WO2023118240A1

WO2023118240A1 - A consumable for use with an aerosol provision device

Info

Publication number: WO2023118240A1
Application number: PCT/EP2022/087134
Authority: WO
Inventors: Robert Press
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29
Anticipated expiration: 2024-06-20
Also published as: CA3241627A1; MX2024007561A; IL313649A; EP4451969A1; JP2024547042A; AU2022419165A1; KR20240113515A; CN118870999A; US20250049109A1

Abstract

A consumable (2) for insertion into an aerosol provision device Is disclosed. The consumable (2) comprises a support (4), aerosol generating material (6), and a sealing element (8, 10). The support (4) comprises one or more flow path faces (20), and the one or more flow path faces (20) of the support (4) at least partially define a flow path for atmospheric air. At least one of the one or more flow path faces (20) of the support (4) supports one or more discrete portions (6) of the aerosol generating material. The sealing element (8, 10) may be moved 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 (8, 10) does not block the flow of atmospheric air along the flow path.

Description

A CONSUMABLE FOR USE WITH AN AEROSOL PROVISION DEVICE

Technical Field

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

Background

Aerosol-generating articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible articles, aerosol generating assemblies, or aerosol provision devices.

One example of such a product is a heating device which release compounds by heating an aerosolisable material, which may be referred to as a solid aerosolgenerating material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat- not-burn devices.

As another example, there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain an active) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain a botanical material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

Summary

According to a first aspect of the present disclosure there is provided a consumable for insertion into an aerosol provision device, the consumable comprising a support, aerosol generating material, and a sealing element, in which the support comprises one or more flow path faces, the one or more flow path faces of the support at least partially define a flow path for atmospheric air, at least one of the one or more flow path faces of the support supports one or more discrete portions of the aerosol generating material, and the sealing element may be moved 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.

According to a second aspect of the present disclosure there is provided a blank for use in making a consumable according to the first aspect in which the blank comprises a support, aerosol generating material, and a sealing element, the support comprises one or more flow path face portions, at least one of the one or more flow path face portions of the support supports one or more discrete portions of the aerosol generating material, and the blank is so configured 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 comprising a support, aerosol generating material, a sealing element, and a flow path for atmospheric air at least partially defined by one or more flow path faces of the support, the method comprising providing a support which comprises one or more flow path face portions, and which is so shaped and dimensioned that the support can be reconfigured to form the consumable, applying aerosol generating material to one or more of the one or more flow path face portions of the support, and reconfiguring the support so that the one or more flow path face 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, in which the device comprises an aerosol generator configured to heat at least a portion of the 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 aerosol from a consumable according to the first aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

Further 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

Figure 1 shows a first perspective view of a first embodiment of a consumable according to the present disclosure;

Figure 2 shows a sectional view of the consumable of Figure 1 along a section line A- A’;

Figure 3 shows a second perspective view of the consumable of Figure 1 ;

Figure 4 shows a third perspective view of the consumable of Figure 1 ;

Figure 5 shows a view of the consumable of Figure 1 during manufacture;

Figure 6 shows a first perspective view of a second embodiment of a consumable according to the present disclosure;

Figure 7 shows a second perspective view of the consumable of Figure 6; and Figure 8 shows a view of the consumable of Figure 6 during manufacture.

Detailed Description

The consumable of the present description may be alternatively referred to as an article. In some embodiments, the consumable comprises aerosol-generating material. The consumable may comprise an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

The apparatus for heating the aerosol-generating material with which the consumable is to be used is a part of a non-combustible aerosol provision system. Non-combustible aerosol provision systems release compounds from an aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality 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 hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

According to a first aspect of the present disclosure there is provided a consumable for insertion into an aerosol provision device, the consumable comprising a support, aerosol generating material, and a sealing element, in which the support comprises one or more flow path faces, the one or more flow path faces of the support at least partially define a flow path for atmospheric air, at least one of the one or more flow path faces of the support supports one or more discrete portions of the aerosol generating material, and the sealing element may be moved 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 so configured that when using the consumable, that is drawing an aerosol from the aerosol generating material out of the consumable, atmospheric air needs to be able to flow along I be drawn along the flow path.

In an embodiment of the above embodiment, the flow path faces of the support fully define 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 faces of the consumable each partially define the flow path for atmospheric air.

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

In an 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. The sealing element is attached to the support when in the first position when either the sealing element is formed of the same material as the support and that material is continuous I unbroken between the support and at least a part 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, for example by being fixed to the support using an adhesive or other fixing or fixing means.

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

In an embodiment of any of the above embodiments, movement of the sealing element from the first position to the second position creates an irreversible indication that the sealing element has moved from the first position to the second position. This is advantageous because it allows a consumable to be supplied with the sealing element in the first position and the user can then determine that the consumable has not been used because if the sealing element had been moved from it’s first position the irreversible indication of that movement would be present. This can assist in the hygienic use of the consumable and device in which the consumable is used and I or help a user know if a consumable has been used.

In an embodiment of any of the above embodiments, the irreversible indication is a physical or visual change to one or both of a part of the support and the sealing element. For example, and without limitation, the indication may be tearing of the material of which the sealing element and I or the consumable is formed, tearing of an indicator material associated with the sealing element, or a change in colour of the material of which the sealing element and I or the consumable is formed.

