WO2025195996A1

WO2025195996A1 - Aerosol generating material product

Info

Publication number: WO2025195996A1
Application number: PCT/EP2025/057277
Authority: WO
Inventors: Dorcas JONES
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-22
Filing date: 2025-03-17
Publication date: 2025-09-25
Anticipated expiration: 2026-09-22
Also published as: EP4620317A1

Abstract

An apparatus (2) for use in the formation of an aerosol generating substrate on a surface from a fluid aerosol generating material (6) is disclosed. The apparatus comprising a storage means (10) configured to store the fluid aerosol generating material, at least one supply means (18) configured to introduce fluid aerosol generating material into the storage means, at least one substrate deposition means (16) configured to deposit fluid aerosol generating material on the surface, and a control means (14) configured to maintain a constant desired volume of fluid aerosol generating material in the storage means.

Description

AEROSOL GENERATING MATERIAL PRODUCT

Technical Field

The present invention relates to a method of manufacturing an aerosol generating material product, and apparatus for manufacturing an aerosol generating material product.

Background

Aerosol generating material products are used in aerosol provision systems which generate an aerosol for a user to inhale. Aerosol provision systems which generate an aerosol for a user to inhale are well known in the art. Such systems are generally battery powered and contain an aerosol provision device comprising the battery and an aerosol generator, and an article which includes aerosol generating material. Such an article is sometimes known as a consumable. The article may comprise an aerosol generating material product, or be formed from part of an aerosol generating material product.

The aerosol can be generated in a variety of ways. For example, the aerosol may be generated by heating a substrate that includes or is formed from an aerosol generating material to form a vapour which subsequently condenses in passing air so to form a condensation aerosol. Alternatively, the aerosol might be generated by mechanical means, vibration etc., so that the substrate becomes dispersed in passing air so as to form an aerosol.

Summary

According to a first aspect of the present disclosure there is provided an apparatus for use in the formation of an aerosol generating substrate on a surface from a fluid aerosol generating material, the apparatus comprising a storage means configured to store fluid aerosol generating material, at least one supply means configured to introduce fluid aerosol generating material into the storage means, at least one substrate deposition means configured to deposit fluid aerosol generating material on the surface, and a control means configured to maintain a constant desired volume of fluid aerosol generating material in the storage means.

According to a second aspect of the present disclosure there is provided a method of manufacture of an aerosol generating material substrate, in which the method comprises providing an apparatus according to the first aspect of the present disclosure and supplying the apparatus with a fluid aerosol generating material; providing a sheet material which has a surface; moving one of the apparatus and the sheet material relative to the other of the apparatus and the sheet material; and causing the apparatus to deposit a layer of fluid aerosol generating material on the surface.

According to a third aspect of the present disclosure there is provided a method of manufacture of an article which comprises aerosol generating material for use in an aerosol provision device, in which the method comprises providing a product manufactured according to the method of the second aspect of the present disclosure, and cutting the product into an appropriate size for use in an article.

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 schematic view of a first embodiment of the apparatus of the present disclosure;

Figure 2 shows a schematic sectional view of the apparatus of Figure 1 ;

Figure 3 shows an enlarged portion of the sectional view in Figure 2; and

Figure 4 shows a shows a schematic sectional view of a second embodiment of the apparatus of the present disclosure.

Detailed Description According to a first aspect of the present disclosure there is provided an apparatus for use in the formation of an aerosol generating material substrate on a surface from a fluid aerosol generating material, the apparatus comprising a storage means configured to store fluid aerosol generating material, at least one supply means configured to introduce fluid aerosol generating material into the storage means, at least one substrate deposition means configured to deposit fluid aerosol generating material on the surface, and a control means configured to maintain a constant desired volume of fluid aerosol generating material in the storage means.

After the deposition of the fluid aerosol generating material on the surface the fluid aerosol generating material transforms from a material which is a flowable and potentially dimensionally unstable material to a more dimensionally stable material which forms the aerosol generating substrate. The aerosol generating substrate may in some embodiments be a gel which is dimensionally stable for at least the intended shelf life of the aerosol generating substrate.

In some embodiments the fluid aerosol generating material is deposited on the surface as a layer or substrate of fluid aerosol generating material.

In an embodiment of the above embodiment, the control means is configured to continuously maintain the desired constant volume of fluid aerosol generating material in the storage means.

