CN118870999A

CN118870999A - Consumables for use with aerosol supply devices

Info

Publication number: CN118870999A
Application number: CN202280092116.5A
Authority: CN
Inventors: 罗伯特·普雷斯
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2024-10-29
Also published as: KR20240113515A; US20250049109A1; EP4451969A1; IL313649A; MX2024007561A; AU2022419165A1; WO2023118240A1; CA3241627A1; JP2024547042A

Abstract

A consumable (2) for insertion into an aerosol supply device is disclosed. The consumable (2) comprises a support (4), an aerosol-generating material (6) and a sealing element (8, 10). The support (4) comprises one or more flow path surfaces (20), the one or more flow path surfaces (20) of the support (4) at least partially defining a flow path for atmospheric air. At least one of the one or more flow path surfaces (20) of the support (4) supports one or more discrete portions (6) of aerosol-generating material. The sealing element (8, 10) is movable from a first position in which the sealing element blocks the flow of atmospheric air along the flow path to a second position in which the sealing element (8, 10) does not block the flow of atmospheric air along the flow path.

Description

Consumable for use with an aerosol supply device

Technical Field

The present disclosure relates to the field of non-combustible aerosol provision systems, in particular to a method of manufacturing a product comprising an aerosol generating material for use as a consumable with an aerosol provision device, a method for manufacturing a consumable for use with an aerosol provision device, and an aerosol provision system comprising a consumable and an aerosol provision device.

Background

Aerosol-generating articles release inhalable aerosols or aerosol-generating gases by releasing a compound from a matrix material by heating but not burning. These may be referred to as non-combustible articles, aerosol-generating components or aerosol-supplying devices.

One example of such a product is a heating device that releases a compound by heating an aerosolizable material, which may be referred to as a solid aerosol-generating material. The heating causes at least one component of the material to aerosolize, typically forming an inhalable aerosol. These products may be referred to as heated non-combustion devices.

As another example, there is a mixing device. These mixing devices contain a liquid source (which may or may not contain an active substance) that is atomized by heating to produce an inhalable atomized gas or aerosol. The device additionally comprises a solid aerosol-generating material (which may or may not comprise plant material) and components of the material are entrained in an inhalable aerosol or aerosol to produce an inhalation medium.

Disclosure of Invention

According to a first aspect of the present disclosure there is provided a consumable for insertion into an aerosol-supply device, the consumable comprising a support, an aerosol-generating material and a sealing element, wherein the support comprises one or more flow path surfaces at least partially defining a flow path for atmospheric air, at least one of the one or more flow path surfaces of the support supporting one or more discrete portions of the aerosol-generating material, and the sealing element is movable from a first position in which the sealing element blocks flow of atmospheric air along the flow path to a second position in which the sealing element does not block flow of atmospheric air along the flow path.

According to a second aspect of the present disclosure there is provided a blank for making a consumable according to the first aspect, wherein the blank comprises a support, an aerosol-generating material and a sealing element, the support comprises one or more flow path surface portions, at least one of the one or more flow path surface portions of the support supports one or more discrete portions of the aerosol-generating material, and the blank is configured such that it can be reconfigured to form a consumable.

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, the consumable comprising a support, an aerosol generating material, a sealing element and a flow path for atmospheric air, the flow path being defined at least in part by one or more flow path surfaces of the support, the method comprising: providing a support comprising one or more flow path surface portions and shaped and dimensioned such that the support can be reconfigured to form a consumable; applying an aerosol-generating material to one or more of the one or more flow path surface portions of the support; and reconfiguring the support such that the one or more flow path surface portions at least partially define a flow path for atmospheric air.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable according to the first aspect of the present disclosure, wherein the device comprises an aerosol generator configured to heat at least a portion of an aerosol generating material supported on the consumable.

According to a fifth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable according to the first aspect of the present disclosure.

According to a sixth aspect of the present disclosure there is provided a method of generating an aerosol from a consumable according to the first aspect of the present disclosure using an aerosol-generating device having at least one aerosol generator arranged to heat but not burn the consumable in use; wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

Other features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure, given by way of example and with reference to the accompanying drawings.

Drawings

FIG. 1 illustrates a first perspective view of a first embodiment of a consumable in accordance with the present disclosure;

FIG. 2 shows a cross-sectional view of the consumable of FIG. 1 along section line A-A';

FIG. 3 shows a second perspective view of the consumable of FIG. 1;

FIG. 4 shows a third perspective view of the consumable of FIG. 1;

FIG. 5 shows a view of the consumable of FIG. 1 during manufacture;

FIG. 6 illustrates a first perspective view of a second embodiment of a consumable in accordance with the present disclosure;

FIG. 7 shows a second perspective view of the consumable of FIG. 6; and

Fig. 8 shows a view of the consumable of fig. 6 during manufacture.

Detailed Description

The consumable of the present specification may alternatively be referred to as an article.

In some embodiments, the consumable comprises an aerosol generating material. The consumable may include an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active ingredients, one or more flavourings, one or more aerosol-former materials, and/or one or more other functional materials.

The device for heating aerosol-generating material for use with a consumable is part of a non-combustible aerosol supply system. The non-combustible aerosol supply system releases compounds, such as electronic cigarettes, tobacco heating products, and mixing systems, from the aerosol-generating material without burning the aerosol-generating material to generate an aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a "non-combustible" aerosol supply system is a system in which the constituent aerosol-generating materials of the aerosol supply system (or components thereof) are not combusted in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, such as a powered non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a vapor smoke device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

In some embodiments, the non-combustible sol supply system is an aerosol generating material heating system, also referred to as a heated non-combustion system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid 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 comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

In general, a non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device.

In some embodiments, the present disclosure relates to a consumable containing an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables are sometimes referred to as articles of manufacture in this disclosure.

In some embodiments, a non-combustible sol supply system (such as a non-combustible sol supply thereof) may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic source. In some embodiments, the heat-generating source comprises a carbon matrix that may be energized to distribute power in the form of heat to the aerosol-generating material or the heat-transfer material in proximity to the heat-generating source.

In some embodiments, the non-combustible aerosol supply system may include a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

According to a first aspect of the present disclosure there is provided a consumable for insertion into an aerosol-supply device, the consumable comprising a support, an aerosol-generating material and a sealing element, wherein the support comprises one or more flow path surfaces, the one or more flow path surfaces of the support at least partially define a flow path for atmospheric air, at least one of the one or more flow path surfaces of the support supports one or more discrete portions of the aerosol-generating material, and the sealing element is movable from a first position in which it blocks the flow of atmospheric air along the flow path to a second position in which the sealing element does not block the flow of atmospheric air along the flow path. The consumable is configured such that when the consumable is used, i.e. when aerosol is drawn from the aerosol-generating material in the consumable, atmospheric air needs to be able to flow along/be drawn along the flow path.

In one of the above embodiments, the flow path surface of the support entirely defines the flow path. In some alternative embodiments, the consumable is for use in a device, and the device or an element of the device and the flow path surface of the consumable each partially define a flow path for atmospheric air.

In one embodiment of any of the above embodiments, the flow path is linear or substantially linear.

In one embodiment of any of the above embodiments, the sealing element is attached to the support when in the first position and before it has been moved to the second position. When the sealing element is made of the same material as the support and the material is continuous/uninterrupted between the support and at least a portion of the sealing element (the sealing element is integrally formed with the support), or when the support and the sealing element are two separate elements and the sealing element is engaged with the support (e.g. secured to the support by using an adhesive or other securing means or securing means), the sealing element is attached to the support when in the first position.

In one embodiment of any of the above embodiments, the sealing element is separated from the support when in the second position.

In one embodiment of any of the above embodiments, movement of the sealing element from the first position to the second position produces an irreversible indication that the sealing element has moved from the first position to the second position. This is advantageous because it allows the consumable to be supplied while the sealing element is in the first position, and the user can then determine that the consumable is not being used, because if the sealing element has been moved from its first position, an irreversible indication of this movement will be revealed. This may facilitate hygienic use of the consumable and the device in which the consumable is used and/or assist the user in knowing whether the consumable has been used.

In one embodiment of any of the above embodiments, the irreversible indication is a physical or visual change to one or both of the sealing element and a portion of the support. For example, but not limited to, the indication may be a tear of the material forming the sealing element and/or the consumable, a tear of an indicating material associated with the sealing element, or a color change of the material forming the sealing element and/or the consumable.

In one embodiment of any of the above embodiments, the sealing element is integrally formed with at least a portion of the support adjacent the sealing element when the sealing element is in the first position and before the sealing element is moved to the second position.

In one embodiment of any of the above embodiments, the sealing element is connected to a portion of the support adjacent the sealing element at a junction, and the junction includes a plurality of perforations.

In one embodiment of any of the above embodiments, the perforation is in a line and the movement of the sealing element to the second position comprises: the sealing element is rotated about or torn from the support along the perforated line. The perforations will assist in tearing the sealing element off the support. The perforations help control the location at which the sealing element tears from the support.

In one embodiment of any of the above embodiments, the perforations do not extend through the entirety of the portion of the support adjacent the sealing element.