In an embodiment of any of the above embodiments, the sealing element is integrally formed with at least a part 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 an embodiment of any of the above embodiments, the sealing element is connected to the part of the support adjacent the sealing element at an interface, and the interface includes a plurality of perforations.

In an embodiment of any of the above embodiments, the perforations are in a line and movement of the sealing element into the second position includes rotating the sealing element around the line of perforations, or tearing the sealing element off the support along the line of perforations. The perforations will assist in tearing off the sealing element from the support. The perforations assist in controlling the position where the tearing of the sealing element from the support occurs.

In an embodiment of any of the above embodiments, the perforations do not extend through the whole of the part of the support adjacent the sealing element.

In an embodiment of any of the above embodiments, 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 is moved to the second position. In some embodiments the sealing element is formed of a material which is easily torn such as paper or a metallic foil. In some embodiments the fixing element is frangible.

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

In an embodiment of any of the above embodiments, the consumable further comprises a second sealing element, the second sealing element may be moved from an alpha position in which it is engaged with the support and blocks the flow of atmospheric air along the flow path, and a beta position in which the second sealing element does not block the flow of atmospheric air along the flow path.

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

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

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

In an embodiment of any of the above embodiments, the perforations are arranged in a line and movement of the second sealing element into the beta position includes rotating the second sealing element around the line of perforations or tearing the second sealing element off the support along the line of perforations.

In an embodiment of any of the above embodiments, one or both of the first and second sealing elements are attached to the support when in the second I beta position.

In an 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 remain at one or more intermediate positions between the first I alpha position and second I beta position. The or each intermediate positions are those 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 an advantage that the intermediate position at which the first and I or second sealing element is positioned will affect the pressure drop across the flow path when the consumable is in use and, as a result, the sensory experience of a user of the consumable. For example, and without limitation, the intermediate position will affect how aerosol generated by the consumable is deposited in the mouth of a user, and or how deeply a user will inhale the aerosol.

In an embodiment of any of the above embodiments, the flow path has a longitudinal extent with a first and 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 is moved to the second position. In some embodiments, the second sealing element blocks the other of the ends of the flow path when the second sealing element is in the alpha position.

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

In an embodiment of any of the above embodiments, the cross-sectional shape of at least a part 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 where the polygon is one in which diagonally opposite faces of the polygon are parallel, an approximately regular polygon where the polygon is one in which diagonally opposite faces of the polygon are parallel or approximately parallel, a circle, an approximate circle, an oval, or an approximate oval.

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 comprises at least two discrete portions of aerosol generating material and the at least two discrete portions are located in positions that are along a deposition line, and each deposition line extends in a direction parallel to 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 comprises at least two discrete portions of aerosol generating material and the at least two discrete portions are located in positions that are along a deposition line, and each deposition line extends in a direction 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 comprises at least two discrete portions of aerosol generating material and the at least two discrete portions of a set are located in positions that are along a deposition line for that set of portions, and each deposition line extends in a direction parallel to or approximately parallel to at least one of the other deposition line.

In some embodiments of the above embodiments, the discrete portions of aerosol generating material are sufficiently spaced from each other along a deposition line and I or between deposition lines that heating of one discrete portion of aerosol generating material does not lead to the heating of any adjacent discrete portions of aerosol generating material.

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 and second ends 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 that 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.

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

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

In an embodiment of any of the above embodiments, there is one set of portions of aerosol generating material supported on each of the flow path faces of the support. In some embodiments each of the sets of portions is the same as each other set of portions in that each set of portions includes the same number of discrete portions of aerosol generating material, and those discrete portions are have the same spacing and positioning relative to the flow path face on which they are supported as the discrete portions of aerosol generating material supported on the other flow path faces.

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

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

In an embodiment of any of the above embodiments, the consumable is adapted for atmospheric air flow along the flow path to be from the first end to the second end, and the quantity 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 an embodiment of any of the above embodiments, the quantity of aerosol generating material in a discrete portion of aerosol generating material decreases as the distance of that discrete portion from the first end increases. This has the effect that the further a discrete portion of aerosol generating material is from the first end of the flow path (or the closer the discrete portion of aerosol generating material is to the user), the less aerosol the discrete portion will generate. This will lead to the amount of aerosol being inhaled by a user of the consumable being approximately equal irrespective of the position of the discrete portion of aerosol generating material on the flow path. This is because the closer the discrete portion of aerosol generating material is to the user, the smaller the volume of aerosol that will reside in the flow path after the user has inhaled aerosol from the consumable and the less aerosol will condense before reaching the user. As such, the aerosol generating material closer to the user needs to generate less aerosol to provide aerosol to be inhaled by the user, and to reside in the flow path, than the aerosol generating material further from the user. In an embodiment of any of the above embodiments, the consumable further comprises a mouthpiece.

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

In an 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 the movement of the sealing element to the second position allows a user to access the mouthpiece.

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

In an embodiment of any of the above embodiments, the socket is positioned in the flow path.