In an embodiment of any of the above embodiments, the control means is configured to allow a flow of fluid aerosol generating material out of the storage means when the volume of fluid aerosol generating material in the storage means exceeds the desired volume.

In an embodiment of any of the above embodiments, the control means comprises one or both of a weir and an overflow pipe.

Overflow pipes have an upwardly facing mouth defined by a lip at the upper end of the overflow pipe. In an embodiment of any of the above embodiments, the fluid aerosol generating material that passes over the weir or over the lip of the overflow pipe is the fluid aerosol generating material in the storage means which is in excess of the desired volume.

In an embodiment of any of the above embodiments, the control means comprises a conduit, and the conduit is configured to permit or cause the flow of fluid aerosol generating material away from the storage means.

In an embodiment of any of the above embodiments, the conduit receives the fluid aerosol generating material that leaves the control means.

In an embodiment of any of the above embodiments, the control means is so configured that the flow of fluid aerosol generating material out of the storage means is reintroduced into the storage means. In some embodiments the flow of fluid aerosol generating material is introduced into the supply means. As a result, the flow of fluid aerosol generating material that leaves the storage means as a result of the control means is recycled back into the storage means. This minimises the amount of fluid aerosol generating material used and maintains the volume of fluid aerosol generating material in the storage means at the desired volume.

In an embodiment of any of the above embodiments, at least one supply means is configured to continuously supply fluid aerosol generating material into the storage means.

In an embodiment of any of the above embodiments, the fluid aerosol generating material in the storage means is unpressurised when the apparatus is in use.

In an embodiment of any of the above embodiments, the storage means is open to ambient atmosphere when the apparatus is in use.

In an embodiment of any of the above embodiments, the apparatus is so configured that the hydrostatic pressure within the fluid aerosol generating material in the storage means adjacent the or each substrate deposition means is independent of the position of the supply means relative to the or each deposition means. In an embodiment of any of the above embodiments, a substrate deposition means comprises a doctor blade and at least one deposition slot, and each deposition slot is configured to extend between a first mouth opening into the storage means, and a second mouth wherein the doctor blade is adjacent to the second mouth.

In an embodiment of any of the above embodiments, the doctor blade is configured to move reciprocally between a closed position in which the doctor blade closes the second mouth, and an open position in which at least a portion of the second mouth is not closed by the doctor blade.

In an embodiment of any of the above embodiments, the apparatus comprises a movement element, the movement element is configured to cause the sheet material to move relative to the storage means and at least one substrate deposition means, and the at least one deposition means is configured and positioned relative to the sheet material to be able to deposit a layer of fluid aerosol generating material on the surface in use

In an embodiment of any of the above embodiments, the apparatus comprises a roller, the roller is configured to have the sheet material pass partially around the roller, the storage means and the at least one deposition means are configured and positioned relative to the roller to be able to deposit a layer of fluid aerosol generating material on the surface in use.

In an embodiment of any of the above embodiments, the storage means comprises a first and second open end, the second open end is defined by a second storage mouth, the second storage mouth is configured to be in at least partial sealing contact with the sheet material as the sheet material moves relative to the apparatus or the apparatus moves relative to the sheet material.

In embodiments where the apparatus comprises a roller the storage means comprises a first and second open end, the second open end is defined by a second storage mouth, the second storage mouth is configured to be in at least partial sealing contact with the sheet material as the sheet material passes around the roller. In an embodiment of any of the above embodiments, the second storage mouth at least partially defines at least one deposition slot.

In an embodiment of any of the above embodiments, the storage means is biased towards the sheet material.

According to the second aspect of the present disclosure there is provided a method of manufacture of an aerosol generating material substrate, in which the method comprises providing an apparatus according to the first aspect of the present disclosure and supplying the apparatus with a fluid aerosol generating material; providing a sheet material which has a surface; moving one of the apparatus and the sheet material relative to the other of the apparatus and the sheet material; and causing the apparatus to deposit a layer of aerosol generating material on the surface.

In an embodiment of the above embodiment, the control means continuously maintains a constant desired volume of fluid aerosol generating material in the storage means.

In an embodiment of any of the above embodiments, the control means allows a flow of fluid aerosol generating material out of the storage means when the volume of fluid aerosol generating material in the storage means exceeds the desired volume, and optionally the control means comprises one or both of a weir or an overflow pipe.