In one embodiment of any of the above embodiments, the sealing element is attached to the support by a securing element when the sealing element is in the first position and before the sealing element is moved to the second position. In some embodiments, the sealing element is made of a material that is easily torn, such as paper or metal foil. In some embodiments, the fixation element is frangible.

In one embodiment of any of the above embodiments, the securing element is an adhesive.

In one embodiment of any of the above embodiments, the consumable further comprises a second sealing element movable from an alpha position in which the second sealing element engages the support and blocks the flow of atmospheric air along the flow path to a beta position in which the second sealing element does not block the flow of atmospheric air along the flow path.

In one embodiment of any of the above embodiments, the second sealing element is engaged with the support when in the alpha position.

In one embodiment of any of the above embodiments, the second sealing element is separated from the support when in the beta position.

In one embodiment of any of the above embodiments, the second sealing element is connected to a portion of the support adjacent to the second sealing element at a junction when in the alpha position, and the junction includes a plurality of perforations.

In one embodiment of any of the above embodiments, the perforations are arranged in a line and the movement of the second sealing element to the beta position comprises: the second sealing element is rotated about or torn off from the support along the perforated line.

In one embodiment of any of the above embodiments, one or both of the first and second sealing elements is attached to the support when in the second position/β position.

In one embodiment of any of the above embodiments, one or both of the first and second sealing elements are configured to be movable to and then held at one or more intermediate positions between the first and second positions/positions. The or each intermediate position is a position in which the sealing element partially blocks the flow of atmospheric air along the flow path. At each intermediate position, the sealing element will block the flow of atmospheric air along the flow path by a different amount. This has the advantage that when the consumable is in use, the intermediate position at which the first sealing element and/or the second sealing element is positioned will affect the pressure drop across the flow path and thus the sensory experience of the user of the consumable. For example, but not limited to, the intermediate position will affect the manner in which the aerosol generated by the consumable is deposited in the user's mouth, and/or the depth to which the user inhales the aerosol.

In one embodiment of any of the above embodiments, the flow path has a longitudinal extent including a first end and a second end, and the sealing element blocks one of the ends of the flow path when the sealing element is in the first position and before the sealing element moves to the second position. In some embodiments, the second sealing element blocks the other end of the flow path when the second sealing element is in the alpha position.

In one embodiment of any of the above embodiments, the flow path has a substantially constant cross-sectional shape along at least a portion of the longitudinal extent of the flow path.

In one embodiment of any of the above embodiments, the cross-sectional shape of at least a portion of the longitudinal extent of the flow path is one of a polygon, an equilateral triangle, an approximately equilateral triangle, a square, a rectangle, a regular polygon, an approximately regular polygon, a circle, an approximately circle, an ellipse, or an approximately ellipse, wherein the regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel, and the approximately regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel or approximately parallel.

In an embodiment of any of the above embodiments, the consumable further comprises one or more sets of portions of aerosol-generating material, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and the at least two discrete portions are positioned at locations along the deposition lines, and each deposition line extends in a direction parallel or approximately parallel to the longitudinal extent of the flow path. The or each deposition line is a virtual line along which two or more discrete portions of aerosol-generating material are located. In some embodiments, the or each deposition line is a straight line.

In an embodiment of any of the above embodiments, the consumable further comprises one or more sets of portions of aerosol-generating material, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and the at least two discrete portions are positioned at locations along the deposition lines, and each deposition line extends in a direction that is not parallel to the longitudinal extent of the flow path.

In an embodiment of any of the above embodiments, the consumable further comprises two or more sets of portions of aerosol-generating material, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and at least two discrete portions of a set being positioned at a location along a deposition line for the set of portions, and each deposition line extending in a direction parallel or approximately parallel to at least one of the other deposition lines.

In some of the above embodiments, the discrete portions of aerosol-generating material are sufficiently spaced apart from each other along and/or between the deposition lines such that heating one discrete portion of aerosol-generating material does not cause heating of any adjacent discrete portion of aerosol-generating material.

In one embodiment of any of the above embodiments, there are two or more sets of portions of aerosol-generating material, each deposition line has a first end and a second end, each deposition line has a discrete portion of aerosol-generating material located at the first end and the second end of the deposition line, the first end of each deposition line is closer to the first end of the flow path than the second end of the deposition line, and the spacing between the discrete portions of aerosol-generating material along one deposition line is the same as the spacing between the discrete portions of aerosol-generating material along at least one other deposition line.

In one embodiment of any of the above embodiments, the distance between the first end of the flow path and the first end of each deposition line is equal or approximately equal in the direction of the longitudinal extension of the flow path.

In one embodiment of any of the above embodiments, there are two or more sets of portions of aerosol-generating material, and each set of portions of aerosol-generating material comprises the same number of discrete portions of aerosol-generating material.

In one embodiment of any of the above embodiments, at least one set of portions of the aerosol-generating material is supported on each flow path surface of the support.

In one embodiment of any of the above embodiments, there is at least one set of portions of aerosol-generating material supported on each flow path surface of the support. In some embodiments, each set of portions is identical to each other set of portions in that each set of portions includes the same number of discrete portions of aerosol-generating material and the discrete portions have the same spacing and positioning relative to the flow path supporting them as the discrete portions of aerosol-generating material supported on the other flow path surfaces.

In an embodiment of any of the above embodiments, at least one of the one or more discrete portions of aerosol-generating material is a longitudinally extending strip of aerosol-generating material.

In one embodiment of any of the above embodiments, at least one of the longitudinally extending strips extends in a direction parallel or approximately parallel to the longitudinal extent of the flow path. In some embodiments, at least one of the longitudinally extending strips extends approximately the length of the entire flow path.

In one embodiment of any of the above embodiments, at least one of the longitudinally extending strips extends in a direction perpendicular or approximately perpendicular to the longitudinal extent of the flow path. In some embodiments, at least one of the longitudinally extending strips is supported on at least two of the flow path surfaces of the support.

In an embodiment of any of the above embodiments, the discrete portions of aerosol-generating material are supported on at least one of the flow path surfaces in an arrangement that is not along a virtual line. In some embodiments, the arrangement and number of discrete portions of aerosol-generating material are the same on each of the flow path surfaces.

In an embodiment of any of the above embodiments, the consumable is adapted such that air flows along the flow path from the first end to the second end, and the amount of aerosol-generating material in each discrete portion of aerosol-generating material is dependent on the distance of the discrete portion of aerosol-generating material from the first end.

In one embodiment of any of the above embodiments, the amount of aerosol-generating material in the discrete portion of aerosol-generating material decreases with increasing distance of the discrete portion from the first end. This has the effect that the further the discrete portion of aerosol-generating material separates the first end of the flow path (or the closer the discrete portion of aerosol-generating material separates the user), the less aerosol will be generated by the discrete portion. This will allow the amount of aerosol inhaled by the user of the consumable to be approximately equal, irrespective of the location of the discrete portion of aerosol-generating material on the flow path. This is because the closer the discrete portions of aerosol-generating material are separated from the user, the smaller the volume of aerosol that remains in the flow path after the user inhales the aerosol from the consumable, and the less aerosol that condenses before reaching the user. Thus, aerosol-generating material closer to the user needs to generate less aerosol than aerosol-generating material further from the user to provide aerosol inhaled by the user and staying in the flow path.

In one embodiment of any of the above embodiments, the consumable further comprises a mouthpiece.

In one embodiment of any of the above embodiments, the mouthpiece is positioned in the flow path.

In one embodiment of any of the above embodiments, the sealing element blocks the flow of atmospheric air along the flow path and covers the mouthpiece when the sealing element is in its first position and before the sealing element is moved to the second position, and movement of the sealing element to the second position allows the user to access the mouthpiece.

In an alternative embodiment to any of the above embodiments, the consumable further comprises a seat adapted to receive the removable mouthpiece.

In one embodiment of any of the above embodiments, the seat is positioned in the flow path.

In one embodiment of any of the above embodiments, the sealing element blocks the flow of atmospheric air along the flow path and covers the seat for the mouthpiece when the sealing element is in its first position and before the sealing element is moved to the second position, and movement of the sealing element to the second position allows the user to access the seat.

In one embodiment of any of the above embodiments, the consumable further comprises at least one filtration portion, and the at least one filtration portion is located in the flow path. The or each filter portion may assist in providing a desired pressure drop along the flow path. Additionally or alternatively, the or each filter portion may assist in converting the aerosol-generating material emitted from the aerosol-generating material into an aerosol. Additionally or alternatively, the or each filter portion may assist in absorbing or adsorbing any condensate formed in the flow path, thereby reducing the likelihood of such condensate exiting the flow path and being ingested by the user or soiling the user or clothing thereof.

In one embodiment of any of the above embodiments, the at least one filtration portion is positioned at or near an end of the flow path. In some embodiments, the consumable comprises two filtration portions, wherein the filtration portions are positioned at or near each end of the flow path.

In one embodiment of any of the above embodiments, the filter portion is positioned at or near an end of the flow path distal from the first sealing element.

In one embodiment of any of the above embodiments, the at least one filtration portion comprises a filtration body and at least one active substance. At least one active may be a flavoring.