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

In an embodiment of any of the above embodiments, the consumable further comprises at least one filter portion, and the at least one filter 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 causing vapour emitted from the aerosol generating material to transition to aerosol. Additionally or alternatively, the or each filter portion may assist in absorbing or adsorbing any condensate that forms in the flow path, thus lowering the likelihood that such condensate will leave the flow path and either be ingested by a user or dirty a user or their clothing. In an embodiment of any of the above embodiments, at least one filter portion is positioned at or adjacent to an end of the flow path. In some embodiments the consumable comprises two filter portions with a filter portion positioned at or adjacent to each end of the flow path.

In an embodiment of any of the above embodiments, a filter portion is positioned at or adjacent to the end of the flow path remote from the first seal element.

In an embodiment of any of the above embodiments, at least one filter portion comprises a filter body and at least one active substance. The at least one active substance may be a flavourant.

In an embodiment of any of the above embodiments, at least one filter portion comprises one or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials. At least one filter portion may comprise other suitable high surface area materials, the high surface area being suitable for assisting the formation of aerosol from vapour.

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

In an embodiment of any of the above embodiments, the blank further comprises a portion that can be reconfigured to form a first seal element. In an embodiment of any of the above embodiments, the blank further comprises a portion that can be reconfigured to form a second seal element.

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

In an embodiment of any of the above embodiments, the blank further comprises one or more perforations between one or both of the portion of the support that is connected to the first or second seal element portion and the first and second seal element portion.

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

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

In an 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 sheet of material may be so shaped and dimensioned that the support can be folded or otherwise reconfigured to form a three dimensional shape that at least partially defines the flow path.

In an embodiment of the above embodiment, the flow path faces of the support will fully define the flow path once the support has been reconfigured. 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 faces of the consumable will each partially define the flow path for atmospheric air once the support has been reconfigured.

In an embodiment of any of the above embodiments, the support is so configured that the flow path will be linear or substantially linear once the support has been reconfigured.

In an embodiment of any of the above embodiments, the method further comprises introducing at least one fold line into the support, and reconfiguration of the support into the consumable comprises folding the support around the at least one fold line. In an embodiment of any of the above embodiments, the support further comprises a sealing element portion, and at the same time as, or after, the support has been reconfigured to at least partially define the 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 it blocks the flow of atmospheric air along the flow path.

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

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

In an embodiment of any of the above embodiments, the method further comprises the provision of a first sealing element, and the sealing element is fixed into a first position in which it blocks the flow of atmospheric air along the flow path. In such an embodiment the sealing element is formed separately to the rest of the consumable.

In an embodiment of any of the above embodiments, the sealing element is fixed 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 an embodiment of any of the above embodiments, the sealing element is engaged with a portion of the support when it is fixed in the first position, and the engagement with that portion of the support is such that movement of the sealing element to a second position in which it does not block the flow of atmospheric air along the flow path irreversibly indicates, for example by physically damaging one or both of the sealing element and the portion of the support, that the sealing portion has been moved to the second position.

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

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

In an embodiment of any of the above embodiments, the second sealing element portion has a perimeter and one or more perforations are introduced into the part of the support adjacent to the perimeter of the second sealing element portion. In an embodiment of any of the above embodiments, the method further comprises the provision of a second sealing element, and the sealing element is fixed into an alpha position in which it blocks the flow of atmospheric air along the flow path.

In an embodiment of any of the above embodiments, the second sealing element is fixed in the alpha position by use of an adhesive. The adhesive may be any appropriate form of adhesive.

In an embodiment of any of the above embodiments, the flow path has a longitudinal extent with a first and 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 of the ends of the flow path.

In an embodiment of any of the above embodiments, the support is so reconfigured that the flow path has a substantially constant cross-sectional shape along at least a part of the longitudinal extent of the flow path. In an embodiment of any of the above embodiments, the cross-sectional shape of at least a part 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 where the polygon is one in which diagonally opposite faces of the polygon are parallel, an approximately regular polygon where the polygon is one in which diagonally opposite faces of the polygon are parallel or approximately parallel, a circle, an approximate circle, an oval, or an approximate oval.

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 face 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 of are located in positions that are along a deposition line, and each deposition line extends in a direction that will be parallel to or approximately parallel to the longitudinal extent of the flow path when the support is reconfigured so that the one or more flow path face portions at least partially define a flow path for atmospheric air. 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 face portions, each set of portions of aerosol generating material comprises at least two discrete portions of aerosol generating material and the at least two discrete portions are located in positions that are along a deposition line, and each deposition line will extend in a direction not parallel to the longitudinal extent of the flow path when the support is reconfigured so that the one or more flow path face 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 face portions, each set of portions of aerosol generating material comprises at least two discrete portions of aerosol generating material and the at least two discrete portions of a set are located in positions that are along a deposition line for that set of portions, and each deposition line extends in a direction that will be parallel to or approximately parallel to at least one of the other deposition lines when the support is reconfigured so that the one or more flow path face 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 and second ends of the deposition line, the first end of each deposition line will be closer to the first end of the flow path than the second end of that deposition line once the support is reconfigured so that the one or more flow path face portions at least partially define a flow path for atmospheric air, 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.

