the advantage that the absorption / adsorption of the substance delivered to the sorbent material may occur at a location separate from the place of manufacture of the consumable of the Disclosure.

[0099] In some embodiments of any of the embodiments described above, steps (b) and (c) are repeated once or more times before step (d). Repeating steps (b) and (c) can, in some embodiments, allow the aerosol-generating material to be constructed in layers on the consumable. In some embodiments, these layers may be formed from different compositions of the aerosol-generating material.

[0100] In some embodiments of any of the embodiments described above, the aerosol-generating material may be applied to one or more distinct areas of the consumable. In some embodiments, at least two of the distinct areas of the consumable may be formed from aerosol-generating material of different compositions, and steps (b) and (c) may be repeated for each different composition of the aerosol-generating material.

[0101] In some embodiments of any of the embodiments described above, step (c) includes the use of one or more of time, conductive heat, radiant heat, or air movement across the exposed surface of the aerosol-generating material.

[0102] In some embodiments of any of the above embodiments, the method includes a further step (f) of preparing a susceptor and fixing the susceptor to a support. This step is included when the aerosol-generating material is heated using a magnetic induction technique or a combination of magnetic induction and resistance heating techniques. If the consumable is heated using only resistance heating techniques, a susceptor is not required but may be present.

[0103] In some embodiments of any of the embodiments described above, step (f) is performed after step (a) to fix the susceptor to the first surface of the support, and step (b) is performed after step (f) to coat the susceptor at least partially with a slurry of aerosol-generating material. In some embodiments, the susceptor is a sheet of metal foil and all of the aerosol-generating material is coated onto the susceptor.

[0104] In some embodiments of any of the embodiments described above, the support is a sheet of material, and the method includes step (h) of cutting the support into two or more consumables. Such a method is advantageous in that it facilitates handling of the support in the manufacturing process, because it can be easier to handle material sheets that are larger than the size of material generally required to form consumables for hand aerosol dispensing devices. The support can be cut to form consumables of any desired shape, such as square, rectangular, or circular.

[0105] In some embodiments of any of the embodiments described above, the method includes step (i) of perforating at least one support to form one or more perforations. One or more of these perforations may extend at least between first and second surfaces of the support; one or more of these perforations may extend at least between one of the first or second surfaces of the support and a surface of the consumable adjacent to the other of the first or second surfaces of the support; one or more of these perforations may extend between a surface of the consumable adjacent to the first surface of the support and a surface of the consumable adjacent to the second surface of the support; one or more of these perforations may extend at least through the sorbent material; one or more of these perforations may extend at least through the aerosol-generating material; or one or more of these perforations may extend between a first dead-end end in the consumable and the other end open through one of the surfaces of the support, the delivered substance, the aerosol-generating material, or the consumable.

[0106] In any embodiment of the above embodiments, the aerosol-generating material and / or the delivered substance includes an active substance.

[0107] When used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive substances. The active substance may be of natural origin or obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, non-cannabinoid terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0108] The active substance may include one or more cannabinoids or terpenes, or one or more components, derivatives, or extracts of cannabis.

[0109] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0110] The active substance may include, or be derived from, one or more plant substances, or components, derivatives, or extracts thereof. As used herein, the term "plant substance" includes, but is not limited to, any plant-derived material including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include synthetically obtained active compounds naturally present in plant substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, fragments, shards, sheets, etc. Examples of plant-based substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazelnut, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green or black), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, curcuma, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0111] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substance being tobacco.

[0112] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0113] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from rooibos and fennel.

[0114] In some embodiments, the aerosol-generating material and / or the substance delivered includes a fragrance or flavoring.

[0115] As used herein, the terms “flavoring” and “flavoring” refer to materials that may be used to create a desired taste, aroma, or other somatosensory sensation in products intended for adult consumers, where local regulations permit.These ingredients include naturally derived fragrance materials, plant substances, plant substance extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits). Papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chats, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, mint oil of any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo leaf, hazelnut, hibiscus, laurel, mate, orange peel, rose, green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, It may contain other additives such as marjoram, olive, lemon balm, lemon basil, chives, curcumin, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-derived substances, or breath fresheners.These materials may be imitations, synthetic or natural ingredients, or mixtures thereof. These materials may be in any suitable form, such as a liquid such as oil, a solid such as powder, or a gas.

[0116] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes flavoring components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring components extracted from tobacco. In some embodiments, the flavoring includes flavoring components extracted from cannabis.

[0117] In some embodiments, the fragrance may contain sensory evokers intended to produce somatosensory sensations that are chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and these may include agents that provide heating, cooling, tingling, or anesthetic effects. A preferred thermal agent may be, but is not limited to, vanillyl ethyl ether, and a preferred cooling agent may be, but is not limited to, eucalyptol WS-3.

[0118] The aerosol-generating material and / or delivered substance is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or any other method. The aerosol-generating material and / or delivered substance may be in the form of, for example, a solid, liquid, or semi-solid (such as a gel), and may or may not contain active substances and / or flavorings.

[0119] The aerosol-generating material and / or delivered substance may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0120] The aerosol-generating material and / or the delivered substance may include a binder such as a gelling agent and an aerosol-forming agent material. Optionally, the delivered substance and / or fillers may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material and / or the delivered substance may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material and / or the delivered substance is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material and / or the delivered substance is substantially free of tobacco.

[0121] The aerosol-generating material and / or the delivered substance may include or take the form of an aerosol-generating film. The aerosol-generating film may contain a binder such as a gelling agent and an aerosol-forming agent. Optionally, the delivered substance and / or fillers may also be present. The aerosol-generating film may not be substantially made of plant-based materials. In particular, in some embodiments, the aerosol-generating material and / or the delivered substance is substantially free of tobacco.

[0122] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0123] An aerosol-generating film can be formed by combining a binder such as a gelling agent with a solvent such as water, an aerosol-forming agent, and one or more other components such as one or more delivered substances to form a slurry, and then heating the slurry to volatilize at least some of the solvent to form an aerosol-generating film.

[0124] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0125] The aerosol-generating material may include or be an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which is an amorphous solid. The amorphous solid may be a monolithic solid. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can hold some fluid, such as a liquid, inside. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0126] Amorphous solids do not necessarily have to contain substantially no plant-based materials. Amorphous solids do not necessarily have to contain substantially no tobacco.

[0127] In some embodiments, the aerosol-generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-generating agent may include one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol-generating agent includes glycerol. In some embodiments, the aerosol-generating agent comprises one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butylene glycol, and glycerin; esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate; and / or one or more aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanediate and dimethyl tetradecanediate.

[0128] In some embodiments, the aerosol-generating material may contain about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of an aerosol-generating agent (all calculated on a dry weight basis). The aerosol-generating agent may act as a plasticizer. For example, the aerosol-generating material may contain 0.5 to 40 wt%, 3 to 35 wt%, or 10 to 25 wt% of an aerosol-generating agent.

[0129] In some embodiments, the aerosol-generating material may contain about 5 wt%, 10 wt%, 20 wt%, 25 wt%, 27 wt%, or 30 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of an aerosol-generating agent (DWB). For example, the aerosol-generating material may contain 10-60 wt%, 20-50 wt%, 25-40 wt%, or 30-35 wt% of an aerosol-generating agent.

[0130] In some embodiments, the aerosol-generating material may contain up to approximately 80 wt% of an aerosol-generating agent (DWB), such as approximately 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55 or 65 wt%.

[0131] The aerosol-generating material may also contain a gelling agent.