In one embodiment of any of the above embodiments, the at least one filtration portion comprises one or more of cellulose acetate, dust free paper, cotton based material, shredded paper, or shredded tobacco, or comprises a mixture of two or more of these materials. The at least one filter portion may comprise other suitable high surface area materials suitable for assisting in the formation of an aerosol from the atomizing gas.

In one embodiment of any of the above embodiments, the at least one filtration portion is an absorbent or adsorbent material.

In one of any of the above embodiments, the blank further comprises a portion that is reconfigurable to form the first sealing element.

In one of any of the above embodiments, the blank further comprises a portion that is reconfigurable to form a second sealing element.

In one of any of the above embodiments, the blank further comprises one or more fold lines, wherein each fold line is located between adjacent portions of the blank.

In one embodiment of any of the above embodiments, the blank further comprises one or more perforations between the portion of the support connected to the first sealing element portion and/or between the portion of the support connected to the second sealing element portion and the second sealing element portion.

In one embodiment of any of the above embodiments, the support comprises a laminate.

In one embodiment of any of the above embodiments, the support comprises a metal foil or a metal film.

In one embodiment of any of the above embodiments, the support comprises a susceptor.

In some embodiments, the support is provided as a flat sheet of material. The shape and size of the sheet of material may be designed such that the support may be folded or otherwise reconfigured to form a three-dimensional shape that at least partially defines the flow path.

In one of the above embodiments, the flow path surface of the support will fully define the flow path after the support is reconfigured. In some alternative embodiments, the consumable is for use in a device, and after reconfiguration of the support, the device or an element of the device and the flow path surface of the consumable will each partially define a flow path for atmospheric air.

In one embodiment of any of the above embodiments, the support is configured such that the flow path will be linear or substantially linear after reconfiguration of the support.

In one of any of the above embodiments, the method further comprises: the step of introducing at least one fold line into the support and reconfiguring the support into a consumable comprises: the support is folded about at least one fold line. In one embodiment of any of the above embodiments, the support further comprises a sealing element portion, and the sealing element portion is reconfigured into the sealing element at the same time or after the support has been reconfigured to at least partially define the flow path for atmospheric air, and the sealing element is in a first position in which it blocks the flow of atmospheric air along the flow path.

In one embodiment of any of the above embodiments, the sealing element portion has a perimeter and the fold line is introduced into a portion of the support adjacent the perimeter of the sealing element portion.

In one embodiment of any of the above embodiments, the sealing element portion has a perimeter and the one or more perforations are introduced into a portion of the support adjacent the perimeter of the sealing element portion.

In one of any of the above embodiments, the method further comprises: a first sealing element is provided and secured in a first position in which the sealing element blocks the flow of atmospheric air along the flow path. In such embodiments, the sealing element is formed separately from the rest of the consumable.

In one embodiment of any of the above embodiments, the sealing element is secured in the first position. The sealing element is thus fixed in a position in which it blocks the flow of atmospheric air along the flow path.

In one of any of the above embodiments, when the sealing element is secured in the first position, the sealing element engages a portion of the support and engagement with the portion of the support causes the sealing element to move to a second position in which the sealing element does not obstruct the flow of atmospheric air along the flow path, such movement irreversibly indicating that the sealing portion has moved to the second position, for example by physically damaging one or both of the sealing element and the portion of the support.

In one embodiment of any of the above embodiments, the sealing element is secured in the first position by use of an adhesive. The adhesive may be any form of adhesive that is not a releasable adhesive, such as a low tack pressure sensitive adhesive.

In one embodiment of any of the above embodiments, the support further comprises a second sealing element portion, and the second sealing element portion is reconfigured to the second sealing element at the same time or after the support has been reconfigured to at least partially define a flow path for atmospheric air, and the second sealing element is in an alpha position in which it blocks the flow of atmospheric air along the flow path.

In one embodiment of any of the above embodiments, the second sealing element portion has a perimeter and the fold line is introduced into a portion of the support adjacent the perimeter of the second sealing element portion.

In one embodiment of any of the above embodiments, the second sealing element portion has a perimeter and the one or more perforations are introduced into a portion of the support adjacent the perimeter of the second sealing element portion.

In one of any of the above embodiments, the method further comprises: a second sealing element is provided and is secured to an alpha position in which it blocks the flow of atmospheric air along the flow path.

In one embodiment of any of the above embodiments, the second sealing element is secured in the alpha position using an adhesive. The adhesive may be any suitable form of adhesive.

In one embodiment of any of the above embodiments, the flow path has a longitudinal extent including a first end and a second end, and the first sealing element blocks one of the ends of the flow path. In some embodiments, the second sealing element blocks the other end of the flow path.

In one of any of the above embodiments, the support is configured such that the flow path has a substantially constant cross-sectional shape along at least a portion of the longitudinal extent of the flow path. In one embodiment of any of the above embodiments, the cross-sectional shape of at least a portion of the longitudinal extent of the flow path is one of a polygon, an equilateral triangle, an approximately equilateral triangle, a square, a rectangle, a regular polygon, an approximately regular polygon, a circle, an approximately circle, an ellipse, or an approximately ellipse, wherein the regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel, and the approximately regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel or approximately parallel.

In an embodiment of any of the above embodiments, one or more sets of portions of aerosol-generating material are applied to one or more of the flow path surface portions, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and for each set of portions, the at least two discrete portions are positioned at positions along a deposition line, and when the support is reconfigured such that the one or more flow path surface portions at least partially define a flow path for atmospheric air, each deposition line extends in a direction parallel or approximately parallel to a longitudinal extent of the flow path. The or each deposition line is a virtual line along which two or more discrete portions of aerosol-generating material are located. In some embodiments, the or each deposition line is a straight line.

In an embodiment of any of the above embodiments, one or more sets of portions of aerosol-generating material are applied to one or more of the flow path surface portions, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and the at least two discrete portions being positioned at positions along a deposition line, and each deposition line extending in a direction that is not parallel to a longitudinal extension of the flow path when the support is reconfigured such that the one or more flow path surface portions at least partially define a flow path for atmospheric air.

In an embodiment of any of the above embodiments, one or more sets of portions of aerosol-generating material are applied to one or more of the flow path surface portions, each set of portions of aerosol-generating material comprising at least two discrete portions of aerosol-generating material, and the at least two discrete portions of a set are positioned at locations along a deposition line for the set of portions, and each deposition line extends in a direction parallel or approximately parallel to at least one of the other deposition lines when the support is reconfigured such that the one or more flow path surface portions at least partially define a flow path for atmospheric air.

In an embodiment of any of the above embodiments, there are two or more sets of portions of aerosol-generating material, each deposition line has a first end and a second end, each deposition line has a discrete portion of aerosol-generating material located at the first end and the second end of the deposition line, after the support is reconfigured such that the one or more flow path surface portions at least partially define a flow path for atmospheric air, the first end of each deposition line is closer to the first end of the flow path than the second end of the deposition line, and the spacing between the discrete portions of aerosol-generating material along one deposition line is the same as the spacing between the discrete portions of aerosol-generating material along at least one other deposition line.

In an embodiment of any of the above embodiments, at least one set of portions of aerosol-generating material is applied to each of the flow path surface portions.

In one embodiment of any of the above embodiments, the longitudinally extending strips extend in a direction parallel or approximately parallel to the longitudinal extent of the flow path. In some embodiments, at least one of the longitudinally extending strips extends approximately the length of the entire flow path.

In an embodiment of any of the above embodiments, the consumable is adapted such that air flows along a flow path from the first end to the second end, and the amount of aerosol-generating material in each discrete portion of aerosol-generating material is dependent on the distance of the discrete portion of aerosol-generating material from the first end.

In one embodiment of any of the above embodiments, the amount of aerosol-generating material in the discrete portion of aerosol-generating material decreases with increasing distance of the discrete portion from the first end.

In one embodiment of any of the above embodiments, the aerosol-generating material is applied as a slurry of aerosol-generating material.

In one embodiment of any of the above embodiments, the aerosol-generating material is a film of aerosol-generating material.

In one of any of the above embodiments, the method further comprises: a mouthpiece is provided.

In one embodiment of any of the above embodiments, the sealing element blocks the flow of atmospheric air along the flow path and covers the mouthpiece when the sealing element is in its first position.

In an alternative to any of the above embodiments, the method further comprises: a seat adapted to receive a removable mouthpiece is provided.

In one of any of the above embodiments, the method further comprises: at least one filter portion is positioned in the flow path.

In one embodiment of any of the above embodiments, the at least one filtration portion is positioned at or near an end of the flow path.

In one of any of the above embodiments, the method further comprises: at least one active substance is introduced into the at least one filter portion.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated, or otherwise energized. The aerosol-generating material may for example be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or a flavour.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.

The aerosol-generating material may comprise a binder (such as a gelling agent) and an aerosol-former. Optionally, substances and/or fillers to be delivered may also be present. Optionally, a solvent (such as water) is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder (such as a gelling agent) and an aerosol-former. Optionally, substances and/or fillers to be delivered may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

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

The aerosol-generating film may be formed by: a binder (such as a gelling agent) is combined with a solvent (such as water), an aerosol former, and one or more other components (such as one or more substances to be delivered) to form a slurry, and then the slurry is heated to aerosolize at least some of the solvent to form an aerosol-generating film.