In an embodiment of any of the above embodiments, the control means comprises a conduit, and the conduit permits the flow of fluid aerosol generating material away from the storage means. Optionally the control means is configured to directly or indirectly reintroduce the flow of fluid aerosol generating material away from the storage means into the storage means. Optionally that reintroduction is via a supply means. In an embodiment of any of the above embodiments, at least one supply means continuously supplies fluid aerosol generating material into the storage means.

In an embodiment of any of the above embodiments, the rate of supply of fluid aerosol generating material into the storage means is greater than the anticipated rate of deposition of the fluid aerosol generating material on the sheet material.

In an embodiment of any of the above embodiments, the deposition means comprises a doctor blade and at least one deposition slot, and each deposition slot is configured to extend between a first mouth opening into the storage means, and a second mouth, wherein the doctor blade is adjacent to the second mouth. Optionally the doctor blade is configured to move reciprocally between a closed position in which the doctor blade closes the second mouth, and an open position in which at least a portion of the second mouth is not closed by the doctor blade.

In an embodiment of any of the above embodiments, the apparatus comprises a roller, the sheet material passes partially around the roller, and the storage means and the at least one deposition means are configured and positioned relative to the roller to deposit a layer of fluid aerosol generating material on the sheet material.

In an embodiment of any of the above embodiments, the sheet material is in tension when it partially passes around the roller.

In an embodiment of any of the above embodiments, the storage means is biased towards the roller.

In an embodiment of any of the above embodiments, the speed of movement of the sheet material relative to the apparatus is selected to result in a predetermined deposition rate of fluid aerosol generating material on the sheet material.

In an embodiment of any of the above embodiments, the desired volume of the fluid aerosol generating material in the storage means is selected to result in a predetermined deposition rate of aerosol generating material on the surface. In an embodiment of any of the above embodiments, the hydrostatic pressure within the fluid aerosol generating material in the storage means adjacent the or each substrate deposition means is selected to result in a predetermined deposition rate of aerosol generating material on the surface.

In an embodiment of any of the above embodiments, the deposition rate of fluid aerosol generating material on the sheet material is in the range of 200 mm³ to 1000 mm³, 300 mm³ to 900 mm³, 400 mm³ to 800 mm³, and 500 mm³ to 700 mm³ per minute per 1 mm width of fluid aerosol generating material deposited. The width being in a direction perpendicular to the longitudinal extent of the deposited fluid aerosol generating material.

In an embodiment of any of the above embodiments, the deposition rate of fluid aerosol generating material on the sheet material is one of 200 mm³, 300 mm³, 400 mm³, 500 mm³, 600 mm³, 700 mm³, 800 mm³, 900 mm³, or 1000 mm³ per minute per 1 mm width of fluid aerosol generating material deposited.

In an embodiment of any of the above embodiments, a 65 mm width of fluid aerosol generating material is deposited on the surface with a thickness of 0.6 mm at a relative speed of 1000 mm per minute between the surface and the substrate deposition means .

In an embodiment of any of the above embodiments, the apparatus is configured to deposit fluid aerosol generating material on the sheet material with a thickness in the range of 0.2 mm to 1.0 mm, 0.3 mm to 0.9 mm, 0.4 mm to 0.8 mm, 0.5 mm to 0.7mm.

In an embodiment of any of the above embodiments, the apparatus is configured to deposit fluid aerosol generating material on the sheet material with a thickness of one of 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, or 0.8 mm.

According to a fourth aspect of the present disclosure there is provided a method of manufacture of an article which comprises aerosol generating material for use in an aerosol provision device, in which the method comprises providing a product manufactured according to the method of the third aspect of the present disclosure, and cutting the product into an appropriate size for use in an article.

In some embodiments, the article comprises aerosol generating material. The article may comprise an aerosol-generating material storage area, an aerosolgenerating 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.

In embodiments of the above embodiments, the aerosol generating material of the aerosol generating article consists of, or is formed from, a fluid aerosol generating material deposited in accordance with the second aspect. In some examples, the aerosol generating material is a layer of fluid aerosol generating material formed on a support or similar (e.g. the aerosol generating material may be fluid aerosol generating material absorbed in a liquid/ fluid form by a support or similar). In other examples, the aerosol generating material is a resultant material (e.g. formed by a subsequent or continual process) formed from the fluid aerosol generating material. For example, the aerosol generating material may be formed by setting, solidifying, gelling or drying the fluid aerosol generating material.