[0132] In some embodiments, the gelling agent comprises a hydrophilic colloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and / or pectin and may be combined with a solidifying agent (such as a calcium source) during the formation of the aerosol-generating material. In some cases, the aerosol-generating material may contain calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0133] In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0134] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0135] In some embodiments, the gelling agent comprises (or is one or more of) hydroxycellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

[0136] In some embodiments, the gelling agent includes (or is one or more non-cellulose gelling agents) one or more non-cellulose gelling agents, but not limited to agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose-based gelling agent is alginic acid or agar.

[0137] In some embodiments, the gelling agent comprises alginic acid, which is present in the aerosol-generating material in an amount of 10-30 wt% (calculated on a dry weight basis) of the aerosol-generating material. In some embodiments, alginic acid is the only gelling agent present in the aerosol-generating material. In other embodiments, the gelling agent comprises alginic acid and at least one further gelling agent, such as pectin.

[0138] In some embodiments, the aerosol-generating material contains approximately 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to approximately 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol-generating material may contain 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent.

[0139] In some embodiments, the aerosol-generating material contains about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol-generating material may contain 20-35 wt% or 25-30 wt% of a gelling agent.

[0140] In some cases, the aerosol-generating material may contain approximately 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt% to approximately 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of a gelling agent (DWB). For example, the aerosol-generating material may contain 10-40 wt%, 15-30 wt%, or 20-25 wt% of a gelling agent (DWB).

[0141] In the example, the aerosol-generating material together comprises a gelling agent and filler in amounts of approximately 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to approximately 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material. In the example, the aerosol-generating material together comprises a gelling agent and filler in amounts of approximately 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-generating material.

[0142] In the example, the aerosol-generating material contains a gelling agent in an amount of approximately 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to approximately 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material (i.e., the amount of filler is not taken into consideration). In the example, the aerosol-generating material contains a gelling agent in an amount of approximately 5 to 60 wt%, 20 to 60 wt%, 25 to 55 wt%, 30 to 50 wt%, or 35 to 45 wt% of the aerosol-generating material (i.e., the amount of filler is not taken into consideration).

[0143] In some examples, alginic acid is included in the gelling agent in an amount of approximately 5-40 wt% or 15-40 wt% of the aerosol-generating material. That is, the aerosol-generating material contains alginic acid in an amount of approximately 5-40 wt% or 15-40 wt% of the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material contains alginic acid in an amount of approximately 20-40 wt% or approximately 15-35 wt% of the aerosol-generating material.

[0144] In some cases, pectin is included in the gelling agent in an amount of approximately 3–15 wt% of the aerosol-generating material. That is, the aerosol-generating material contains approximately 3–15 wt% of pectin by dry weight of the aerosol-generating material. In some cases, the aerosol-generating material contains approximately 5–10 wt% of pectin by dry weight of the aerosol-generating material.

[0145] In some examples, guar gum is included in the gelling agent in an amount of approximately 3–40 wt% of the aerosol-generating material. That is, the aerosol-generating material contains guar gum in an amount of approximately 3–40 wt% of the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material contains guar gum in an amount of approximately 5–10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material contains guar gum in an amount of approximately 15–40 wt%, or approximately 20–40 wt%, or approximately 15–35 wt% of the aerosol-generating material.

[0146] In the example, alginate is present in an amount of at least about 50 wt% of the gelling agent. In the example, the aerosol-generating material contains alginate and pectin, with an alginate-to-pectin ratio of 1:1 to 10:1. The alginate-to-pectin ratio is usually >1:1, meaning that alginate is present in greater quantities than pectin. In the example, the alginate-to-pectin ratio is about 2:1 to 8:1 or about 3:1 to 6:1, or roughly 4:1.

[0147] Aerosol-generating materials can be formed by (a) forming a slurry containing components of an aerosol material or its precursor, (b) forming a layer of slurry, (c) solidifying the slurry to form a gel, and (d) drying to form an aerosol-generating material.

[0148] (b) Forming a slurry layer typically involves spraying, casting, or extruding the slurry. In one example, the slurry layer is formed by electrostatic spraying the slurry. In another example, the slurry layer is formed by casting the slurry.

[0149] In some cases, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrostatic spraying). In some cases, (b), (c), and (d) are performed sequentially.

[0150] In some examples, the slurry is applied to a support. A layer can be formed on the support.

[0151] In the example, the slurry comprises a gelling agent, an aerosol-forming agent material, and an active substance. The slurry may contain these components in any of the ratios given herein with respect to the composition of the aerosol-generating material. For example, the slurry may (on a dry weight basis): The mixture contains a gelling agent and optionally a filler, with the combined amount of the gelling agent and filler being approximately 10-60 wt% of the slurry. The slurry contains approximately 40-80 wt% of aerosol-forming agent material. The slurry may optionally contain up to approximately 20 wt% of the active substance.

[0152] Solidifying the gel (c) may include supplying a solidifying agent to the slurry. For example, the slurry may contain sodium alginate, potassium alginate, or ammonium alginate as gel precursors, and a solidifying agent containing a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel. In some examples, the solidifying agent includes or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the solidifying agent includes or consists of calcium formate and / or calcium lactate. In certain examples, the solidifying agent includes or consists of calcium formate. The inventors have found that, as a result of using calcium formate as a solidifying agent, aerosol-generating materials with higher tensile strength and higher resistance to stretching are obtained.

[0153] The total amount of solidifying agent, such as a calcium source, may be 0.5 to 5 wt% (calculated on a dry weight basis). Preferably, the total amount may be about 1 wt%, 2.5 wt%, or 4 wt% to about 4.8 wt% or 4.5 wt%. The inventors have found that if the amount of solidifying agent added is too small, the components of the aerosol generating material will not be stabilized, and as a result, an aerosol generating material may be obtained in which these components detach from the aerosol generating material. The inventors have also found that if the amount of solidifying agent added is too large, as a result, an aerosol generating material may be obtained that is extremely sticky and as a result, inconvenient to handle.

[0154] When the aerosol-generating material does not contain tobacco, a larger amount of solidifying agent may need to be applied. Therefore, in some cases, the total amount of solidifying agent may be 0.5 to 12 wt%, such as 5 to 10 wt%, calculated on a dry weight basis. Preferably, the total amount may be about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-generating material usually does not contain tobacco.

[0155] In this example, supplying a solidifying agent to the slurry includes spraying the solidifying agent onto the slurry, such as onto the top surface of the slurry.

[0156] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer in which β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) are linked by (1,4)-glycosidic bonds to form polysaccharides. In addition to calcium cations, alginic acid crosslinks to form a gel. Alginates with a high G monomer content have been shown to form gels more readily with the addition of a calcium source. Therefore, in some cases, the gel precursor may contain alginates, where at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-guluronic acid (G) units.

[0157] In the example, drying (d) removes approximately 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to approximately 80 wt%, 90 wt%, or 95 wt% (WWB) of water from the slurry.

[0158] In the example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% to 87%. For example, if the slurry is cast to a thickness of 2 mm, the resulting dried aerosol-producing material will have a thickness of 0.2 mm.

[0159] In some examples, the slurry solvent consists of or is essentially water. In some examples, the slurry contains about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% of solvent (WWB).

[0160] In the example where the solvent is water, the dry weight content of the slurry may coincide with the dry weight content of the aerosol-generating material. Therefore, the discussion herein regarding the solid composition is explicitly disclosed in conjunction with embodiments of the slurry of the present invention.