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

The aerosol-generating material may comprise or may be an "amorphous solid". In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid (such as a liquid) within their interior. In some embodiments, the amorphous solids may include, for example, from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids.

The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

Susceptors are materials that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that its penetration with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material such that its penetration with a varying magnetic field causes hysteresis heating of the susceptor. The susceptor may be electrically conductive and magnetic such that the susceptor can be heated by both heating mechanisms. The device configured to generate a varying magnetic field is referred to as a magnetic field generator.

The susceptor may comprise a ferromagnetic metal, such as iron or an iron alloy, such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grades of stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In paramagnetic conductive materials, induction heating occurs only by resistive heating caused by eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated only by hysteresis loss. Susceptors may include commercial alloys such as Phytherm 230 (having a composition with 50wt% Ni, 10wt% Cr and the balance Fe (weight percent = wt%)) or Phytherm 260 (having a composition with 50wt% Ni, 9wt% Cr and the balance Fe).

In one embodiment of any of the above embodiments, the aerosol-generating material comprises an active substance.

An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof.

The active substance may comprise one or more components, derivatives or extracts of tobacco or another plant.

In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B12.

The active substance may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Alternatively, the material may comprise an active compound naturally occurring in plants, which is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like. Exemplary plants are tobacco, eucalyptus, star anise, cocoa, fennel, lemon grass, peppermint, spearmint, black leaf tea, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorice root), green tea, mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, clove, cinnamon, coffee, star anise (fennel), basil, bay leaf, cardamon, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elder, vanilla, wintergreen, perilla, turmeric root powder, sandalwood, coriander leaf, bergamot, orange flower, myrtle, blackcurrant, valerian, sweet pepper, nutmeg, damine, carrageenan, olive, lemon balm, lemon basil, bergamot, horsetail, tarragon, pelargil, geranium, mulberry, ginseng, tea, tetramethyl, uric acid, guava, kudzuvine, or combinations thereof. The mint may be selected from the following mint varieties: spearmint, peppermint cultivar, egyptian mint, spearmint cultivar, peppermint cultivar, spearmint, peppermint, pineapple, spearmint cultivar, and apple mint.

In some embodiments, the active comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is tobacco.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from eucalyptus, star anise and cocoa.

In some embodiments, the active comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from the group consisting of camellia sinensis and fennel.

In some embodiments, the aerosol-generating material comprises a flavoring or a flavoring.

As used herein, the terms "flavoring" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatosensory in a product for an adult consumer, as permitted by local regulations. They may include naturally occurring flavour materials, plants, extracts of plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice root), hydrangea, eugenol, japanese white magnolia leaf, chamomile, fenugreek, clove, maple, green tea, menthol, japanese mint, star anise (fennel), cinnamon, turmeric, indian condiment, asian condiment, herb, holly, cherry, berry, raspberry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, du Linbiao wine, bouillon, scotch whiskey, juniper, wine, glory, spearmint, peppermint, lavender, aloe, cardamom, celery, alopecan, nutmeg, sandalwood, bergamot, geranium, lilac Arabian tea leaf, sorghum, betel leaf, caraway, pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry flower, cinnamon, caraway, cogongrass, jasmine, ylang-ylang, sage, fennel, mustard, green pepper, ginger, coriander, coffee, peppermint oil from any variety of mentha plants, eucalyptus, star anise, cocoa, lemon grass, red bean, flax, ginkgo leaf, hazelnut, hibiscus, bay, mate, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elder, basil, bay leaf, cumin, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, perilla, turmeric, coriander, myrtle, black currant, valerian, spanish sweet pepper, nutmeg dried skin, damiane, marjoram, olive, lemon balm, lemon basil, north onion, celery, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. They may be imitation, synthetic or natural ingredients or mixtures thereof. They may be in any suitable form, for example, a liquid such as oil, a solid such as powder or a gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes a flavoring component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component extracted from tobacco.

In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of an aromatic or gustatory nerve, and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

The aerosol-generating material comprises an aerosol-generating agent. In some embodiments, the aerosol-generating agent may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenyl acetate, glycerol tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In a specific example, the aerosol-generating agent comprises glycerin.

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

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

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

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

The aerosol-generating material may further comprise a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin, and may be combined with a curing agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may comprise calcium-crosslinked alginate and/or calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of cellulose gelling agents, non-fibrous gelling agents, guar gum, gum arabic, and mixtures thereof.

In some embodiments, the cellulose gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose Acetate (CA), cellulose Acetate Butyrate (CAB), cellulose Acetate Propionate (CAP), and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or gum arabic.

In some embodiments, the gelling agent includes (or is) one or more non-cellulosic gelling agents including, but not limited to, agar, xanthan, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In a preferred embodiment, the non-cellulose based gelling agent is alginate or agar.

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

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

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

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

In examples, the aerosol-generating material comprises a gelling agent and a filler added together in an amount of from about 10wt%, 20wt%, 25wt%, 30wt% or 35wt% to about 60wt%, 55wt%, 50wt% or 45wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises a gelling agent and a filler added together in an amount of from about 20wt% to 60wt%, 25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the aerosol-generating material.

In examples, the aerosol-generating material includes a gelling agent (i.e., regardless of the amount of filler) in an amount from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol-generating material. In examples, the aerosol-generating material includes a gelling agent (i.e., regardless of the amount of filler) in an amount of from about 5wt% to 60wt%, 20wt% to 60wt%,25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the aerosol-generating material.

In some examples, the alginate is included in the gelling agent in an amount from about 5wt% to 40wt%, or 15wt% to 40wt% of the aerosol-generating material. That is, the aerosol-generating material comprises alginate in an amount of about 5wt% to 40wt%, or 15wt% to 40wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises alginate in an amount of from about 20wt% to 40wt%, or about 15wt% to 35wt% of the aerosol-generating material.

In some examples, pectin is included in the gelling agent in an amount from about 3wt% to 15wt% of the aerosol-generating material. That is, the aerosol-generating material comprises pectin in an amount of from about 3wt% to 15wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises pectin in an amount of from about 5wt% to 10wt% of the aerosol-generating material.

In some examples, guar gum is included in the gelling agent in an amount from about 3wt% to 40wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of from about 3wt% to 40wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of from about 5wt% to 10wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of from about 15wt% to 40wt%, or from about 20wt% to 40wt%, or from about 15wt% to 35wt% of the aerosol-generating material.

In an example, the alginate is present in an amount of at least about 50wt% of the gelling agent. In an example, the aerosol-generating material comprises alginate and pectin, and the ratio of alginate to pectin is from 1:1 to 10:1. The ratio of alginate to pectin is typically > 1:1, i.e. the alginate is present in a greater amount than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

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

Step (b) of forming the slurry layer typically comprises spraying, casting or extruding the slurry. In an example, the slurry layer is formed by electrospraying a slurry. In an example, the slurry layer is formed by casting a slurry.

In some examples, step (b) and/or step (c) and/or step (d) occur at least partially simultaneously (e.g., during electrospraying). In some examples, step (b), step (c), and step (d) occur sequentially.

In some examples, the slurry is applied to the support. The layer may be formed on the support.

In an example, the slurry includes a gelling agent, an aerosol former material, and an active substance. The slurry may include these components in any of the proportions given herein with respect to the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis):

-a gelling agent and optionally a filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry;

-an aerosol former material in an amount of about 40 to 80wt% of the slurry; and

-Optionally, an active substance in an amount of up to about 20wt% of the slurry;

step (c) of curing the gel may comprise supplying a curing agent to the slurry. For example, the slurry may include sodium, potassium or ammonium alginate as a gel precursor, and a setting agent including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

In examples, the curing 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 curing agent includes or consists of calcium formate and/or calcium lactate. In specific examples, the curing agent comprises or consists of calcium formate. The inventors have identified that typically the use of calcium formate as a curing agent results in an aerosol-generating material having greater tensile strength and greater elongation resistance.

The total amount of curing agent (such as a calcium source) may be 0.5wt% to 5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that the addition of too little curing agent may result in the aerosol-generating material not being able to stabilize the aerosol-generating material components and in these components falling out of the aerosol-generating material. The inventors have found that adding too much curing agent results in the aerosol-generating material being very viscous and thus having poor operability.

When the aerosol-generating material does not comprise tobacco, it may be desirable to apply a higher amount of curing agent. Thus, in some cases, the total amount of curing agent may be 0.5wt% to 12wt%, such as 5wt% to 10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case, the aerosol-generating material will generally not comprise any tobacco.

In an example, supplying the curing agent to the slurry includes: the curing agent is sprayed onto the slurry, such as the top surface of the slurry.

Alginate is a derivative of alginic acid and is typically a high molecular weight polymer (10 kDa to 600 kDa). Alginic acid is a copolymer of β -D-mannuronic acid (M) and α -L-guluronic acid (G) units (blocks) linked together by (1, 4) -glycosidic linkages to form a polysaccharide. Upon addition of the calcium cations, the alginate crosslinks to form a gel. It has been found that alginates with a high G monomer content form a gel more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate, wherein at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are alpha-L-guluronic acid (G) units.

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

In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry includes from about 50wt%, 60wt%, 70wt%, 80wt%, or 90wt% solvent (WWB).