The aerosol generating material can interchangeably be called a resultant aerosol generating material. The fluid aerosol generating material can interchangeably be called a precursor aerosol generating material. The fluid aerosol generating material may be a liquid or gel-based aerosol generating material (said gel-based aerosol generating material being able to flow prior to and during deposition of the fluid aerosol generating material).

In some examples, the fluid aerosol generating material is a slurry. The aerosol generating material may be formed by (a) forming the 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, casting or extruding the slurry.

In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously. 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. It has been 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%. It has been 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. It has been 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 apparatus for heating the aerosol-generating material with which the article is to be used is a part of a non-combustible aerosol provision system. Noncombustible 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 article 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.

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 0.1wt%, 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 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.

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.

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 it has been 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 non-combustible 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 0.1mm 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, and absent 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.

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 when 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, food- grade 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.

With reference to Figures 1 to 3, an apparatus 2 includes a storage means 10 which is adapted to store a supply of fluid aerosol generating material 6. The apparatus 2 is configured for use in the formation of an aerosol generating substrate 4 from a fluid aerosol generating material 6 on a surface of a sheet material 8. The formation of the aerosol generating substrate 4 is the result of the application of a layer of fluid aerosol generating material 6 to the sheet material 8 and the subsequent curing or transformation of the fluid aerosol generating material 6. The curing or transformation of the fluid aerosol generating material 6 causes the fluid aerosol generating material 6, which is a flowable and potentially dimensionally unstable material, to become a much more dimensionally stable material in the form of the aerosol generating substrate 4. The aerosol generating substrate 4 may in some embodiments be a gel which is dimensionally stable for at least the intended shelf life of the aerosol generating substrate 4.

In use, one of the apparatus 2 and sheet material 8 moves relative to the other. In the illustrated example, the apparatus 2 includes a movement means in the form of a roller 40, and the sheet material 8 moves relative to the apparatus 2 in a direction M which is shown by the arrows M.

In other, non-illustrated examples, the apparatus 2 may be caused to move relative to the sheet material 8.

In other, non-illustrated examples, the apparatus 2 may include other types of movement means, for example a moving flat bed, or one or more rails or similar along which the apparatus 2 may travel.

The apparatus 2 is configured to form a layer of fluid aerosol generating material 6 which will become aerosol generating substrate 4 on the surface of the sheet material 8 as that sheet material passes partially around the roller 40.

The storage means 10 includes a first open end or storage mouth 54, a sump 12, a weir 14, and a deposition slot 16. The sump 12 is adapted to hold a desired volume of fluid aerosol generating material 6.

The storage means 10, sump 12, and weir 14 are configured to have a longitudinal extent of a sufficient length that they each extend for at least the width of the desired aerosol generating material substrate 4. Width in this context is a direction perpendicular to the direction M.

The storage means 10 is so configured that the inside of the storage means, for example the portion of the volume inside the storage means defined by side walls 42, 44, 46, 48 of the storage means 10 which is not the sump 12 is in fluid communication with the ambient atmosphere that surrounds the apparatus 2 via one or more vent holes (not shown). That is the inside of the storage means is not pressurised relative to the ambient atmosphere.

When the apparatus 2 is in use, the side and end walls 44, 46, 48 of the storage means 10 are in sliding contact with the sheet material 8 at wall edges 44E, 46E, 48E. The wall edges 44E, 46E, 48E partially define a second open end or storage mouth 56 of the storage means The sump 12 is, when apparatus 2 is in use, defined by the side and end walls 42, 44, 46, 48 of the storage means 10 and the portion of the sheet material 8 that extends between the wall edges 44E, 46E, 48E and overlies the second open end or storage mouth 56.

The contact between the wall edges 44E, 46E, 48E and sheet material 8 is a sealing contact and, as such, fluid aerosol generating material 6 does not flow out of the sump 12 between the wall edges 44E, 46E, 48E and the sheet material 8.

To assist the contact between the wall edges 44E, 46E, 48E and sheet material 8 the apparatus 2 is biased against the roller 401 sheet material 8.