[0161] The aerosol-generating material may contain a fragrance. Preferably, the aerosol-generating material may contain up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the fragrance. In some cases, the aerosol-generating material may contain at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of the fragrance (all calculated on a dry weight basis). For example, the aerosol-generating material may contain 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of the fragrance. In some cases, the fragrance consists of or is essentially menthol.

[0162] The aerosol-generating material may contain fillers.

[0163] In some embodiments, the aerosol-generating material includes less than 60 wt% of filler, such as 1 wt% to 60 wt%, 5 wt% to 50 wt%, 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

[0164] In other embodiments, the aerosol-generating material contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% of filler. In some cases, the aerosol-generating material contains less than 1 wt% of filler, and in some cases, it contains no filler.

[0165] In some such cases, the aerosol-generating material includes at least 1 wt% of filler, for example, at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of filler. In some embodiments, the aerosol-generating material includes 5 to 25 wt% of filler.

[0166] The filler, if present, may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves, as well as other suitable inorganic adsorbents. The filler may also include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives (methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC), etc.). In certain cases, the aerosol-generating material does not contain calcium carbonate such as chalk.

[0167] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibers, cellulose, or cellulose derivatives (methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC), etc.).

[0168] While we do not wish to be bound by theory, it is believed that the tensile strength of an aerosol-generating material can be increased by including a fibrous filler within the material. This may be particularly advantageous in cases where the aerosol-generating material is prepared as a sheet, such as when an aerosol-generating material sheet surrounds a rod of aerosolizable material.

[0169] In some embodiments, the aerosol-generating material does not contain tobacco fibers. In certain embodiments, the aerosol-generating material does not contain fibrous material.

[0170] In some embodiments, the aerosol-generating material does not contain tobacco fibers. In certain embodiments, the aerosol-generating material does not contain fibrous material.

[0171] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0172] In some embodiments, the aerosol-generating material further comprises an active substance. For example, in some cases, the aerosol-generating material further comprises tobacco material and / or nicotine. In some embodiments, the aerosol-generating material comprises powdered tobacco and / or nicotine and / or tobacco extract.

[0173] In some cases, the aerosol-generating material may contain 5 to 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the aerosol-generating material may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of active substance. In some cases, the aerosol-generating material may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the aerosol-generating material may contain 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco material. In some cases, the aerosol-generating material may contain approximately 1 wt%, 2 wt%, 3 wt%, or 4 wt% to approximately 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the aerosol-generating material may contain 1-20 wt%, 2-18 wt%, or 3-12 wt% of nicotine.

[0174] In some cases, the aerosol-generating material contains an active substance such as tobacco extract. In some cases, the aerosol-generating material may contain 5 to 60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol-generating material may contain approximately 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to approximately 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the aerosol-generating material may contain 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol-generating material contains 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to approximately 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% (calculated on a dry weight basis) of nicotine. In some cases, the aerosol-generating material may not contain any nicotine other than that resulting from the tobacco extract.

[0175] In some embodiments, the aerosol-generating material does not contain tobacco material but contains nicotine. In some such cases, the aerosol-generating material may contain about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the aerosol-generating material may contain 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0176] In some cases, the total content of the active substance and / or fragrance may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of the active substance and / or fragrance may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0177] In some cases, the total content of tobacco materials, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of active substances and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0178] The aerosol-generating composition may contain one or more active substances. For example, the aerosol-generating material may contain, for instance, one or more active substances in an amount of up to about 20 wt% of the aerosol-generating material. For example, the aerosol-generating material may contain active substances in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0179] The active substance may include physiologically and / or olfactory active substances contained in the aerosol-generating composition to achieve physiological and / or olfactory responses.

[0180] Tobacco material may be present in the aerosol-generating composition in amounts of approximately 50-95 wt%, approximately 60-90 wt%, approximately 70-90 wt%, or approximately 75-85 wt%.

[0181] The tobacco material may exist in any form, but is usually shredded (e.g., torn into thin strips). The shredded tobacco material can be advantageously mixed with the aerosol-generating material to result in an aerosol-generating composition having a uniform dispersion of the tobacco material and the aerosol-generating material throughout the aerosol-generating composition.

[0182] In the example, the tobacco material comprises one or more of ground tobacco, tobacco fibers, shredded tobacco, extruded tobacco, tobacco stems, re-grown tobacco, and / or tobacco extracts. Surprisingly, the inventors have found that it is possible to use a relatively large amount of laminated tobacco in the aerosol-generating composition and still provide an aerosol that is acceptable when heated by a non-combustible aerosol supply system. Laminated tobacco typically provides excellent sensory properties. In the example, the tobacco material comprises laminated tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In a specific example, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0183] The tobacco used to manufacture the tobacco material may be any suitable tobacco, including Virginia and / or Burley and / or Oriental varieties, single grade or blend, cut rag or whole leaf.

[0184] In some embodiments, one or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0185] In some cases, the aerosol-generating material may further contain an emulsifier that emulsifies the fragrance that melted during manufacturing. For example, the aerosol-generating material may contain about 5 wt% to about 15 wt%, preferably about 10 wt%, of emulsifier (calculated on a dry weight basis). The emulsifier may include acacia gum.

[0186] In some embodiments, the aerosol-generating material is a hydrogel containing less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0187] The aerosol-generating material can have any suitable water content, such as 1 wt% to 15 wt%. Preferably, the water content of the aerosol-generating material is about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-generating material can be determined, for example, by Karl-Fischer titration or gas chromatography (GC-TCD) using a thermal conductivity detector.

[0188] In some cases, the aerosol-generating material consists essentially of or may consist of a gelling agent, water, an aerosol-generating agent, a fragrance, and optionally an active substance.

[0189] In some cases, the aerosol-generating material essentially consists of or may consist of a gelling agent, water, an aerosol-generating agent, a flavoring agent, and optionally tobacco material and / or a nicotine source.

[0190] In the example, the aerosol-generating material essentially consists of a gelling agent, an aerosol-generating agent, an active substance, and water, or may consist of these.

[0191] In the example, the aerosol-generating material does not contain flavorings, and in certain examples, the aerosol-generating material does not contain active substances.

[0192] In some embodiments, the aerosol generating material is 1-60 wt% gelling agent, 0.1-50 wt% aerosol generating agent, and 0.1-80 wt% fragrance, These include, and these weights are calculated on a dry weight basis.

[0193] In some embodiments, the aerosol-generating material contains 1 to 80 wt% of fragrance (on a dry weight basis).

[0194] In some embodiments, the aerosol generating material is 1-50 wt% gelling agent, 0.1-50 wt% aerosol generating agent, and 30-60 wt% fragrance, These include, and these weights are calculated on a dry weight basis.

[0195] In an alternative embodiment of the aerosol-generating material, the aerosol-generating material is 1-60 wt% gelling agent, 5-60 wt% aerosol generating agent, and 10-60 wt% tobacco extract, These include, and these weights are calculated on a dry weight basis.

[0196] In some embodiments, the aerosol generating material is 1-60 wt% gelling agent, 20-60 wt% aerosol generating agent, and 10-60 wt% tobacco extract, These include, and these weights are calculated on a dry weight basis.

[0197] In some embodiments, the aerosol-generating material comprises 20-35 wt% gelling agent, 10-25 wt% aerosol-forming agent material, 5-25 wt% fiber-containing filler, and 35-50 wt% flavoring and / or active substance.