In some embodiments of the above embodiments, the discrete portions of aerosol generating material are sufficiently spaced from each other along a deposition line and / or between deposition lines that heating of one discrete portion of aerosol re generating material does not lead to the heating of any adjacent discrete portions of aerosol generating material.

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 face portions.

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

In an embodiment of any of the above embodiments, at least one of the longitudinally extending strips extends in a direction perpendicular to 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 faces of the support.

In an embodiment of any of the above embodiments, the consumable is adapted for air flow along the flow path to be from the first end to the second end, and the quantity 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 what will be the first end.

In an embodiment of any of the above embodiments, the quantity of aerosol generating material in a discrete portion of aerosol generating material decreases as the distance of that discrete portion from what will be the first end increases.

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

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

In an embodiment of any of the above embodiments, the method further comprises providing a mouthpiece.

In an 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 embodiment of any of the above embodiments, the method further comprises providing a socket adapted to receive a removable mouthpiece.

In an embodiment of any of the above embodiments, the sealing element blocks the flow of atmospheric air along the flow path and covers the socket for the mouthpiece when the sealing element is in its first position and before the sealing element is moved to the second position, and the movement of the sealing element to the second position allows a user to access the socket. In an embodiment of any of the above embodiments, the method further comprises locating at least one filter portion in the flow path.

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

In an embodiment of any of the above embodiments, the method further comprises introducing at least one at least one active substance into at least one filter portion.

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. 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 flavourants.

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 material.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler 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 from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, 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 heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

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

The aerosol-generating material may comprise or 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. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically- conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the 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 example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight = wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe).

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

The 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, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

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

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular examples, the aerosol generating agent comprises glycerol.

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

In some embodiments, the aerosol generating material may comprise from about 0.1 wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10- 25wt% of an 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% of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30- 35wt% of an aerosol generating agent.

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

The aerosol generating material may also 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 comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol generating material. In some cases, the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin. In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (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 cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

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

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further 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 a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent.

In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a 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 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).

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

In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of 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 comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.

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

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

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

In examples, the alginate is present in an amount of at least about 50wt% of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1 :1, i.e. the alginate is present in an amount greater 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 is approximately 4:1.

The aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.

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

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

In some examples, the slurry is applied to a support. The layer may be formed on a support. In examples, the slurry comprises gelling agent, aerosol-former material and active substance. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material. For example, the slurry may comprise (on a dry weight basis): gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry; aerosol-former material in an amount of about 40 to 80wt% of the slurry; and optionally, active substance in an amount of up to about 20wt% of the slurry.

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

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (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 setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability. When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, 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 not generally contain any tobacco.

In examples, supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of p-D-mannuronic (M) and a- L-guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-L- guluronic acid (G) units.

In examples, the drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry.

In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm.

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

In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention. The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35- 55wt% or 30-45wt% of a flavour. In some cases, the flavour 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% of a filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.

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

In some such cases the aerosol generating material comprises at least 1 wt% of the filler, for example, at least 5 wt%, at least 10wt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of the filler. In some embodiments, the aerosol generating material comprises 5-25wt% of the 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 sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk. In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.

In some embodiments, the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.

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

In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of a 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 an 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 weight basis) of a tobacco material. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of a 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) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.

In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of 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) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration 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) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.

In some embodiments the aerosol generating material comprises no 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) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.

In some cases, the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour 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 flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour 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 examples, the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, 15wt% 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 in order to achieve a physiological and/or olfactory response.

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

The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly, the inventors have identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a noncombustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

In some embodiments the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.

In some embodiments, the aerosol generating material is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1wt%, 2wt% or at least about 5wt% of 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, for example, be determined by Karl-Fischer-titration or Gas Chromatography with 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 flavour, 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 flavour, and optionally a tobacco material and/or a nicotine source. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.

In examples, the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.

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

1-60 wt% of a gelling agent;

0.1-50 wt% of an aerosol generating agent; and

0.1 -80 wt% of a flavour; wherein these weights are calculated on a dry weight basis

In some embodiments, the aerosol generating material comprises 1-80 wt% of a flavour (dry weight basis).

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

0.1-50 wt% of an aerosol generating agent; and

30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

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

1-60 wt% of a gelling agent;

5-60 wt% of an aerosol generating agent; and

10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

20-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance. 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 flavour. In some cases, the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.

In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of 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% Virginia tobacco extract and about 32wt% glycerol (DWB).

The “thickness” of the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where 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 which opposes the first planar surface of the sheet.

In some cases, the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1 ,5mm or 0.05mm to about 1.0mm. Suitably, the thickness may be in the range of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.

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

A material having a thickness of 0.2mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

It has been found that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness 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 around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.

Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the aerosol generating material comprises a filler, the aerosol generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is included in an aerosol generating article/assembly 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 around 200 N/m to around 2600 N/m. In some examples, the aerosol generating material may have a tensile strength of from 600 N/m to 2000 N/m, or from 700 N/m to 1500 N/m, or around 1000 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosolgenerating material comprising the aerosol generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

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

All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.

As used herein, the term “sheet” denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions then the sheet is flat. The sheet may be a strip, for example.