Fluid aerosol generating material 6 is supplied to the storage means 10 by a supply means 18. The supply means 18 includes a remote source 20 of fluid aerosol generating material 6. The fluid aerosol generating material 6 is conveyed to the storage means 10 from the remote source 20 by a conduit 22. The fluid aerosol generating material 6 is stored in the sump 12 of the storage means 10.

The deposition slot 16 is configured to allow the fluid aerosol generating material 6 to exit the sump 12 and is located at a position that is, when the apparatus 2 is in use, vertically at the lowest position in the sump 12. The deposition slot 16 is defined by the edge 42E of the side wall 42 of the storage means 10, by a part of each of the end walls 44, 48 of the storage means 10, and the part of the sheet material 8 that extends between the wall edges 44E, 48E and which is closest to the edge 42E. The deposition slot 16 extends for the width of the desired aerosol generating substrate 4.

The deposition slot 16 also extends between a first mouth 50 opening into the storage means 10 / sump 12, and a second mouth 52. The doctor blade 38 may move between an open position in which it does not overlie the second mouth 52 (as shown in Figure 1) and a closed position in which it overlies the second mouth 52 (as shown in Figure 3) . The deposition slot 16 is configured to deposit a substrate or layer of aerosol generating material 6 on the surface of the sheet material 8. That substrate or layer will cure to become aerosol generating substrate 4.

The weir 14 is a control means that controls the volume and thus the level of the fluid aerosol generating material 6 in the sump 12. The weir 14 has a weir edge 26 which is so positioned and orientated that, when the apparatus 2 is in use, the weir edge 26 is horizontal and at a predetermined vertical height above the deposition slot 16. This has the effect that the fluid pressure I hydrostatic pressure in the fluid aerosol generating material 6 in the sump 12 and adjacent the deposition slot 16 is a predetermined value. This enables the rate of flow of the fluid aerosol generating material 6 out of deposition slot 16 to be accurately predicted. It also causes the rate of flow to be constant as long as the fluid aerosol generating material 6 in the sump remains topped up to the level represented by the dashed line 28 which is equal to the level of the weir edge 26.

To ensure that the fluid aerosol generating material 6 in the sump 12 is a constant volume I is constantly filled to the level of the weir edge 26 when the apparatus 2 is in use, fluid aerosol generating material 6 is supplied to the sump 12 via the conduit 22 at a rate greater than the rate at which the fluid aerosol generating material 6 exits the sump 12 through the deposition slot 16. The excess fluid aerosol generating material 6 that flows into the sump 12 will flow over the weir lip 26 and into a collection element 30.

The configuration of the control means in the form of the weir 14 and the fluid aerosol generating material 6 supply system 16 is such that neither of the method of introduction of the fluid aerosol generating material 6 into the sump 12 or the flow of the excess fluid aerosol generating material 6 out of the sump 12 over the weir edge 26 has any significant effect on the hydrostatic I fluid pressure within the fluid aerosol generating material 6 within the sump 12 and adjacent the deposition slot 16. This assists in maintaining a constant and consistent flow rate of fluid aerosol generating material 6 out of the deposition slot 16 and results in a high degree of consistency in the characteristics of the layer of fluid aerosol generating material 6 and once cured, aerosol generating substrate 4. The collection element 30 is configured to receive the excess fluid aerosol generating material 6 and channel it to a conduit 32. The conduit 32 extends between the collection element 30 and a fluid return inlet 36 which opens into the conduit 22. The conduit 32 includes a pump 34 which causes fluid aerosol generating material 6 to pass along the conduit 32 to the fluid return inlet 36.

The volume of fluid aerosol generating material 6 flowing into the sump 12 is thus a combination of the flow of the excess fluid aerosol generating material 6 from the collection element 30 and fluid aerosol generating material 6 from the remote source 20. The apparatus 2 further includes a flow measuring device (not shown) which measures flow of the fluid aerosol generating material 6 in either or both of the conduits 22 and 32 and, based on the measured flow or flows, controls the rate of flow of the fluid aerosol generating material 6 from the remote source 20.