[0198] In some cases, the aerosol-generating material consists essentially of or may consist of a gelling agent, an aerosol-generating agent, tobacco extract, water, and optionally a fragrance. In some cases, the aerosol-generating material consists essentially of or may consist of glycerol, alginic acid and / or pectin, tobacco extract, and water.

[0199] In some embodiments, the aerosol-generating material may have the following composition (DWB): a gelling agent (preferably containing alginic acid) in an amount of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt% or about 15 wt% to about 25 wt%; a tobacco extract in an amount of about 30 wt% to about 70 wt% or about 40 wt% to 55 wt% or about 45 wt% to about 50 wt%; and an aerosol-generating agent (preferably containing glycerol) in an amount of about 10 wt% to about 50 wt% or about 20 wt% to about 40 wt% or about 25 wt% to about 35 wt% (DWB).

[0200] In one embodiment, the aerosol-generating material comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (DWB).

[0201] The "thickness" of the aerosol-generating material describes the shortest distance between the first surface and the second surface. In embodiments where the aerosol-generating material takes the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between the first flat surface of the sheet and the second flat surface of the sheet opposite the first flat surface.

[0202] In some cases, the aerosol-forming material layer that forms the aerosol has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.

[0203] In some cases, the aerosol-generating material can have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0204] A material having a thickness of 0.2 mm is particularly preferred. The aerosol-generating material may have two or more layers, and the thickness described herein refers to the combined thickness of these layers.

[0205] It has been observed that if the aerosol-generating material is excessively thick, heating efficiency is impaired. This negatively impacts power consumption during use. Conversely, if the aerosol-generating material is excessively thin, it becomes difficult to manufacture and handle, casting very thin materials can be more challenging, and it may be fragile, impairing aerosol formation during use.

[0206] In this specification, thickness refers to the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0207] In some cases, the aerosol-generating material in sheet form may have a tensile strength of approximately 200 N / m to 900 N / m. In some cases, such as when the aerosol does not contain fillers, the aerosol-generating material may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or approximately 250 N / m.

[0208] Such tensile strength may be particularly suitable for embodiments in which the aerosol - forming material is formed as a sheet, then torn, and incorporated into the aerosol - forming article. In some examples, such as when the aerosol - forming material contains a filler, the aerosol - forming material may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strength may be particularly suitable for embodiments in which the aerosol - forming material is included in the aerosol - forming article / assembly in the form of a roll sheet, preferably in the form of a tube.

[0209] In some examples, the aerosol - forming material in sheet form may have a tensile strength of about 200 N / m to 2600 N / m. In some examples, the aerosol - forming material may have a tensile strength of 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strength may be particularly suitable for embodiments in which the aerosol - forming material is formed as a sheet and incorporated into the aerosol - forming consumable.

[0210] The aerosol - forming material can have any suitable areal density (mass per unit area), such as 30 - 120 g / m 2 In some cases, the sheet may have an areal density of 80 - 120 g / m 2 or about 70 - 110 g / m 2 or particularly about 90 - 110 g / m 2 or preferably about 100 g / m 2 (having a density similar to cut - rag tobacco and being such that mixtures of these substances do not easily separate). In some cases, the sheet may have an areal density of about 30 - 70 g / m 2 40 - 60 g / m 2 or 25 - 60 g / m 2 and may be used to wrap aerosolizable materials such as tobacco.

[0211] All weight percentages (expressed in wt%) described herein are calculated on a dry weight basis unless otherwise explicitly indicated. All weight ratios are also calculated on a dry weight basis. Weights cited on a dry weight basis refer to the entire extract, slurry, or material other than water, and may include components that are themselves liquid at room temperature and room pressure, such as glycerol. Conversely, weight percentages cited on a wet weight basis refer to all components, including water.

[0212] Aerosol-generating materials may contain colorants. The addition of colorants may alter the visual appearance of the aerosol-generating material. The presence of colorants in an aerosol-generating material can improve its visual appearance. By adding colorants to an aerosol-generating material, the aerosol-generating material may match the color of other components of the article containing the aerosol-generating material.

[0213] A wide range of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also possible. Natural or synthetic colorants such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants may be used. In some embodiments, the colorant is caramel, which can impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components in the aerosol-generating material (such as tobacco material).

[0214] The coloring agent can be incorporated during the formation of the aerosol-generating material (for example, when forming a slurry containing the material that forms the aerosol-generating material), or it can be applied to the aerosol-generating material after its formation (for example, by spraying it onto the aerosol-generating material).

[0215] In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder, or other powder is applied to the exposed surface of at least one distinct portion of the aerosol-generating material. This can reduce the level of tackiness or adhesion of the aerosol-generating material.

[0216] In the following discussion of the attached drawings in which the same element exists in two or more embodiments, the same reference numeral is used throughout for that element, and if similar elements exist, similar reference numerals (the same numeral plus a multiple of 100) are used.

[0217] Referring to Figure 1, the aerosol supply device 2 includes a casing 4, within which the heater assembly 6 is located. The heater assembly 6 consists of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator for use with a susceptor.

[0218] The heating chamber 8 defines an opening or mouth portion 12 at its first end. An aperture 14 is located at the opposite end of the heating chamber 8. The aperture 14 is in fluid communication with the mouthpiece 16 via a conduit 18.

[0219] A controller 20 is also located within the casing 4, which electronically communicates with the heater 10 and controls the function of the heater 10. The controller 20 may include a memory (not shown) that can store one or more tables relating to the operation of the heater 10. The heater 10 and the controller 20 are powered by a power supply 22, which is a rechargeable battery. In other embodiments, the power supply may be another suitable power source.

[0220] The aerosol supply device 2 is suitable for use with consumables 24. The consumables 24 consist of one or more distinct portions of aerosol-generating material 26 supported on a first surface 30 of a support 28. The distinct portions of the aerosol-generating material 26 are supported on the support 28 in a rectangular grid pattern. Other not-illustrated embodiments of the consumables 24 may include a single portion of the aerosol-generating material 26, or other substantially distinct portions of the aerosol-generating material 26 other than those shown in Figure 1, which can be dispersed on the surface of the support 28 in any pattern. The distinct portions of the aerosol-generating material 26 are shown in Figure 1 having a suitably generally circular shape, and may have other shapes in other embodiments.

[0221] Referring to Figure 2, the support 28 is a laminate of three substrates or layers 34, 36, and 38. Layer 34 forms the first surface 30 and is composed of a layer of aluminum foil. When the consumable 24 is in use, layer 34 acts as a susceptor and can heat a separate portion of the aerosol-generating material 26. In other embodiments not shown, the susceptor layer 34 may be formed from other susceptor materials. In this embodiment, the susceptor layer 34 is impermeable.

[0222] The support layer 36 of the support 28 is a support layer and is present to give the consumable 24 sufficient strength so that the consumable 24 does not deform or bend during normal use. The layer 28 can be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be understood that the layer 36 may contain other materials.

[0223] The layer 38 of the support 28 is composed of a material that is a solvent for at least one delivered substance 40, i.e., an absorbent or adsorbent. The delivered substance 40 is desired to be included in the aerosol produced when the aerosol generating material 26 is heated, and is the substance that the user inhales a puff from the aerosol supply device 2. The sorbent layer 38 forms the second surface 32 of the support 48.

[0224] In some embodiments, the substance to be delivered 40 is applied to a separate portion of the aerosol-generating material 26 on the first surface 30 of the support, and to the sorbent layer 38 at locations on the second surface 32 corresponding to the locations of the substance to be delivered, which are simply allowed to diffuse into the sorbent layer 38. In other embodiments, referring to Figure 3, on the second surface 32 of the support 28, one or more separate zones 42 are defined, each by a boundary 44 (represented by a line 44). The boundary 44 helps to retain the substance to be delivered 40 within the separate zone 42.