In examples where the solvent consists of water, the dry weight content of the slurry may be matched to the dry weight content of the aerosol-generating material. Thus, the discussion herein regarding the composition of solids is explicitly disclosed in connection with the slurry aspects of the present invention.

The aerosol-generating material may comprise a flavour. Suitably, the aerosol-generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% flavouring agent. In some cases, the aerosol-generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of the flavouring agent (all on a dry weight basis). For example, the aerosol-generating material may comprise from 1wt% to 80wt%, from 10wt% to 80wt%, from 20wt% to 70wt%, from 30wt% to 60wt%, from 35wt% to 55wt% or from 30wt% to 45wt% of the flavouring agent. In some cases, the flavoring agent comprises, consists essentially of, or consists of menthol.

The aerosol-generating material may comprise a filler.

In some embodiments, the aerosol-generating material comprises less than 60wt% (such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20 wt%) of filler.

In other embodiments, the aerosol-generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% filler. In some cases, the aerosol-generating material comprises less than 1wt% filler, and in some cases, no filler.

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

The filler, if present, may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives such as methyl cellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC). In particular cases, the aerosol-generating material does not comprise calcium carbonate, such as chalk.

In embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, cellulose or cellulose derivatives such as methyl cellulose, hydroxypropyl cellulose and carboxymethyl cellulose (CMC).

Without wishing to be bound by theory, it is believed that including fibrous fillers in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in examples where the aerosol-generating material is provided as a sheet, such as when the sheet of aerosol-generating material surrounds a strip of aerosolizable material.

In some embodiments, the aerosol-generating material does not comprise tobacco fibers. In a specific embodiment, the aerosol-generating material does not comprise a fibrous material.

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

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

In some cases, the aerosol-generating material comprises an active substance, such as a tobacco extract. In some cases, the aerosol-generating material may comprise from 5wt% to 60wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the aerosol-generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of tobacco extract. For example, the aerosol-generating material may comprise from 10wt% to 50wt%, from 15wt% to 40wt%, or from 20wt% to 35wt% of the tobacco extract. The tobacco extract may comprise a concentration of nicotine such that the aerosol-generating material comprises 1wt%, 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) nicotine. In some cases, the aerosol-generating material may be free of nicotine other than the material produced by the tobacco extract.

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

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

The aerosol-generating composition may comprise one or more active substances. In an example, the aerosol-generating material comprises one or more active substances, for example up to about 20wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises the active in an amount of from about 1wt%, 5wt%, 10wt% or 15wt% to about 20wt%, 15wt%, 10wt% or 5wt% of the aerosol-generating material.

The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition to effect a physiological and/or olfactory reaction.

The tobacco material may be present in the aerosol-generating composition in an amount from about 50wt% to 95wt%, or about 60wt% to 90wt%, or about 70wt% to 90wt%, or about 75wt% to 85 wt%.

The tobacco material may be present in any form, but is typically fine cut (e.g., cut into filaments). The fine cut tobacco material may advantageously be mixed with an aerosol-generating material to provide an aerosol-generating composition having a uniform dispersion of tobacco material and aerosol-generating material throughout the aerosol-generating composition.

In examples, the tobacco material includes one or more of ground tobacco, tobacco fibers, cut filler, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extracts. Surprisingly, the present inventors have found that a relatively large amount of sheet tobacco can be used in an aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Sheet tobacco generally provides excellent organoleptic properties. In examples, the tobacco material includes lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In specific examples, the tobacco material includes cut filler in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grade or mixed, chopped rags or whole leaf, including virginia and/or burley and/or oriental tobacco.

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

In some cases, the aerosol-generating material may additionally include an emulsifier that emulsifies the melted flavoring during manufacture. For example, the aerosol-generating material may comprise from about 5wt% to about 15wt%, suitably about 10wt% (calculated on dry weight) of the emulsifier. The emulsifier may comprise gum arabic.

In some embodiments, the aerosol-generating material is a hydrogel and comprises less than about 20wt% water, calculated on a wet weight basis. In some cases, the hydrogel may include less than about 15wt%, 12wt%, or 10wt% water, calculated on a wet weight basis. In some cases, the hydrogel may include at least about 1wt%, 2wt%, or at least about 5Wt% Water (WWB).

The aerosol-generating material may have any suitable water content, such as from 1wt% to 15wt%. Suitably, the water content of the aerosol-generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%. The water content of the aerosol-generating material may be determined, for example, by karl fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

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

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

In an example, the aerosol-generating material consists essentially of, or consists of, a gelling agent, an aerosol-generating agent, an active substance and water. In an example, the aerosol-generating material consists essentially of, or consists of, a gelling agent, an aerosol-generating agent, and water.

In an example, the aerosol-generating material does not include a flavour; in a specific example, the aerosol-generating material does not comprise an active substance.

In some embodiments, the aerosol-generating material comprises an aerosol-generating material comprising:

-1 to 60wt% of a gelling agent;

-0.1 to 50wt% of an aerosol generator; and

-0.1 To 80wt% of a flavouring agent;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises from 1wt% to 80wt% of the flavoring agent (on a dry weight basis).

In some embodiments, the aerosol-generating material comprises:

-1 to 50wt% of a gelling agent;

-0.1 to 50wt% of an aerosol generator; and

-30 To 60wt% of a flavouring agent;

wherein these weights are calculated on a dry weight basis.

In an alternative embodiment of the aerosol-generating material, the aerosol-generating material comprises an aerosol-generating material comprising:

-1 to 60wt% of a gelling agent;

-5 to 60wt% of an aerosol generator; and

-10 To 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises:

-1 to 60wt% of a gelling agent;

-20 to 60wt% of an aerosol generator; and

-10 To 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises from 20wt% to 35wt% of the gelling agent; 10 to 25wt% of an aerosol former material; 5 to 25wt% of a filler comprising fibers; and 35 to 50wt% of a flavoring and/or active. In some cases, the aerosol-generating material may consist essentially of, or consist of, a gelling agent, an aerosol-generating agent, a tobacco extract, water, and optionally a flavoring agent. In some cases, the aerosol-generating material may consist essentially of, or consist of, glycerin, alginate and/or pectin, tobacco extract and water.

In some embodiments, the aerosol-generating material may have the following composition (DWB): a gelling agent (preferably comprising alginate) in an amount from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; a tobacco extract in an amount from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; the aerosol generating agent, preferably comprising glycerin, is present in an amount from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).

In one embodiment, the aerosol-generating material comprises about 20wt% alginate gelling agent, about 48wt% tobacco virginia extract, and about 32wt% glycerin (DWB).

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

In some cases, the aerosol-generating material layer forming the aerosol has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1.5mm or 0.05mm to about 1.0 mm. Suitably, the thickness may be in the range from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3 mm.

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

A material having a thickness of 0.2mm may be particularly suitable. The aerosol-generating material may comprise more than one layer and the thicknesses described herein refer to the total thickness of those layers.

It has been found that if the aerosol-generating material is too thick, the heating efficiency may be affected. This can adversely affect power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; very thin materials are more difficult to cast and can be fragile, affecting aerosol formation in use.

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

In some examples, the aerosol-generating material in sheet form may have a tensile strength of from about 200N/m to about 900N/m. In some examples, such as where the aerosol-generating material does not include a filler, the aerosol-generating material may have a tensile strength of from 200N/m to 400N/m, or 200N/m to 300N/m, or about 250N/m.

Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet and then shredded and incorporated into an aerosol-generating article. In some examples, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of from 600N/m to 900N/m, or from 700N/m to 900N/m, or about 800N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol-generating article/component as a rolled sheet (suitably in the form of a tube).

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

The aerosol-generating material comprising the aerosol-generating material may have any suitable areal density, such as from 30g/m ² to 350g/m ². In some cases, the sheet may have a mass per unit area of 50g/m ² to 250g/m ² or from about 70g/m ² to 210g/m ², or from about 90g/m ² to 190g/m ² or suitably about 100g/m ² (so that it has a density similar to shredded tobacco and a mixture of these materials will not readily separate). In some cases, the sheet may have a mass per unit area of about 30g/m ² to 70g/m ²、40g/m² to 60g/m ² or 25g/m ² to 60g/m ² and may be used to encase an aerosolizable material, such as tobacco.

All weight percentages (expressed as wt%) described herein are calculated on a dry weight basis unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. The weight quoted on a dry weight basis refers to the entire extract or slurry or material other than water and may include components that are themselves liquid at room temperature and pressure, such as glycerin. Conversely, the weight percentages quoted on a wet weight basis refer to all components, including water.

As used herein, the term "sheet" refers to an element having a width and length that are substantially greater than its thickness. The major surface of the sheet is a surface that extends in both the width and length dimensions when the sheet is flat. For example, the sheet may be a strip.

The aerosol-generating material may comprise a colourant. The addition of a colorant may alter the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and the aerosol-generating material.

By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color matched with other components of the aerosol-generating material or with other components of an article comprising the aerosol-generating material.