The aerosol generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol generating material. The presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material and the aerosol-generating material. By adding a colourant to the aerosol generating material, the aerosol generating material may be colour-matched to other components of the aerosol-generating material or to other components of an article comprising the aerosol generating material.

A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, foodgrade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material). In some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating material.

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).

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

In the following discussions of the accompanying drawings, where the same element is present in a more than one embodiment the same reference numeral is used for that element throughout, where there are similar elements similar reference numerals (the same numeral plus a multiple of 100) are used.

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

The support 4 is so configured that a portion of the support 4 defines the walls of a tube and a flow path 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 fall within the scope of the present disclosure.

The support 4 includes a first seal element 8 which, when it’s first position (shown in Figures 1 and 2), blocks I closes I seals a first end of the tube I flow path, and a second seal element 10 which, when it’s first position (shown in Figures 1 and 2), blocks I closes I seals a second end of the tube I flow path.

The first seal element 8 is formed from a main seal element 8A, a flap 8B and an indicator element 8C. The main seal portion 8A is, when the consumable 2 is manufactured, part of the support 4. When the first seal element 8 is in the first position, the main seal portion 8A blocks the end of the tube and a portion of the main seal element 8A adjacent the perimeter of the main seal portion 8A abuts the end of the tube. The flap 8B is fixed to a portion of the support 4 that defines the tube by an adhesive (not shown). The indicator element 8C is fixed to the flap 8B and to a portion of the support 4 that defines the tube by an adhesive (not shown). The indictor element 8C is formed 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 that defines the tube will result in the indicator element tearing or losing structural integrity. In some examples, the indicator element 8C is formed from a thin paper.

The second seal element 10 has the same structure as that of the first seal element 8 and is formed from a main seal element 10A, a flap 10B and an indicator element 10C. The main seal portion 10A is, when the consumable 2 is manufactured, part of the support 4. When the second seal element 10 is in the first position, the main seal portion 10A blocks the end of the tube and a portion of the main seal element 10A adjacent the perimeter of the main seal portion 10A abuts the end of the tube. The flap 10B is fixed to a portion of the support 4 that defines the tube by an adhesive (not shown). The indicator element 10C is fixed to the flap 10B and to a portion of the support 4 that defines the tube by an adhesive (not shown). The indictor element 10C is formed 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 that defines the tube will result in the indicator element tearing or losing structural integrity. In some examples, the indicator element 10C is formed from a thin paper

When the first or second seal elements 8, 10 are moved from their first I alpha positions to their second I beta positions the main seal portions 8A, 10A and the flaps 8B, 10B are pulled away from the parts of the support 4 to which they are affixed. The pulling of the main seal portions 8A, 10A and the flaps 8B, 10B away from the parts of the support 4 to which they are affixed causes the indicator elements 8C, 10C to tear and a part of the indicator elements 8C, 10C is left fixed to the support 4, and a part remains attached to the flaps 8B, 10B. This allows a user to easily identify whether the first or second seal elements 8, 10 are moved from their first positions to their second positions by a quick visual inspection.

In some embodiments of the present disclosure the first and second seal elements 8, 10 being in a position in which they do not block the tube defined by the support 4 (as shown in Figure 3) is sufficient for the consumable 2 to be ready to use. This is because the ends of the tube defined by the support 4 are both now unblocked and as a result the flow path along the inside of the tube is open for the flow of atmospheric air along the inside of the tube.

In some other embodiments of the present disclosure the first and second seal elements 8, 10 are next separated from the support 4 by tearing the first and second seal elements 8, 10 off the support leaving a stump 8D (as shown in Figure 4) and are thus in their second I beta positions in which they do not block the tube defined by the support 4. The consumable 2 is now ready to use because the ends of the tube defined by the support 4 are both now unblocked and as a result the flow path along the inside of the tube is open for the flow of atmospheric air along the inside of the tube. With reference to Figure 5, to make the consumable 2, a blank 12 is cut out of a sheet of support 4. The blank 12 includes four flow path regions 14, a flap element 16 and the first and second sealing elements 8, 10.

A plurality of discrete portions 6 of aerosol generating material are applied to a flow path surface 20 of each of the flow path regions 14. The flow path surfaces 20 are the surfaces of the flow part portions 14 of the support 4 that define the inside of the tube into which the blank 12 will be reconfigured and hence the flow path that is defined by that tube. The flow path is intended to be in the direction of the arrow 22 in Figure 5 once the blank 12 of the support has been reconfigured.

The discrete portions 6 are applied to each flow path surface 20 along a deposition line 14 (not shown in connection with all of the flow path surfaces 20 for clarity). The deposition lines 14 are virtual and not physically visible to a user. The discrete portions 6 on a deposition line can be labelled i to vi with portion i being the discrete portion closest to the beginning or upstream end of the flow path (the right hand end of deposition line 18 in Figure 5), and portion vi being the portion closest to the end or downstream end of the flow path (the left hand end of deposition line 18 in Figure 5). Each of the portions i to vi are of the same dimensions in the plane of the flow path surfaces 20. The thickness of the portions does, however, decrease from portion i which is the thickest to portion iv. As a result, the amount of aerosol that can be generated by portion i is greater than portions ii to vi, that can be generated by portion ii is greater than portions 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 flap 16 and the adjacent flow path region 14, and between the first and second seal elements 8, 10 and the adjacent flow path regions 14. The flow path regions 14 are folded around the fold lines 24 between the adjacent flow path regions 14 to form a tube of square cross-section. The folding is such that the discrete portions 6 all face into the flow path defined by the flow path surfaces 20. To maintain the folding of the blank 12 into the tube, flap 16 is fixed to a portion of the flow path portion 14 most distant from the flap 16 when the blank 12 is not folded. The fixing of the flap 16 is by an adhesive, not shown. Once the flap 16 has been fixed to the flow path portion 14, the first and second seal elements 8, 10 are folded over the ends of the tube and the flaps 8B, 10B and indicator elements 8C, 10C are fixed to the portions of the flow path portions 14 that the flaps 8B, 10B overlie.