[0225] The boundary 44 is at the interface between the sorbent material in a separate zone 42 having a first level of absorbance / adsorption (X) and the sorbent material outside the separate zone 42 having a second level of absorbance / adsorption (Y), where X is greater than Y. The level Y of absorbance / adsorption of the sorbent material outside the separate zone 42 is the result of treatment of the sorbent material to reduce its level of absorbance / adsorption.

[0226] In some embodiments not shown, the boundaries 44 of the separate zones 42 may have the same shape as the separate zones of the aerosol-generating material 26. In some embodiments, these may surround a second surface area of ​​the support, which is different from a first surface area of ​​the support covered by the separate portion of the aerosol-generating material 26.

[0227] The delivered substance 40 comprises one of the following: a flavoring agent, an active substance, a mixture of flavoring agents, a mixture of active substances, or a mixture of one or more flavoring agents and one or more active substances. In one embodiment of the consumable 24 shown in Figure 3, the delivered substance 40 in each separate zone 42 has the same composition as in each other separate zone 42. In an alternative embodiment, the delivered substances 40 in at least two of the separate zones 42 have different compositions from each other.

[0228] One or more perforations 46 extend through the support 28 and separate portions of the aerosol generating material 26. These perforations 46 are sized such that aerosol generated from one surface of the support can travel along the perforations to the other side of the support. This can help achieve aerosol mixing before the aerosol exits the mouthpiece 16 when the user inhales a puff from the aerosol supply device 2. The perforations 46 are at least 0.01 mm wide. 2 at least 0.05 mm 2 at least 0.1 mm 2 at least 0.5 mm 2 at least 1 mm 2 , at least 2mm 2 , or at least 3 mm 2 It may have the following cross-sectional area.

[0229] The aerosol supply device 2, for use with the consumable 24 shown in Figure 2, has a heater 10 consisting of one or more magnetic field generators (not shown). The magnetic field generators are distributed in the heater 10 such that each magnetic field generator independently heats a portion of the susceptor supporting a separate portion of the aerosol-generating material 26. This allows one or more separate portions of the aerosol-generating material to be heated at the same time. When the consumable 24 is placed in the heating chamber 8 through the heating chamber opening 12, each separate portion of the aerosol-generating material 26 overlaps the magnetic field generators. The controller 20 determines which separate single or multiple portions of the aerosol-generating material 26 are heated to generate fluctuating magnetic fields in the appropriate single or multiple magnetic field generators. This heats the single or multiple portions of the susceptor layer 34 that intersect with these fluctuating magnetic fields, and consequently heats the separate single or multiple portions of the aerosol-generating material 26.

[0230] When the aerosol-generating material 26 or each of its separate parts is heated, some of the heat generated in the susceptor layer 34 is transferred by the support layer 36 away from the susceptor layer 34 into the sorbent layer 38. This heat aerosolizes the volatile material 40 that is absorbed or adsorbed into the sorbent layer 38 corresponding to the aerosol-generating material 26 or each of its separate heated parts.

[0231] In some embodiments not shown, portions of the support layer 36 corresponding to separate portions of the aerosol-generating material 26 may be modified to increase or decrease the thermal conductivity of these portions. This will result in an increase or decrease in the heating rate of the sorbent layer 38 and the temperature at which the sorbent layer 38 is heated.

[0232] Referring to Figures 4 and 5, the consumable 124 consists of a support 128 on which one or more distinct portions of the aerosol-generating material 26 are supported. The support 128 is a laminate of first and second substrates / layers 34, 36. The first layer 34 is a susceptor in the form of a layer of aluminum foil.

[0233] The support layer 36 of the support 128 is a support layer and is present to give the consumable 124 sufficient strength so that the consumable 124 does not deform or bend during normal use. The layer 36 can be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be understood that the layer 36 may also contain other materials.

[0234] On the impermeable surface of the susceptor layer 34, one or more distinct portions of the aerosol-generating material 26 and an equal number of portions of the sorbent material 50 are supported. Each portion of the sorbent material 50 has a ring shape, and each portion of the sorbent material 50 is supported on the first surface 30 of the support 128 in a position that surrounds the distinct portions of the aerosol-generating material 26 in the plane of the first surface of the support 128.

[0235] Each portion of the sorbent material 50 contains at least one substance absorbed / adsorbed by the sorbent material. The substance absorbed / adsorbed and delivered by the sorbent material may differ for one or more portions of the sorbent material 50.

[0236] Consumable 124 is used in a similar form to consumable 24 in Figures 2 and 3, but differs in that the heating of the sorbent material 50 portion is by direct conduction from separate parts of the susceptor 34 and / or aerosol generating material 26.

[0237] Referring to Figure 6, the consumable 224 consists of a support 228 on which one or more distinct portions of the aerosol-generating material 26 are supported. The support 228 is a laminate of first and second substrates / layers 34, 36. The first layer 34 is a susceptor in the form of a layer of aluminum foil.

[0238] The support layer 36 of the support 128 is a support layer and is present to give the consumable 224 sufficient strength so that the consumable 224 does not deform or bend during normal use. The layer 36 can be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be understood that the layer 36 may also contain other materials.

[0239] One or more distinct portions of the aerosol-generating material 26 are supported on the impermeable first surface 30 of the susceptor layer 34. One or more portions of the sorbent material 150 are supported on the second surface 32 at positions corresponding to the distinct positions of the aerosol-generating material 26 on the first surface 30. The number of portions of the sorbent material 150 is equal to the number of distinct portions of the aerosol-generating material 26. Each portion of the sorbent material 150 has the same shape as the distinct portion of the aerosol-generating material 26 and covers a larger area than that portion.

[0240] Each portion of the sorbent material 150 contains at least one substance absorbed / adsorbed by the sorbent material. The substance absorbed / adsorbed by at least one portion of the sorbent material 110, or delivered, may be different from that of the other portions of the sorbent material 150.

[0241] Consumable 224 is used in a similar form to consumable 24 in Figures 2 and 3.

[0242] Referring to Figure 7, the consumable 324 consists of a support 328 on which one or more distinct portions of the aerosol-generating material 26 are supported. The support 328 is a laminate of first and second substrates / layers 36, 38. The first layer 36 of the support 328 is a support layer and is present to give the consumable 324 sufficient strength so that it does not deform or bend during normal use. Layer 36 can be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be understood that layer 36 may contain other materials.

[0243] The second layer 38 of the support 328 is a layer of sorbent material. The second layer 38 forms the first surface 30 of the support 328.

[0244] One or more distinct portions of the aerosol-generating material 26 are supported on the sorbent surface of the sorbent layer 38. The sorbent layer 38 includes one or more distinct zones 342 having boundaries represented by lines 344. The number of distinct zones 342 is equal to the number of distinct portions of the aerosol-generating material 26, and each distinct zone 342 surrounds a distinct portion of the aerosol-generating material 26 in the plane of the first surface of the support 328.

[0245] The boundary 344 is at the interface between the sorbent material in a separate zone 342 having a first level of absorbance / adsorption (X) and the sorbent material outside the separate zone 342 having a second level of absorbance / adsorption (Y), where X is greater than Y. The level Y of absorbance / adsorption of the sorbent material outside the separate zone 342 is the result of treatment to reduce its level of absorbance / adsorption.