Depending on the desired color of the aerosol-generating material, a variety of colorants may be used. The colour of the aerosol-generating material may be, for example, white, green, red, violet, blue, brown or black. Other colors are also contemplated. Natural or synthetic colorants such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants may be used. In certain embodiments, the colorant is caramel, which may 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 (such as the tobacco material). In some embodiments, the addition of a colorant to the aerosol-generating material renders it visually indistinguishable from other components in the aerosol-generating material.

The colorant may be incorporated during formation of the aerosol-generating material (e.g., when forming a slurry comprising the material forming the aerosol-generating material), or it may be applied to the aerosol-generating material after formation of the aerosol-generating material (e.g., by spraying it onto the aerosol-generating material).

In some of any of the above embodiments, talc, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of the aerosol-generating material. This may reduce the tack or adhesion level of the aerosol-generating material.

In the following discussion of the figures, like reference numerals are used throughout for more than one embodiment when like elements are present, and like reference numerals are used (like numerals plus multiples of 100) when like elements are present.

Referring to fig. 1 to 4, the consumable 2 is formed from a plurality of discrete portions 6 of the support 4 and aerosol-generating material (not all of the discrete portions 6 are labeled for clarity). The number of discrete portions 6 shown in the figures is for illustration only, and the scope of the present disclosure encompasses more and fewer discrete portions 6 than illustrated.

The support 4 is configured such that a portion of the support 4 defines a wall of the tube along which atmospheric air may pass. In the figures, the tube has a square cross-section along the length of the tube, other cross-sectional shapes are possible and are within the scope of the present disclosure.

The support 4 comprises a first sealing element 8 which in its first position (shown in fig. 1 and 2) blocks/closes/seals a first end of the tube/flow path and a second sealing element 10 which in its first position (shown in fig. 1 and 2) blocks/closes/seals a second end of the tube/flow path.

The first sealing element 8 is formed by a main sealing element 8A, a flap 8B and an indicator element 8C. The main sealing portion 8A is part of the support 4 when the consumable 2 is manufactured. When the first sealing element 8 is in the first position, the main sealing portion 8A blocks the end of the pipe and the portion of the main sealing element 8A adjacent to the periphery of the main sealing portion 8A abuts the end of the pipe. The flaps 8B are fixed to the portion of the support 4 defining the tube by means of an adhesive (not shown). The indicator element 8C is fixed to the flap 8B and to the portion of the support 4 defining the tube by means of an adhesive (not shown). The indicator element 8C is made of a material that is sufficiently weak that any attempt to separate the indicator element from the flap 8B or the portion of the support 4 defining the tube will result in the indicator element tearing or losing structural integrity. In some examples, the indicator element 8C is made of tissue.

The second sealing element 10 has the same structure as the first sealing element 8 and is formed by a main sealing element 10A, a flap 10B and an indicator element 10C. The main sealing portion 10A is part of the support 4 when the consumable 2 is manufactured. When the second sealing element 10 is in the first position, the main sealing portion 10A blocks the end of the pipe and the portion of the main sealing element 10A adjacent to the periphery of the main sealing portion 10A abuts the end of the pipe. The flaps 10B are fixed to the portion of the support 4 defining the tube by means of an adhesive (not shown). The indicator element 10C is fixed to the flap 10B and to the portion of the support 4 defining the tube by means of an adhesive (not shown). The indicator element 10C is made of a material that is sufficiently weak that any attempt to separate the indicator element from the flap 10B or the portion of the support 4 defining the tube will result in the indicator element tearing or losing structural integrity. In some examples, the indicator element 10C is made of tissue.

When the first sealing element 8 or the second sealing element 10 is moved from their first/alpha position to their second/beta position, the main sealing portions 8A, 10A and flaps 8B, 10B are pulled away from the portions of the support 4 to which the main sealing portions and flaps are fixed. Pulling the main seal portion 8A, 10A and the flap 8B, 10B away from the portion of the support 4 to which the main seal portion and the flap are secured causes the indicator element 8C, 10C to tear and a portion of the indicator element 8C, 10C remains secured to the support 4 and a portion remains attached to the flap 8B, 10B. This allows the user to easily identify whether the first sealing element 8 or the second sealing element 10 is moved from their first position to their second position by a quick visual inspection.

In some embodiments of the present disclosure, the first sealing element 8 and the second sealing element 10 are in a position in which they do not obstruct the tube defined by the support 4 (as shown in fig. 3), which is sufficient to prepare the consumable 2 for use. This is because the ends of the tube defined by the support 4 are now all unobstructed and therefore the flow path along the interior of the tube is open to the flow of atmospheric air along the interior of the tube.

In some other embodiments of the present disclosure, by tearing the first sealing element 8 and the second sealing element 10 off the support, leaving a stub 8D (as shown in fig. 4), the first sealing element 8 and the second sealing element 10 are then separated from the support 4 and thus in their second/β position, in which they do not obstruct the tube defined by the support 4. The consumable 2 is now ready for use, since the ends of the tube defined by the support 4 are now both unobstructed and thus the flow path along the interior of the tube is open to the flow of atmospheric air along the interior of the tube.

Referring to fig. 5, to make consumable 2, blank 12 is cut from the sheet of support 4. The blank 12 comprises four flow path regions 14, a flap element 16, a first sealing element 8 and a second sealing element 10.

A plurality of discrete portions 6 of aerosol-generating material are applied to the flow path surface 20 of each of the flow path regions 14. The flow path surface 20 is the surface of the flow path region 14 of the support 4 that defines the interior of the tube into which the blank 12 is to be reconfigured and thus defines the flow path defined by the tube. After the blank 12 of the support has been reconfigured, the flow path will be intended to be in the direction of arrow 22 in fig. 5.

Discrete portions 6 are applied to each flow path surface 20 along deposition lines 14 (not shown with all flow path surfaces 20 for clarity). The deposition line 14 is virtual and physically invisible to the user. The discrete portions 6 on the deposition line may be labeled i through vi, where portion i is the discrete portion closest to the beginning or upstream end of the flow path (the right hand end of deposition line 18 in fig. 5) and portion vi is the portion closest to the end or downstream end of the flow path (the left hand end of deposition line 18 in fig. 5). Each of the sections i to vi has the same size in the plane of the flow path surface 20. However, the thickness of these portions decreases from the thickest portion i to portion iv. Thus, the amount of aerosol that can be generated by part i is greater than parts ii to vi, the amount of aerosol that can be generated by part ii is greater than parts iii to vi, etc.

To reconfigure the blank 12 into the consumable 2, fold lines 24 are introduced into the blank 12 between each of the flow path regions 14, between the flaps 16 and adjacent flow path regions 14, and between the first and second sealing elements 8, 10 and adjacent flow path regions 14. The flow path regions 14 are folded about fold lines 24 between adjacent flow path regions 14 to form square cross-section tubes. The folds are such that the discrete portions 6 all face the flow path defined by the flow path surface 20. To keep the blank 12 folded into a tube, the flaps 16 are secured to the portion of the flow path portion 14 that is furthest from the flaps 16 when the blank 12 is unfolded. The fixing of the flaps 16 is carried out by means of an adhesive, not shown.

After the flaps 16 are secured to the flow path portion 14, the first and second sealing elements 8, 10 are folded over the ends of the tube, and the flaps 8B, 10B and the indicating elements 8C, 10C are secured to the portions of the flow path portion 14 over which the flaps 8B, 10B are overlaid.

The consumable 2 may then be packaged for sale or storage.

Referring to fig. 6 and 7, the consumable 102 is formed from a support 104, a plurality of discrete portions 6 of aerosol-generating material, a mouthpiece. The discrete portions 6 of aerosol-generating material are identical in location, composition and configuration to the portions described above in fig. 1 to 5 and will not be further described in connection with the consumable 102.

The support 104 is configured such that a portion of the support 104 defines a wall of the tube and a flow path along which atmospheric air may pass. In fig. 6 and 7, the tube has a square cross section along the length of the tube. Other cross-sectional shapes are possible and are within the scope of the present disclosure.

The mouthpiece 126 is supported on a mouthpiece plate 128 and positioned such that the mouthpiece plate 128 partially encloses a first end of the tube formed by the support 104. The flow path defined by the support 104 passes through the tube defined by the support 104 and through the aperture 130 of the mouthpiece 126.

The support 104 includes a first sealing element 108 that covers the mouthpiece 126 and blocks/closes/seals the first end of the tube/flow path when the first sealing element is in a first position (shown in fig. 6).

Referring to fig. 6-8, the first seal member 108 is formed from a main seal member 108A, a flap 108B, an indicator member 108C, a pair of side members 108E, and a pair of side flaps 108F. When manufacturing the consumable 2, the main seal portion 108A is part of the support 104. When the first seal element 108 is in the first position, the main seal portion 108A in combination with the side element 108E occludes the end of the tube and mouthpiece 126. Flaps 108B and 108F are secured to the tube-defining portion of support 104 by an adhesive (not shown). Indicator element 108C is secured to flap 108B and to the portion of support 104 defining the tube by an adhesive (not shown). Indicator element 108C is made of a material that is sufficiently weak that any attempt to separate the indicator element from either flap 108B or the portion of support 104 defining the tube will result in the indicator element tearing or losing structural integrity.