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

With reference to Figures 6 and 7, a 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 as those described in connection with Figures 1 to 5 above in terms of location, composition and configuration and will not be described further in connection with consumable 102.

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

The mouthpiece 126 is supported on a mouthpiece plate 128 and is positioned so that the mouthpiece plate 128 partially closes 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 a bore 130 through the mouthpiece 126.

The support 104 includes a first seal element 108 which, when in it’s first position (shown in Figure 6), covers the mouthpiece 126 and blocks I closes I seals a first end of the tube I flow path.

With reference to Figures 6 to 8, the first seal element 108 is formed from a main seal element 108A, a flap 108B, an indicator element 108C, a pair of side elements 108E, and a pair of side flaps 108F . The main seal portion 108A is, when the consumable 2 is manufactured, 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 elements 108E blocks the end of the tube and mouthpiece 126. The flaps 108B and 108F are fixed to portions of the support 104 that define the tube by an adhesive (not shown). The indicator element 108C is fixed to the flap 108B and to a portion of the support 104 that defines the tube by an adhesive (not shown). The indictor element 108C is formed of a material that is sufficiently weak that any attempt to separate the indicator element from the flap 108B or the portion of the support 104 that defines the tube will result in the indicator element tearing or losing structural integrity.

When the seal element 108 is moved from it’s first position to it’s second position the main seal portion 108A, side elements 108E and the flaps 108B, 108F are pulled away from the parts of the support 4 to which they are affixed. The pulling of the main seal portion 108A, side elements 108E and the flaps 108B, 108F away from the parts of the support 104 to which they are affixed causes the indicator element 108C to tear and a part of the indicator element 108C is left fixed to the support 104, and a part remains attached to the flap 108B. the seal element 108 is then torn off the support 104 leaving a stump 108D. The tearing of the indicator element 108C allows a user to easily identify whether the seal element 108 has moved from it’s first position to a second position by a quick visual inspection.

With reference to Figure 8, to make the consumable 102, a blank 112 is cut out of a sheet of support 104. The blank 112 includes four flow path regions 114, a flap element 116 and the sealing element 108.

A mouthpiece plate 128 is positioned on the blank 112 in a position such that the mouthpiece plate will be supported in an end of the tube that will be formed by the flow path regions 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 flap 116 and the adjacent flow path region 114, and between the seal element 108 and the adjacent flow path region 114. The flow path regions 114 are folded around the fold lines 124 between the adjacent flow path regions 114 to form a tube of square cross-section. The folding is such that the discrete portions 6 all face into the flow path. To maintain the folding of the blank 112 into the tube, flap 116 is fixed to a portion of the flow path portion 114 most distant from the flap 116 when the blank 112 is not folded. The fixing of the flap 116 is by an adhesive, not shown. Once the flap 116 has been fixed to the flow path portion 114, the seal element 108 is folded over the end of the tube and the mouthpiece 126, and flaps 108B, 108F and indicator element 108C are fixed to the portions of the flow path portions 114 that the flaps 108B, 108F and indicator element 108C overlie.

The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure.

Various aspects of the method and consumable disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its 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. Although 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 this invention in its broader aspects. The scope of the following claims should not be limited by 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 provision device, the consumable comprising: a support, aerosol generating material, and a sealing element, in which the support comprises one or more flow path faces, the one or more flow path faces of the support at least partially define a flow path for atmospheric air, at least one of the one or more flow path faces of the support supports one or more discrete portions of the aerosol generating material, and the sealing element may be moved 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.

2 A consumable according to claim 1 in which the sealing element is attached to the support when in the first position.

3 A consumable according to claim 1 or 2 in which the sealing element is detached from the support when in the second position.

4 A consumable according to any of claims 1 to 3 in which movement of the sealing element from the first position to the second position creates an irreversible indication that the sealing element has moved from the first position to the second position.

5 A consumable according to claim 4 in which the irreversible indication is a physical or visual change to one or both of a part of the support and the seal element.

6 A consumable according to any of claims 1 to 5 in which the sealing element is integrally formed with at least a part 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. 7 A consumable according to claim 6 in which the sealing element is connected to the part of the support adjacent the sealing element at an interface when in the first position, and the interface includes a plurality of perforations.

8 A consumable according to claim 7 in which the perforations are arranged in a line and movement of the sealing element into the second position includes rotating the sealing element around the line of perforations or tearing the sealing element off the support along the line of perforations.