[0246] Each separate zone 342 contains at least one delivered substance that is absorbed / adsorbed onto the sorbent material of the separate zone. The delivered substance absorbed / adsorbed onto the sorbent material may differ for one or more of the separate zones 342 compared to the other separate zones 342.

[0247] Consumable 324 is used in a similar form to consumable 24 in Figures 2 and 3, with the exception that heating of consumable 324 is by a resistance heater. The resistance heater may include one or more separate zones that can be heated one at a time to allow each separate part of the aerosol-generating material 26 to be heated.

[0248] In a further embodiment not shown of the consumable 324 in Figure 7, the support may be a single sheet of the sorbent material 38. The remainder of the details of this embodiment relates to the embodiment in Figure 7.

[0249] Referring to Figure 8, the consumable 424 consists of a support 428. One or more separate portions of the aerosol-generating material 26 are supported on the first surface 30 of the support 428. The support 428 is formed from an adsorbent material. The consumable 424 is adapted to be heated using an external heat source (not shown), for example, a resistance heater that emits radiant heat.

[0250] The delivered substance 40 is absorbed or adsorbed onto the second surface 32 of the support 428 in a region of the second surface 32 corresponding to a separate portion of the aerosol-generating material 26. One or more perforations 446 extend through the separate portion of the aerosol-generating material 26, the support 428, and the delivered substance 40.

[0251] Referring to Figure 9, a schematic manufacturing method for consumables is shown, which includes the following steps.

[0252] In step 60, a support 28 is prepared, which includes a susceptor layer 34, a support layer 36, and an adsorbent layer 38.

[0253] In step 62, a slurry of the aerosol-generating material is prepared, comprising a solvent for the aerosol-generating material and one or more desired active substances.

[0254] In step 64, a slurry of the aerosol-generating material 26 is applied to one or more areas on the surface 30, 32 of the support 28.

[0255] In step 66, the applied slurry is dried to form a solid or gel aerosol-generating material on the surface of the support. The drying process may allow the solvent of the aerosol-generating material to evaporate under ambient conditions. Alternatively, the drying process can be accelerated by heating the slurry to a temperature below the temperature at which the aerosol-generating material begins to aerosolize in order to promote the evaporation of the solvent. Heating may be done by induction or radiation heating methods. Alternatively or further, step 66 may include exposing the aerosol-generating material to a high airflow to promote the evaporation of the solvent from the aerosol-generating material.

[0256] Step 66 may include a technique to evaporate several desired active ingredients from the aerosol-generating material slurry at a rate sufficient to ensure that, upon completion of drying, the remaining aerosol-generating material does not contain the desired amount of these active ingredients.

[0257] Once step 66 is complete, step 68 can determine whether it is necessary to apply a further slurry of the aerosol-generating material. If the answer to the question in step 68 is "yes", steps 64-68 are repeated. The second or subsequent application of the slurry may be the same slurry as the first application, or a slurry with at least a different composition from the first application.

[0258] If the answer to the question in step 68 is "no", then in step 70, one or more delivered substances 40 are applied to the sorbent material 38. These delivered substances may be highly volatile. However, they are not subject to the drying conditions of step 66, and therefore the amount of substance that needs to be applied to the adsorption area can be significantly less than if it were subject to drying step 66. The delivered substances are applied to the surface of the sorbent material 38, followed by absorption or adsorption to the sorbent material 38.

[0259] In step 72, at least the support 28 is perforated by a perforating means.

[0260] In step 74, the support is cut into two or more individual consumables that are ready for use or packaging and distribution for sale to users.

[0261] Referring to Figure 10, a second schematic method for manufacturing the consumables is shown, the method comprising the steps described below. These steps, which are the same as those in the method in Figure 7, have the same reference numerals and are not described again below.

[0262] A support 28 including a support layer 36 is prepared in step 76.

[0263] Steps 62 to 68 are as shown in the manufacturing method in Figure 9.

[0264] If the answer to the question in step 68 is "no", then in step 78, one or more portions of the adsorbent material 50, 150 are fixed to the support 28. The adsorbent material can be applied to the pre-formed support together with one or more deliverable substances 40 that have already been absorbed / adsorbed by a portion of the adsorbent material 50, 150. Alternatively, a portion of the adsorbent material 50, 150 may have a deliverable substance that is applied to the portion of the adsorbent material 50, 150 after it has been fixed to the support. In this alternative, the deliverable substance is then available for absorption or adsorption.

[0265] Steps 72 and 74 follow step 78.

[0266] Referring to FIG. 11, a third exemplary method of manufacturing a consumable is shown, the method including the steps described below. These steps that are the same as those of the method of FIG. 9 or FIG. 10 have the same reference numerals and are not described again below.

[0267] Steps 62 and 64 follow step 76.

[0268] In step 80, it is determined whether a paste for forming the sorbent materials 50, 150 by drying is applied to the support 28.

[0269] If the answer to step 80 is "yes", in step 82 that paste is provided and applied to the support. Next, the process moves to the drying step 66.

[0270] If the answer to step 80 is "no", the process moves to the drying step 66.

[0271] Next, steps 68, 70, 72 and 74 follow.

[0272] The consumable that is a result of the present disclosure has been found to have advantageous storage characteristics in that the delivered substance maintains a substantially consistent flavour amplitude over at least 90 days after manufacture of the consumable.

[0273] The long-term flavor intensity of a substance delivered in the form of a citrus flavor composition was tested. In the test, a consumable was manufactured that included a card support layered with a layer of aluminum foil. A layer of aerosol-generating material (consisting of a binder and an aerosol-forming agent (glycerol)) was applied to the surface of the support formed by the aluminum layer, allowing the aerosol-forming material to solidify. Once the aerosol-generating material had solidified, 0.34 mg of the citrus flavor composition was applied using a pipette to the surface of the consumable formed from the card at a location corresponding to a predetermined heating zone. The consumable was then heated in the predetermined heating zone.

[0274] After applying a citrus fragrance composition to consumables, the samples were subjectively evaluated over five periods (T).

[0275] The following procedure was followed to conduct the evaluation during period T.

[0276] Two days prior to period T, control samples were prepared using the same techniques and supports as those used to prepare the test samples.

[0277] During period T, one of the predetermined heating zones on the test consumable was heated using an aerosol supply device comprising a heater, a chamber (where an aerosol is formed upon heating), and a mouthpiece. The tester then performed a sensory evaluation of the aerosol received from the mouthpiece. This was repeated using a control sample after the aerosol supply device was cleaned.

[0278] The evaluation results are shown in Table 1 below.

[0279] [Table 1]

[0280] As can be seen from Table 1, there was minimal fragrance loss over the 90-day study.

[0281] Studies were conducted on consumer responses to various fragrances, as shown in Table 2.

[0282] [Table 2]

[0283] Next, the sample was heated as described above, and the resulting aerosol was sampled by the tester. The fragrance was found to be cleaner in flavor than that of a cigarette, and did not contain any ashy or burnt off-notes.

[0284] Furthermore, the testers found that when exhaling the inhaled aerosol, a lower level of visible aerosol / particles was present compared to the case of cigarettes, and that almost no odor remained in the test room after the test.