When the sealing element 108 moves from its first position to its second position, the main sealing portion 108A, the side elements 108E and the flaps 108B, 108F are pulled away from the portion of the support 4 to which they are fixed. Pulling the main seal portion 108A, side members 108E, and flaps 108B, 108F away from the portion of support 104 to which they are secured causes the indicator member 108C to tear and a portion of the indicator member 108C remains secured to support 104 and a portion remains attached to flap 108B. The sealing element 108 is then torn off the support 104, leaving a residue 108D. Tearing of the indicator element 108C allows a user to easily identify, through a quick visual inspection, whether the sealing element 108 has moved from its first position to its second position.

Referring to fig. 8, to make consumable 102, blank 112 is cut from a sheet of support 104. The blank 112 includes four flow path regions 114, a flap member 116, and a sealing member 108.

The position of the mouthpiece plate 128 on the blank 112 is such that the mouthpiece plate is supported in the end of the tube formed by the flow path region 114, with the mouthpiece 126 extending out of the tube.

To reconfigure the blank 112 into the consumable 102, fold lines 124 are introduced into the blank 112 between each of the flow path regions 114, between the flaps 116 and adjacent flow path regions 114, and between the sealing element 108 and adjacent flow path regions 114. The flow path regions 114 are folded about fold lines 124 between adjacent flow path regions 114 to form square cross-section tubes. The folds are such that the discrete portions 6 are all facing the flow path. To keep the blank 112 folded into a tube, the flap 116 is secured to the portion of the flow path portion 114 that is furthest from the flap 116 when the blank 112 is unfolded. The fixing of the flaps 116 is carried out by means of an adhesive, not shown.

After the flaps 116 are secured to the flow path portion 114, the sealing element 108 is folded over the end of the tube and the mouthpiece 126, and the flaps 108B, 108F and the indicator element 108C are secured to the portions of the flow path portion 114 over which the flaps 108B, 108F and the indicator element 108 are overlaid.

The above description is exemplary only, and those skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the disclosed invention. Other modifications that fall within the scope of the invention will be apparent to those skilled in the art in view of this disclosure.

The various aspects of the methods and consumables disclosed in the various embodiments may be used alone, in combination, or in various arrangements not specifically discussed in the embodiments described above. Accordingly, the disclosure is not limited in application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. While particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. The scope of the following claims should not be limited to the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

1. A consumable for insertion into an aerosol supply device, the consumable comprising:

A support, an aerosol generating material and a sealing element, wherein

the support comprises one or more flow path surfaces, the one or more flow path surfaces of the support at least partially defining a flow path for atmospheric air,

At least one of the one or more flow path surfaces of the support supports one or more discrete portions of the aerosol generating material, and

The sealing element is movable from a first position, in which the sealing element blocks the flow of atmospheric air along the flow path, to a second position, in which the sealing element does not block the flow of atmospheric air along the flow path.

2. The consumable product of claim 1, wherein the sealing element is attached to the support when in the first position.

3. A consumable product according to claim 1 or 2, wherein the sealing element is separated from the support member when in the second position.

4. The consumable product of any one of claims 1 to 3, wherein movement of the sealing element from the first position to the second position produces an irreversible indication that the sealing element has moved from the first position to the second position.

5. The consumable product of claim 4, wherein the irreversible indication is a physical or visual change to one or both of a portion of the support and the sealing element.

6. The consumable product according to any one of claims 1 to 5, wherein the sealing element is integrally formed with at least a portion of the support member adjacent to the sealing element when the sealing element is in the first position and before the sealing element moves to the second position.

7. The consumable product of claim 6, wherein the sealing element is connected to a portion of the support member adjacent to the sealing element at a joint when in the first position, and the joint includes a plurality of perforations.

8. The consumable product of claim 7, wherein the perforations are arranged in a line, and movement of the sealing element to the second position comprises rotating the sealing element about the line of perforations or tearing the sealing element off the support along the line of perforations.

9. A consumable product according to claim 7 or 8, wherein the perforation does not extend through the entirety of a portion of the support member adjacent the sealing element.

10. The consumable product according to any one of claims 1 to 5, wherein the sealing element is attached to the support by a fixing element when the sealing element is in the first position and before the sealing element moves to the second position.

The consumable product according to claim 10 , wherein the fixing element is an adhesive.

12. A consumable according to any one of claims 1 to 11, wherein the consumable further comprises a second sealing element, which can be moved from an α position to a β position, wherein in the α position, the second sealing element engages with the support member and blocks the flow of atmospheric air along the flow path, and in the β position, the second sealing element does not block the flow of atmospheric air along the flow path.

13. The consumable product of claim 12, wherein the second sealing element engages the support member when in the α position.

14. A consumable product according to claim 12 or 13, wherein the second sealing element is separated from the support member when in the beta position.

15. The consumable product according to any one of claims 12 to 14, wherein the second sealing element is connected to a portion of the support adjacent to the second sealing element at a joint when in the α position, and the joint includes a plurality of perforations.

16. The consumable product of claim 15, wherein the perforations are arranged in a line, and movement of the second sealing element to the β position comprises rotating the second sealing element about the line of perforations or tearing the second sealing element off the support along the line of perforations.

17. A consumable according to any one of claims 1 to 16, wherein one or both of the first and second sealing means are attached to the support when in the second position/the beta position.

18. A consumable according to claim 17, wherein one or both of the first sealing device and the second sealing device are configured to be movable to one or more intermediate positions between the first position/the α position and the second position/the β position, and then maintained at the one or more intermediate positions.

19. A consumable according to any one of claims 1 to 18, wherein the flow path has a longitudinal extension range including a first end and a second end, and when the sealing element is in the first position and before the sealing element moves to the second position, the sealing element blocks one of the ends of the flow path.

20. A consumable product according to any one of claims 1 to 19, wherein the flow path has a substantially constant cross-sectional shape along at least a portion of the longitudinal extension of the flow path.

21. A consumable according to claim 20, wherein the cross-sectional shape of at least a portion of the longitudinal extension range of the flow path is one of a polygon, an equilateral triangle, an approximately equilateral triangle, a square, a rectangle, a regular polygon, an approximately regular polygon, a circle, an approximately circle, an ellipse or an approximately ellipse, wherein the regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel, and the approximately regular polygon is a polygon in which diagonally opposite faces of the polygon are parallel or approximately parallel.

22. A consumable according to any one of claims 1 to 21, wherein the consumable further comprises one or more groups of portions of aerosol generating material,

each group of portions of aerosol generating material comprises at least two discrete portions of aerosol generating material, and the at least two discrete portions are positioned at locations along the deposition line,

Each of the deposition lines extends in a direction parallel or approximately parallel to the longitudinal extension of the flow path.

23. A consumable product according to claim 22, wherein there are two or more groups of portions of aerosol generating material,

Each deposition line has a first end and a second end,

each deposition line having discrete portions of aerosol generating material located at a first end and a second end of the deposition line,

The first end of each deposition line is closer to the first end of the flow path than the second end of the deposition line, and

The spacing between discrete portions of the aerosol generating material along one deposition line is the same as the spacing between discrete portions of the aerosol generating material along at least one other deposition line.

24. The consumable product according to claim 23, wherein, in the direction of the longitudinal extension of the flow path, the distance between the first end of the flow path and the first end of each deposition line is equal or approximately equal.

25. A consumable product according to any one of claims 22 to 24, wherein there are two or more groups of portions of aerosol generating material and each group of portions of aerosol generating material comprises the same number of discrete portions of aerosol generating material.

26. A consumable product according to any one of claims 1 to 25, wherein at least one set of portions of aerosol generating material is supported on each flow path surface of the support.

27. A consumable product according to claim 19 or any one of claims 20 to 26 when appended to claim 19, wherein at least one of the one or more discrete portions of aerosol generating material is a longitudinally extending strip of aerosol generating material.

28. A consumable product according to claim 27, wherein at least one of the longitudinally extending strips extends in a direction parallel or approximately parallel to the longitudinal extension of the flow path.

29. A consumable product according to claim 27 or 28, wherein at least one of the longitudinally extending strips extends in a direction perpendicular or approximately perpendicular to the longitudinal extension of the flow path.

30. A consumable according to claim 19 or any one of claims 20 to 29 as dependent on claim 19, wherein the consumable is suitable for allowing air to flow along the flow path from the first end to the second end, and the amount of aerosol generating material in each discrete portion of the aerosol generating material depends on the distance between the discrete portion of the aerosol generating material and the first end.

31. A consumable product according to claim 30, wherein the amount of aerosol generating material in the discrete portions of aerosol generating material decreases as the distance of the discrete portions from the first end increases.

32. A consumable product according to any one of claims 1 to 31 , further comprising a mouthpiece.

33. The consumable product of claim 32, wherein the mouthpiece is positioned in the flow path.

34. A consumable according to claim 32 or 33, wherein, when the sealing element is in the first position and before the sealing element moves to the second position, the sealing element blocks the flow of atmospheric air along the flow path and covers the mouthpiece, and the movement of the sealing element to the second position allows a user to access the mouthpiece.

35. The consumable product according to any one of claims 1 to 34, wherein the consumable product further comprises at least one filter portion, and the at least one filter portion is located in the flow path.

36. The consumable product of claim 35, wherein at least one filter portion is positioned at or near an end of the flow path.