9 A consumable according to claim 7 or 8 in which the perforations do not extend through the whole of the part of the support adjacent the sealing element.

10 A consumable according to any of claims 1 to 5 in which the sealing element is attached to the support by a fixing element when the sealing element is in the first position before the sealing element is moved to the second position.

11 A consumable according to claim 10 in which the fixing element is an adhesive.

12 A consumable according to any of claims 1 to 11 in which the consumable further comprises a second sealing element, the second sealing element may be moved from an alpha position in which it is engaged with the support and blocks the flow of atmospheric air along the flow path, and a beta position in which the second sealing element does not block the flow of atmospheric air along the flow path.

13 A consumable according to claim 12 in which the second sealing element is engaged with the support when in the alpha position.

14 A consumable according to claim 12 or 13 in which the second sealing element is detached from the support when in the beta position.

15 A consumable according to any of claims 12 to 14 in which the second sealing element is connected to the part of the support adjacent the second sealing element at an interface when in the alpha position, and the interface includes a plurality of perforations. 16 A consumable according to claim 15 in which the perforations are arranged in a line and movement of the second sealing element into the beta position includes rotating the second sealing element around the line of perforations or tearing the second sealing element off the support along the line of perforations.

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

18 A consumable according to claim 17 in which one or both of the first and second sealing means are configured to be movable to and then remain at one or more intermediate positions between the first I alpha position and second I beta position,

19 A consumable according to any of claims 1 to 18 in which the flow path has a longitudinal extent with a first and 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 is moved to the second position.

20 A consumable according to any of claims 1 to 19 in which the flow path has a substantially constant cross-sectional shape along at least a part of the longitudinal extent of the flow path.

21 A consumable according to claim 20 in which the cross-sectional shape of at least a part 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 where the polygon is one in which diagonally opposite faces of the polygon are parallel, an approximately regular polygon where the polygon is one in which diagonally opposite faces of the polygon are parallel or approximately parallel, a circle, an approximate circle, an oval, or an approximate oval.

22 A consumable according to any of claims 1 to 21 in which the consumable further comprises one or more sets of portions of aerosol generating material, each set of portions of aerosol generating material comprises at least two discrete portions of aerosol generating material and the at least two discrete portions are located in positions that are along a deposition line, each deposition line extends in a direction parallel to or approximately parallel to the longitudinal extent of the flow path.

23 A consumable according to claim 22 in which 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 and second ends 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 that 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.

24 A consumable according to claim 23 in which the distance between the first end of the flow path and the first end of each of deposition lines in the direction of the longitudinal extent of the flow path is equal or approximately equal.

25 A consumable according to any of claims 22 to 24 in which 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.

26 A consumable according to any of claims 1 to 25 in which at least one set of portions of aerosol generating material is supported on each flow path face of the support.

27 A consumable according to claim 19 or any of claims 20 to 26 when dependent on claim 19 in which at least one of the one or more discrete portions of the aerosol generating material is a longitudinally extending strip of aerosol generating material. 28 A consumable according to claim 27 in which at least one of the longitudinally extending strips extends in a direction parallel to or approximately parallel to the longitudinal extent of the flow path.

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

30 A consumable according to claim 19 or any of claims 20 to 29 when dependent on claim 19 in which the consumable is adapted for air flow along the flow path to be from the first end to the second end, and the quantity 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.

31 A consumable according to claim 30 in which the quantity of aerosol generating material in a discrete portion of aerosol generating material decreases as the distance of that discrete portion from the first end increases.

32 A consumable according to any of claims 1 to 31 in which the consumable further comprises a mouthpiece.

33 A consumable according to claim 32 in which the mouthpiece is positioned in the flow path.

34 A consumable according to claim 32 or 33 in which 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 the movement of the sealing element to the second position allows a user to access the mouthpiece.

35 A consumable according to any of claims 1 to 34 in which the consumable further comprises at least one filter portion, and the at least one filter portion is located in the flow path. 36 A consumable according to claim 35 in which at least one filter portion is positioned at or adjacent to an end of the flow path.

37 A consumable according to claim 36 in which a filter portion is positioned at or adjacent to the end of the flow path remote from the first seal element.

38 A consumable according to any of claims 35 to 37 in which at least one filter portion comprises a filter body and at least one active substance.

39 A consumable according to any of claims 35 to 38 in which at least one filter portion comprises one or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials.

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

41 A blank for use in making a consumable according to any of claims 1 to 40 in which the blank comprises a support, aerosol generating material, and a sealing element, in which the support comprises one or more flow path face portions, at least one of the one or more flow path face portions of the support supports one or more discrete portions of the aerosol generating material, and the blank is so configured that it can be reconfigured to form a consumable.

42 A blank according to claim 41 in which the blank further comprises a portion that can be reconfigured to form a first seal element.

43 A blank according to claim 42 in which the blank further comprises a portion that can be reconfigured to form a second seal element.

44 A blank according to any of claims 40 to 43 in which the blank further comprises one or more fold lines, with each fold line located between adjacent portions of the blank. 45 A blank according to claim 43 or 43 or claim 44 when dependent on claim

42 or 43 in which the blank further comprises one or more perforations between one or both of the portion of the support that is connected to the first or second seal element portion and the first and second seal element portion.