[0285] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are given only as representative examples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims or to equivalents thereof, and that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, preferred combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not claimed herein but may be claimed in the future. This disclosure includes the following embodiments. (Embodiment 1) A consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol generating material, and the deliverable substance volatilizes when one or both of the support and / or the aerosol generating material are heated. (Embodiment 2) The consumable according to Embodiment 1, wherein the support comprises an adsorbent material, and the adsorbent material comprises the delivered substance. (Embodiment 3) The consumable according to Embodiment 2, wherein the delivered substance is located within one or more separate zones of the adsorbent material and not outside these separate zones. (Embodiment 4) The consumable according to Embodiment 2 or 3, wherein the support is a laminate, and the laminate includes at least a first and a second substrate, and at least one of the substrates is formed from an adsorbent material. (Embodiment 5) The consumable product according to any one of embodiments 2 to 4, wherein the adsorbent material forms one or both of the first or second surfaces of the support. (Embodiment 6) A consumable product according to any one of embodiments 1 to 5, wherein the surface of the support is formed from an impermeable material. (Embodiment 7) A consumable product according to any one of embodiments 1 to 6, wherein the surface of the support is formed from a susceptor. (Embodiment 8) The consumable according to Embodiment 7, wherein the susceptor is a metal foil. (Embodiment 9) A consumable product according to any one of embodiments 2 to 8, wherein the aerosol generating material is supported on the surface of the support which is an adsorbent material. (Embodiment 10) A consumable according to any one of Embodiments 1 to 8, wherein the aerosol generating material is supported on the surface of the support, which is not an adsorbent material. (Embodiment 11) The consumable product according to any one of embodiments 1 to 9, wherein the support is formed from an adsorbent material. (Embodiment 12) A consumable according to any one of embodiments 1 to 11, wherein the delivered substance is supported on the surface of the support. (Embodiment 13) The consumable according to Embodiment 12, further comprising an adsorbent material, wherein the adsorbent material comprises the delivered substance, and the adsorbent material is supported on the surface of the support. (Embodiment 14) A consumable according to any one of Embodiments 1 to 13, wherein the delivered substance is volatilized after a certain period PS from the start of heating of the support or aerosol generating material, and the aerosol generating material is configured to release an aerosol after a certain period PA from the start of heating of the support or aerosol generating material, and the period PS is less than or equal to PA. (Embodiment 15) A consumable product according to Embodiment 14, wherein the period PS is less than PA. (Embodiment 16) A consumable according to any one of Embodiments 1 to 15, wherein the temperature at which the delivered substance needs to be heated in order to volatilize the delivered substance is lower than the temperature at which the aerosol-generating material needs to be heated in order to generate an aerosol. (Embodiment 17) A consumable according to Embodiment 3, or any one of Embodiments 4 to 16 when dependent on Embodiment 3, wherein at least one separate zone has a shape and size, and the shape and size of the separate zone is at least partially defined by an adsorbent material surrounding the separate zone, and the adsorbent material has a capacity for the adsorption of the at least one substance into the adsorbent material that is reduced to the capacity for the adsorption of the at least one substance into the adsorbent material in the separate zone. (Embodiment 18) The consumable according to Embodiment 17, wherein the consumable includes two or more separate zones. (Embodiment 19) The consumable according to Embodiment 18, wherein at least two of the aforementioned separate zones contain different substances to be delivered. (Embodiment 20) A consumable according to Embodiment 3, or any one of Embodiments 4 to 19 when dependent on Embodiment 3, wherein the aerosol-generating material is supported on the support in one or more distinct parts, and at least one distinct zone is associated with each distinct part of the aerosol-generating material. (Embodiment 21) A consumable according to Embodiment 3, or any one of Embodiments 4 to 20 when dependent on Embodiment 3, wherein a separate zone lies on the same surface as the separate portion of the aerosol-generating material of the support and substantially surrounds the separate portion of the aerosol-generating material. (Embodiment 22) A consumable according to Embodiment 3, or any one of Embodiments 4 to 21 dependent on Embodiment 3, wherein a separate portion of the aerosol-generating material is on a first surface of the support, a separate zone is on a second surface of the support, and the separate portion of the aerosol-generating material and the separate zone are in corresponding positions on their respective surfaces. (Embodiment 23) The consumable according to Embodiment 22, wherein the shapes of the separate portions and the separate zones of the aerosol-generating material on the planes of the first and second surfaces of the support are substantially the same. (Embodiment 24) The consumable according to Embodiment 22, wherein the separate portion of the aerosol-generating material covers a first area on the surface of the support on which the separate portion is supported, the separate zone covers a second area on the surface of the support on which the separate zone is supported, and one of the first and second areas is larger than the other of the first and second areas. (Embodiment 25) The consumable according to any one of embodiments 1 to 24, wherein the consumable further includes one or more perforations extending between at least the first and second surfaces of the support. (Embodiment 26) The consumable according to embodiment 25, wherein at least one perforation extends between one of the first or second surfaces of the support and the surface of the consumable adjacent to the other of the first or second surfaces of the support. (Embodiment 27) The consumable according to embodiment 25 or 26, wherein at least one perforation extends between the surface of the consumable adjacent to the first surface of the support and the surface of the consumable adjacent to the second surface of the support. (Embodiment 28) A consumable according to any one of embodiments 25 to 27, wherein at least one of the perforations extends through the delivered substance. (Embodiment 29) The consumable according to any one of embodiments 25 to 28, wherein at least one of the perforations extends through the aerosol-generating material. (Embodiment 30) A consumable according to any one of embodiments 25 to 29, wherein at least one of the perforations has a first dead-end end within the consumable and the other end is open through one of the surfaces of the support, the delivered substance, the aerosol-generating material, or the surface of the consumable. (Embodiment 31) The perforations are at least 0.01 mm 2 at least 0.05 mm 2 at least 0.1 mm 2 at least 0.5 mm 2 at least 1 mm 2 , at least 2mm 2 , or at least 3 mm 2 A consumable product according to any one of embodiments 25 to 30, having the cross-sectional area. (Embodiment 32) A consumable product according to any one of Embodiments 1 to 31, wherein the at least one substance comprises a flavoring agent, an active substance, a mixture of flavoring agents, a mixture of active substances, a mixture of one or more flavoring agents and one or more active substances, one or more solvents, and / or one or more aerosol generating agents or aerosol forming agent materials. (Embodiment 33) A consumable according to any one of embodiments 1 to 32, wherein the support is flat. (Embodiment 34) A method for manufacturing a consumable for use with an aerosol supply device, wherein the consumable comprises a support, an aerosol generating material, and a volatilizable delivered substance, and the method is a) The step of preparing a support, b) The step of applying the slurry of the aerosol generating material to the surface of the consumable, c) A step of drying the coated aerosol-generating material, d) The step of applying the delivered substance to the surface of the consumable, Methods that include... (Embodiment 35) The method according to Embodiment 34, wherein step (b) is performed at any point after step (a), step (c) follows step (b), and step (d) is performed at any point after step (c). (Embodiment 36) The method according to Embodiment 34 or 35, wherein the method includes step (e) of preparing an adsorbent material, step (e) is performed before step (d), and step (d) includes applying the delivered substance to the adsorbent material to form an adsorbent material containing the delivered substance, and, if the support does not contain the adsorbent material, applying the adsorbent material containing the delivered substance to the consumable. (Embodiment 37) The method according to Embodiment 36, wherein step (e) includes applying a paste to the consumable and then drying the paste, the paste drying to form an adsorbent material. (Embodiment 38) The method according to Embodiment 36, wherein step (e) includes forming a desired shape of the adsorbent material and fixing the shape of the adsorbent material to a desired position on the consumable. (Embodiment 39) The method according to Embodiment 38, wherein step (d) is performed before the sorbing material is fixed to the consumable. (Embodiment 40) The method according to any one of embodiments 34 to 39, wherein steps (b) and (c) are repeated once or more times before step (d). (Embodiment 41) The method according to any one of embodiments 34 to 40, wherein step (c) includes the use of one or more of time, conductive heat, or radiant heat. (Embodiment 42) The method according to any one of embodiments 34 to 41, wherein the method further includes step (f) of preparing a susceptor and fixing the susceptor to the support. (Embodiment 43) The method according to Embodiment 42, wherein step (f) is performed after step (a) to fix the susceptor to the first surface of the support, and step (b) is performed after step (f) to at least partially coat the surface of the aerosol generating material of the slurry of the susceptor. (Embodiment 44) The method according to any one of embodiments 34 to 43, wherein the support is a sheet of material, and the method further comprises step (h) of cutting the support into two or more consumables. (Embodiment 45) The method includes step (i) of perforating at least a portion of the consumable to form one or more perforations, One or more perforations extend between at least the first and second surfaces of the support, One or more perforations extend between one of the first or second surfaces of the support and the surface of the consumable adjacent to the other of the first or second surfaces of the support. One or more perforations extend between the surface of the consumable adjacent to the first surface of the support and the surface of the consumable adjacent to the second surface of the support. One or more perforations extend through at least the adsorbent material, One or more perforations extend through at least the aerosol-generating material, and One or more perforations have a first dead-end end within the consumable, and the other end is open through one of the surfaces of the support, the delivered substance, the aerosol-generating material, or the consumable. The method according to any one of embodiments 36 to 44, which is one or more of the above. (Embodiment 46) The method according to one of embodiments 34 to 45, which forms a consumable product according to one of embodiments 1 to 33. (Embodiment 47) An aerosol supply system comprising an aerosol supply device and a consumable item described in any one of embodiments 1 to 33. (Embodiment 48) A method for generating an aerosol from a consumable described in any one of Embodiments 1 to 33 using an aerosol generating device, wherein the aerosol generating device has at least one heat source arranged to heat the consumable without burning it during use, and at least one heat source is a resistance heating element. (Embodiment 49) A method for generating an aerosol from a consumable described in any one of Embodiments 1 to 33 using an aerosol generating device, wherein the aerosol generating device has at least one heat source arranged to heat the consumable without burning it during use, and at least one heat source is a magnetic field generator suitable for generating eddy currents in a susceptor. (Embodiment 50) A method for generating an aerosol according to Embodiment 48 or 49, wherein the consumables include one or more separate parts of an aerosol generating material, and the heat source is configured to heat one or more of the separate parts at a time.