37. The consumable product of claim 36, wherein a filter portion is positioned at or near an end of the flow path distal from the first sealing element.

38. The consumable product according to any one of claims 35 to 37, wherein at least one filter portion comprises a filter body and at least one active substance.

39. A consumable product according to any one of claims 35 to 38, wherein at least one filter portion comprises one or more of cellulose acetate, dust-free paper, cotton-based material, shredded paper or shredded tobacco, or a mixture of two or more of these materials.

40. A consumable product according to any one of claims 35 to 39, wherein at least one filter portion is an absorbent or adsorbent material.

41. A blank for making a consumable product according to any one of claims 1 to 40, wherein the blank comprises:

A support, an aerosol generating material and a sealing element, wherein

The support member comprises one or more flow path surface portions,

At least one of the one or more flow path surface portions of the support supports one or more discrete portions of the aerosol generating material, and

The blank is configured such that the blank can be reconfigured to form a consumable product.

42. The blank of claim 41, wherein the blank further comprises a portion reconfigurable to form a first sealing element.

43. The blank of claim 42, wherein the blank further comprises a portion reconfigurable to form a second sealing element.

44. A blank according to any one of claims 40 to 43, wherein the blank further comprises one or more fold lines, wherein each fold line is located between adjacent portions of the blank.

45. A blank according to claim 43 or 43 or claim 44 dependent on claim 42 or 43, wherein the blank also includes one or more perforations, and the one or more perforations are located between the part of the support member connected to the first sealing element part and the first sealing element part and/or between the part of the support member connected to the second sealing element part and the second sealing element part.

46. A consumable product according to any one of claims 1 to 45, wherein the support member comprises a laminate material.

47. A consumable product according to any one of claims 1 to 46, wherein the support member comprises a metal foil or a metal film.

48. A consumable product according to any one of claims 1 to 47, wherein the support comprises a susceptor.

49. A method of making a consumable for use with a non-flammable aerosol supply device, the consumable comprising a support, an aerosol generating material, a sealing element, and a flow path for atmospheric air, the flow path being defined at least in part by one or more flow path surfaces of the support,

The method comprises:

providing a support member comprising one or more flow path surface portions and shaped and dimensioned so that the support member can be reconfigured to form the consumable,

applying an aerosol generating material to one or more of the one or more flow path surface portions of the support, and

The support is reconfigured so that the one or more flow path surface portions at least partially define a flow path for atmospheric air.

50. The method of claim 49, further comprising introducing at least one fold line into the support member, and reconfiguring the support member into the consumable product comprises folding the support member about the at least one fold line.

51. A method according to claim 49 or 50, wherein the support member further includes a sealing element portion, and while or after the support member has been reconfigured to at least partially define a flow path for atmospheric air, the sealing element portion is reconfigured into a sealing element, and the sealing element is in a first position, in which the sealing element blocks the flow of atmospheric air along the flow path.

52. A method according to claim 51, wherein the sealing element portion has a perimeter and the fold line is introduced into a portion of the support member adjacent the perimeter of the sealing element portion.

53. A method according to claim 51 or 52, wherein when the sealing element is in the first position, the sealing element portion is connected to a portion of the support member adjacent to the sealing element at a joint, and the joint includes a plurality of perforations.

54. The method of claim 49 or 50, further comprising providing a first sealing element and securing the sealing element into a first position in which the sealing element blocks the flow of atmospheric air along the flow path.

55. A method according to any one of claims 51 to 54, wherein the sealing element is fixed in the first position.

56. A method according to any one of claims 51 to 53, wherein, when the sealing element is fixed in the first position, the sealing element engages with a portion of the support member, and the engagement with the portion of the support member causes the sealing element to move to a second position, in which the sealing element does not block the flow of atmospheric air along the flow path and physically damages one or both of the sealing element and the portion of the support member that engages with the sealing portion.

57. A method according to any one of claims 52 to 56, wherein the sealing element is fixed in the first position by use of an adhesive.

58. A method according to any one of claims 49 to 57, wherein the support member further includes a second sealing element portion, and while or after the support member has been reconfigured to at least partially define a flow path for atmospheric air, the second sealing element portion is reconfigured into a second sealing element, and the second sealing element is in an α position, in which the second sealing element blocks the flow of atmospheric air along the flow path.

59. The method of claim 58, wherein the second sealing element portion has a perimeter and a fold line is introduced into a portion of the support member adjacent the perimeter of the second sealing element portion.

60. The method of claim 58 or 59, wherein when the sealing element is in the first position, the second sealing element portion is connected to a portion of the support adjacent the sealing element at a junction, and the junction includes a plurality of perforations.

61. A method according to any one of claims 49 to 57, wherein the method further comprises providing a second sealing element and securing the sealing element into an alpha position in which the sealing element blocks the flow of atmospheric air along the flow path.

62. The method of any one of claims 58 to 61, wherein the second sealing element is fixed to the alpha position.

63. The method of any one of claims 58 to 62, wherein the second sealing element is secured in the alpha position by use of an adhesive.

64. A method according to any one of claims 49 to 63, wherein the flow path has a longitudinal extension including a first end and a second end, and the sealing element blocks one of the ends of the flow path.

65. A method according to any one of claims 49 to 64, wherein one or more groups of portions of aerosol generating material are applied to one or more of the flow path surface portions,

each set of portions of aerosol generating material comprises at least two discrete portions of aerosol generating material, and for each set of portions, the at least two discrete portions are located at positions along the deposition line, and

When the support is reconfigured such that the one or more flow path surface portions at least partially define a flow path for atmospheric air, each deposition line extends in a direction parallel or approximately parallel to the longitudinal extension of the flow path.

66. A method according to claim 65, wherein there are two or more groups of portions of aerosol generating material,

Each deposition line has a first end and a second end,

After the support is reconfigured so that the one or more flow path surface portions at least partially define a flow path for atmospheric air, the first end of each deposition line will be closer to the first end of the flow path than the second end of the deposition line, and

The spacing between the discrete portions of the aerosol generating material along one of the deposition lines is the same as the spacing between the discrete portions of the aerosol generating material along at least one other deposition line.

67. A method according to claim 65 or 66, wherein the distance between the first end of the flow path and the first end of each deposition line in the direction of the longitudinal extension of the flow path is equal or approximately equal.

68. A method according to any one of claims 65 to 67, wherein there are two or more groups of portions of aerosol generating material and each group of portions of aerosol generating material comprises the same number of discrete portions of aerosol generating material.

69. A method according to any one of claims 49 to 68, wherein at least one set of portions of aerosol generating material is applied to each of the flow path surface portions.

70. A method according to claim 64 or any one of claims 65 to 69 as appended to claim 64, wherein at least one of the one or more discrete portions of aerosol generating material is a longitudinally extending strip of aerosol generating material.

71. The method of claim 70, wherein at least one of the longitudinally extending strips extends in a direction parallel or approximately parallel to the longitudinal extension of the flow path.

72. A method according to claim 70 or 71, wherein at least one of the longitudinally extending strips extends in a direction perpendicular or approximately perpendicular to the longitudinal extension of the flow path.

73. A method according to claim 64 or any one of claims 65 to 72 dependent on claim 64, wherein the consumable is suitable for causing air to flow along the flow path from the first end to the second end, and the amount of aerosol generating material in each discrete portion of the aerosol generating material depends on the distance between the discrete portion of the aerosol generating material and the first end.

74. A method according to claim 73, wherein the amount of aerosol generating material in the discrete portions of aerosol generating material decreases as the distance of the discrete portions from the first end increases.

75. A method according to claim 64 or any one of claims 65 to 74 as appended to claim 64, wherein the aerosol generating material is applied as an aerosol generating material slurry.

76. The method of claim 75, wherein the aerosol generating material is a film of aerosol generating material.

77. A method according to any one of claims 49 to 76, wherein the method further comprises providing a mouthpiece.

78. The method of claim 77, wherein the mouthpiece is positioned in the flow path.

79. A method according to claim 77 or 78, wherein when the sealing element is in the first position, the sealing element blocks the flow of atmospheric air along the flow path and covers the mouthpiece.

80. The method of any one of claims 49 to 76, further comprising positioning at least one filter portion in the flow path.

81. The consumable product of claim 80, wherein at least one filter portion is positioned at or near an end of the flow path.

82. The consumable product of claim 81, wherein a filter portion is positioned at or near an end of the flow path distal from the first sealing element.

83. The method according to any one of claims 80 to 82, wherein the method further comprises: introducing at least one active substance into at least one filtration portion.

84. A method according to any one of claims 49 to 83, wherein the support comprises a laminate material.

85. A method according to any one of claims 49 to 84, wherein the support comprises a metal foil or a metal film.

86. A method according to any one of claims 49 to 85, wherein the support comprises a susceptor.

87. An aerosol supply device for use with a consumable according to any one of claims 1 to 48, wherein the device includes an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

88. An aerosol supply system comprising an aerosol supply device according to claim 87 and a consumable according to any one of claims 1 to 48.

89. A method for generating an aerosol from a consumable product according to any one of claims 1 to 48 using an aerosol generating device, the aerosol generating device having at least one aerosol generator configured to heat but not burn the consumable product during use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a receptor.