The apparatus 2 further includes a doctor blade 38 and a doctor blade actuator (not shown). The doctor blade 38 is mounted on the exterior of the side wall 42 of the storage means 10 via appropriate blade mounting means (not shown). The blade mounting means are so positioned and configured that the doctor blade 38 may reciprocally I reversibly move between a closed position in which the doctor blade closes the mouth 52 of the deposition slot 16 and thus blocks the flow of the fluid aerosol generating material 6 (as shown in Figure 2 and 3) and an open position in which the doctor blade 38 does not close the mouth 52 of the deposition slot or interfere with the flow of fluid aerosol generating material 6 out of the deposition slot 16 (as shown in Figure 1).

The blade mounting means are further configured so that the movement of the doctor blade between the open and closed positions is a linear movement. That linear movement is caused and controlled by the doctor blade actuator.

With reference to Figure 4, an alternative embodiment of the apparatus 2 is shown. This alternative embodiment is the same as the embodiment described in connection with Figures 1 to 3 with the following exception:

The storage means 10 does not include a weir 14 as in the previous example but instead includes an overflow pipe 114. The overflow pipe 114 has a vertically upper lip 126 when the apparatus is in use. Excess fluid aerosol generating material 6 flows over the upper lip 126 and into the overflow pipe 114.

The overflow pipe 114 is in fluid communication with the conduit 32 and the excess fluid aerosol generating material 6 is accordingly caused to flow to the return inlet 36.

The overflow pipe 114 has the same effect and provides the same benefits as the weir 14 in the previous example.

In some alternative, non-illustrated examples of the apparatus 2, the storage means extends at least the width of a plurality of desired aerosol generating material substrates 4 and any spaces therebetween in the width direction. The edge 42E of the storage means 10 defines the same number of deposition slots 16 as there are desired aerosol generating substrates 4 across the width of the sheet material, and a single doctor blade 38 is provided which, in its closed position, closes the mouth 54 of each deposition slot 16.

In use the apparatus 2 as described in Figures 1 to 3 is set up with the wall edges 44E, 46E, 48E in contact with the sheet material 8 which has been passed partially around a roller 40 as described above. The doctor blade is moved to the closed position so that the mouth 54 of the deposition slot 16 is closed.

Fluid aerosol generating material 6 is fed from the remote source 20 via conduit 22 and into the sump 12. Once the fluid aerosol generating material 6 fills the sump 12 to the level of the weir edge 26 the excess fluid aerosol generating material 6 flows over the weir 14 and is recirculated back to the return inlet 36 and back into conduit 22.

Once the fluid aerosol generating material 6 is circulating as described above, the sheet material is caused to move in direction M by a suitable means (not shown). Thereafter the doctor blade 38 is caused to move to the open position with the result that fluid aerosol generating material 6 is deposited on the surface of the sheet material 8 closest to the storage means 10 to form an aerosol generating material substrate 4. The doctor blade 38 remains in the open position for a desired period of time which equates to the formation of an aerosol generating material substrate 4 with a desired dimension in the direction M. At that time the doctor blade 38 is returned to the closed position.

The doctor blade 38 remains in the closed position for a desired period of time which equates to the formation of a gap of a desired dimension in the direction M between adjacent aerosol generating material substrates 4.

The open and closed cycle of the doctor blade 38 my be repeated as required.

To assist in the accuracy of the positioning of the aerosol generating material substrates 4 on the sheet material 8, the sheet material 8 is in tension as it passes around the roller 40. The tension may be in one or both of the direction M and perpendicular to direction M.

The speed of movement of the sheet material 8 relative to the apparatus 21 the storage means 10 may be selected to result in a predetermined deposition rate of fluid aerosol generating material 6 on the surface of the sheet material 8.

The desired volume of the fluid aerosol generating material 6 in the storage means 10 may be selected to result in a predetermined deposition rate of aerosol generating material 6 on the surface of the sheet material 8.

The hydrostatic pressure within the fluid aerosol generating material 6 in the storage means 10 adjacent the or each substrate deposition means 16 is selected to result in a predetermined deposition rate of aerosol generating material 6 on the surface of the sheet material 8.

In an embodiment of any of the above embodiments, the deposition rate of fluid aerosol generating material 6 on the surface of the sheet material 8 is in the range of 200 mm³ to 1000 mm³, 300 mm³ to 900 mm³, 400 mm³ to 800 mm³, and 500 mm³ to 700 mm³ per minute per 1 mm width of fluid aerosol generating material deposited. The width being in a direction perpendicular to the longitudinal extent of the deposited fluid aerosol generating material.