Claims

1. A consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol generating material, and the deliverable substance volatilizes when one or both of the support or the aerosol generating material are heated. The support comprises an adsorbent material, and the adsorbent material comprises the substance to be delivered. A consumable item in which the aerosol-generating material is supported on the surface of the support, which is an adsorbent material.

2. The consumable according to claim 1, wherein the delivered substance is located within one or more separate zones of the sorbent material and not outside these separate zones.

3. The consumable product according to claim 1, wherein the support is a laminate, and the laminate includes at least a first and a second substrate, and at least one of the substrates is formed from an adsorbent material.

4. The consumable product according to claim 1, wherein the adsorbent material forms one or both of the first or second surfaces of the support.

5. The consumable product according to claim 1, wherein the surface of the support is formed from an impermeable material.

6. The consumable product according to claim 1, wherein the surface of the support is formed from a susceptor.

7. The consumable product according to claim 1, wherein the support is formed from an adsorbent material.

8. The consumable according to claim 1, wherein the delivered substance is supported on the surface of the support.

9. The consumable according to claim 8, further comprising an adsorbent material, wherein the adsorbent material comprises the delivered substance, and the adsorbent material is supported on the surface of the support.

10. The consumable product according to claim 1, wherein the delivered substance is volatilized after a certain period PS from the start of heating of the support or aerosol generating material, and the aerosol generating material is configured to release an aerosol after a certain period PA from the start of heating of the support or aerosol generating material, and the period PS is less than or equal to PA.

11. The consumable according to claim 1, wherein the temperature at which the delivered substance needs to be heated in order to volatilize it is lower than the temperature at which the aerosol-generating material needs to be heated in order to generate an aerosol.

12. The consumable according to claim 2, wherein at least one separate zone has a shape and size, the shape and size of the separate zone is at least partially defined by an adsorbent material surrounding the separate zone, and the adsorbent material has a capacity for adsorption of the delivered substance to the adsorbent material that is reduced to the capacity for adsorption of the delivered substance to the adsorbent material in the separate zone.

13. The consumable according to claim 2, wherein the aerosol-generating material is supported on the support in one or more distinct portions, and at least one distinct zone is associated with each distinct portion of the aerosol-generating material.

14. The consumable according to claim 2, wherein a separate zone lies on the same surface as the separate portion of the aerosol-generating material of the support and substantially surrounds the separate portion of the aerosol-generating material.

15. The consumable according to claim 2, wherein a separate portion of the aerosol-generating material is on a first surface of the support, a separate zone is on a second surface of the support, and the separate portion of the aerosol-generating material and the separate zone are in corresponding positions on their respective surfaces.

16. The consumable according to claim 15, wherein the shapes of the separate portions and the separate zones of the aerosol-generating material on the planes of the first and second surfaces of the support are substantially the same.

17. The consumable according to claim 15, wherein the separate portion of the aerosol-generating material covers a first area on the surface of the support on which the separate portion is supported, the separate zone covers a second area on the surface of the support on which the separate zone is supported, and one of the first and second areas is larger than the other of the first and second areas.

18. The consumable product according to claim 1, wherein the delivered substance comprises a flavoring agent, an active substance, a mixture of flavoring agents, a mixture of active substances, a mixture of one or more flavoring agents and one or more active substances, one or more solvents, and / or one or more aerosol generating agents or aerosol forming agent materials.

19. A consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol generating material, and the deliverable substance volatilizes when one or both of the support or the aerosol generating material are heated. A consumable item in which the aforementioned support is formed from an adsorbent material.

20. A consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol generating material, and the deliverable substance volatilizes when one or both of the support or the aerosol generating material are heated. The support comprises an adsorbent material, and the adsorbent material comprises the substance to be delivered. The delivered substance is located within one or more separate zones of the sorbent material and not outside these separate zones. A consumable in which a separate zone lies on the same surface as the separate portion of the aerosol-generating material of the support and substantially surrounds the separate portion of the aerosol-generating material.

21. A consumable for use with an aerosol supply device, the consumable comprising a support, an aerosol generating material, and a deliverable substance that can be volatilized, wherein the support supports the aerosol generating material, and the deliverable substance volatilizes when one or both of the support or the aerosol generating material are heated. The support comprises an adsorbent material, and the adsorbent material comprises the substance to be delivered. The delivered substance is located within one or more separate zones of the sorbent material and not outside these separate zones. A consumable product wherein a separate portion of the aerosol-generating material is located on a first surface of the support, a separate zone is located on a second surface of the support, and the separate portion and the separate zone of the aerosol-generating material are located in corresponding positions on their respective surfaces.

22. The consumable according to claim 21, wherein the shapes of the separate portions and the separate zones of the aerosol-generating material on the planes of the first and second surfaces of the support are substantially the same.

23. The consumable according to claim 21, wherein the separate portion of the aerosol generating material covers a first area on the surface of the support on which the separate portion is supported, the separate zone covers a second area on the surface of the support on which the separate zone is supported, and one of the first and second areas is larger than the other of the first and second areas.

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