46 A consumable according to any of claims 1 to 45 in which the support comprises a laminate material.

47 A consumable according to any of claims 1 to 46 in which the support comprises a metal foil or metal film.

48 A consumable according to any of claims 1 to 47 in which the support comprises a susceptor.

49 A method of making a consumable for use with a non-combustible aerosol provision device comprising a support, aerosol generating material, a sealing element, and a flow path for atmospheric air at least partially defined by one or more flow path faces of the support, the method comprising providing a support which comprises one or more flow path face portions, and which is so shaped and dimensioned that the support can be reconfigured to form the consumable, applying aerosol generating material to one or more of the one or more flow path face portions of the support, and reconfiguring the support so that the one or more flow path face portions at least partially define a flow path for atmospheric air.

50 A method according to claim 49 in which the method further comprises introducing at least one fold line into the support, and reconfiguration of the support into the consumable comprises folding the support around the at least one fold line.

51 A method according to claim 49 or 50 in which the support further comprises a sealing element portion, and at the same time as or after the support has been reconfigured to at least partially define the 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 it blocks the flow of atmospheric air along the flow path.

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

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

54 A method according to claim 49 or 50 in which the method further comprises the provision of a first sealing element, and the sealing element is fixed into a first position in which it blocks the flow of atmospheric air along the flow path.

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

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

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

58 A method according to any of claims 49 to 57 in which the support further comprises a second sealing element portion, and at the same time as or after the support has been reconfigured to at least partially define the 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 alpha position in which it blocks the flow of atmospheric air along the flow path. 59 A method according to claim 58 in which the second sealing element portion has a perimeter and a fold line is introduced into the part of the support adjacent to the perimeter of the second sealing element portion.

60 A method according to claim 58 or 59 in which the second sealing element portion is connected to the part of the support adjacent the sealing element at an interface when in the first position, and the interface includes a plurality of perforations..

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

62 A method according to any of claims 58 to 61 in which the second sealing element is fixed into the alpha position.

63 A method according to any of claims 58 to 62 in which the second sealing element is fixed in the alpha position by use of an adhesive.

64 A method according to any of claims 49 to 63 in which the flow path has a longitudinal extent with a first and second end, and the sealing element blocks one of the ends of the flow path.

65 A method according to any of claims 49 to 64 in which one or more sets of portions of aerosol generating material are applied to one or more of the flow path face 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 of are located in positions that are along a deposition line, and each deposition line extends in a direction that will be parallel to or approximately parallel to the longitudinal extent of the flow path when the support is reconfigured so that the one or more flow path face portions at least partially define a flow path for atmospheric air. 66 A method according to claim 65 in which 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 and second ends of the deposition line, the first end of each deposition line will be closer to the first end of the flow path than the second end of that deposition line once the support is reconfigured so that the one or more flow path face portions at least partially define a flow path for atmospheric air, 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 in which the distance between the first end of the flow path and the first end of each of deposition lines in the direction of the longitudinal extent of the flow path is equal or approximately equal.

68 A method according to any of claims 65 to 67 in which 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.

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

70 A method according to claim 64 or any of claims 65 to 69 when dependent on claim 64 in which at least one of the one or more discrete portions of the aerosol generating material is a longitudinally extending strip of aerosol generating material.

71 A method according to claim 70 in which at least one of the longitudinally extending strips extends in a direction that will be parallel to or approximately parallel to the longitudinal extent of the flow path. - 60 -

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

73 A method according to claim 64 or any of claims 65 to 72 when dependent on claim 64 in which the consumable is adapted for air flow along the flow path to be from the first end to the second end, and the quantity 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 what will be the first end.

74 A method according to claim 73 in which the quantity of aerosol generating material in a discrete portion of aerosol generating material decreases as the distance of that discrete portion from what will be the first end increases.

75 A method according to any of claims 64 or claims 65 to 74 when dependent on claim 64 in which the aerosol generating material is applied as an aerosol generating material slurry.

76 A method according to claim 75 in which the aerosol generating material is a film of aerosol generating material.

77 A method according to any of claims 49 to 76 in which the method further comprises providing a mouthpiece.

78 A method according to claim 77 in which the mouthpiece is positioned in the flow path.

79 A method according to claim 77 or 78 in which 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.

80 A method according to any of claims 49 to 76 which the method further comprises locating at least one filter portion in the flow path. - 61 -

81 A consumable according to claim 80 in which at least one filter portion is positioned at or adjacent to an end of the flow path.

82 A consumable according to claim 81 in which a filter portion is positioned at or adjacent to the end of the flow path remote from the first seal element.

83 A method according to any of claims 80 to 82 in which the method further comprises introducing at least one at least one active substance into at least one filter portion.

84 A method according to any of claims 49 to 83 in which the support comprises a laminate material.

85 A method according to any of claims 49 to 84 in which the support comprises a metal foil or metal film.

86 A method according to any of claims 49 to 85 in which the support comprises a susceptor.

87 An aerosol provision device for use with a consumable according to any of claims 1 to 48, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

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

89 A method of generating aerosol from a consumable according to any of claims 1 to 48 using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.