In an embodiment of any of the above embodiments, the deposition rate of fluid aerosol generating material 6 on the surface of the sheet material 8 is one of 200 mm³, 300 mm³, 400 mm³, 500 mm³, 600 mm³, 700 mm³, 800 mm³, 900 mm³, or 1000 mm³ per minute per 1 mm width of fluid aerosol generating material deposited.

In an embodiment of any of the above embodiments, a 65 mm width of fluid aerosol generating material 6 is deposited on the surface of the sheet material 8 with a thickness of 0.6 mm at a relative speed of 1000 mm per minute between the surface and the substrate deposition means.

In an embodiment of any of the above embodiments, the apparatus is configured to deposit fluid aerosol generating material on the surface of the sheet material with a thickness in the range of 0.2 mm to 1.0 mm, 0.3 mm to 0.9 mm, 0.4 mm to 0.8 mm, 0.5 mm to 0.7mm.

In an embodiment of any of the above embodiments, the apparatus is configured to deposit fluid aerosol generating material 6 on the surface of the sheet material 8 with a thickness of one of 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, or 0.8 mm.

Various aspects of the aerosol provision devices and systems 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 disclosure 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 An apparatus for use in the formation of an aerosol generating substrate on a surface from a fluid aerosol generating material, the apparatus comprising a storage means configured to store the fluid aerosol generating material, at least one supply means configured to introduce fluid aerosol generating material into the storage means, at least one substrate deposition means configured to deposit fluid aerosol generating material on the surface, and a control means configured to maintain a constant desired volume of fluid aerosol generating material in the storage means.

2 An apparatus according to claim 1 in which the control means is configured to continuously maintain the desired volume of fluid aerosol generating material in the storage means.

3 An apparatus according to claim 1 or 2 in which the control means is configured to allow a flow of fluid aerosol generating material out of the storage means when the volume of fluid aerosol generating material in the storage means exceeds the desired volume.

4 An apparatus according to claim 3 in which the control means comprises one or both of a weir and an overflow pipe.

5 An apparatus according to claim 3 or 4 in which the apparatus is so configured that the flow of fluid aerosol generating material out of the storage means is reintroduced into the storage means.

6 An apparatus according to any of claims 1 to 5 in which at least one supply means is configured to continuously supply fluid aerosol generating material into the storage means.

7 An apparatus according to any of claims 1 to 6 in which the apparatus is so configured that the hydrostatic pressure within the fluid aerosol generating material in the storage means adjacent the or each deposition means is independent of the position of the supply means relative to the or each deposition means. 8 An apparatus according to any of claims 1 to 7 in which the deposition means comprises a deposition slot and a doctor blade, the deposition slot is configured to extend between a first mouth opening into the storage means, and a second mouth, wherein the doctor blade is positioned adjacent to the second mouth.

9 An apparatus according to claim 8 in which the doctor blade is configured to move reciprocally between a closed position in which the doctor blade closes the second storage mouth, and an open position in which at least a portion of the second storage mouth is not closed by the doctor blade.

10 A method of manufacture of an aerosol generating substrate, in which the method comprises providing an apparatus according to any of claims 1 to 9 and supplying the apparatus with a fluid aerosol generating material; providing a sheet material which has a surface; moving one of the apparatus and the sheet material relative to the other of the apparatus and the sheet material; and causing the apparatus to deposit a layer of fluid aerosol generating material on the surface.

11 A method according to claim 10 in which the rate of supply of fluid aerosol generating material into the storage means of the apparatus is greater than the anticipated rate of deposition of the fluid aerosol generating material on the surface.

12 A method according to any of claim 10 or 11 in which the sheet material passes partially around a roller, and the storage means and the at least one substrate deposition means are configured and positioned relative to the roller to deposit a layer of fluid aerosol generating material on the surface of the sheet material as the sheet material partially passes around the roller.

13 A method according to any of claim 12 in which the sheet material is in tension when it partially passes around the roller. 14 A method according to any of claims 10 to 13 in which the speed of movement of the sheet material relative to the apparatus is selected to result in a predetermined deposition rate of aerosol generating material on the surface. 15 A method according to any of claims 10 to 14 in which the hydrostatic pressure within the fluid aerosol generating material in the storage means adjacent the or each substrate deposition means is selected to result in a predetermined deposition rate of aerosol generating material on the surface.