CN118555913A - Method of making a product comprising an aerosol generating material - Google Patents

Abstract

An article (2) for use with a non-flammable aerosol supply device is disclosed. The article (2) comprises an aerosol-generating material and a support (8). The support (8) has a first surface and a second surface (10, 12) opposite each other, at least one discrete portion (6) of the aerosol-generating material being supported on the first surface (10) and at least one discrete portion (6) of the aerosol-generating material being supported on the second surface (12).

Description

Method of making a product comprising an aerosol generating material

Technical Field

The present disclosure relates to the field of non-flammable aerosol supply systems, and specifically to a method for manufacturing a product comprising an aerosol generating material, which serves as a consumable for use with an aerosol supply device. The present disclosure also relates to a method for manufacturing a consumable for use with an aerosol supply device and an aerosol supply system comprising a consumable and an aerosol supply device.

Background Art

The aerosol supply system generates an aerosol (an inhalable aerosol or vapour) during use by releasing compounds from an aerosol generating material. For example, these may be referred to as non-combustible smoking articles, aerosol generating components or aerosol supply devices.

An example of such a product is an aerosol supply device, which releases compounds by heating without burning an aerosol-generating material. In some cases, the solid aerosol-generating material may include a tobacco material. Heating aerosolizes at least one component of the aerosol-generating material to form an inhalable aerosol. For example, these products may be referred to as heat-not-burn devices, tobacco heating devices, or tobacco heating products.

As another example, there are mixing devices. These mixing devices contain a liquid aerosol-generating material that is evaporated by heating to produce a respirable vapor or aerosol. The device additionally contains a solid aerosol-generating material, and components of this material are entrained in the respirable vapor or aerosol to produce an inhalation medium.

Summary of the invention

According to a first aspect of the present disclosure, there is provided an article for use with a non-flammable aerosol supply device, wherein the article comprises an aerosol generating material and a support member having a first surface and a second surface relative to each other, at least one discrete portion of the aerosol generating material being supported on the first surface, and at least one discrete portion of the aerosol generating material being supported on the second surface.

According to a second aspect of the present disclosure, there is provided a consumable for use with a non-flammable aerosol supply device, wherein the consumable comprises a portion of the article according to the first aspect of the present disclosure, and the portion of the article has been configured into a shape and size suitable for use with the device.

According to a third aspect of the present disclosure, there is provided a method for manufacturing an article, wherein the article comprises an aerosol generating material and a support, wherein the method comprises:

Provide support,

applying an aerosol generating material to at least one predetermined area on the first surface of the support,

An aerosol generating material is applied to at least one predetermined area on the second surface of the support.

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

According to a fifth aspect of the present disclosure, an aerosol supply system is provided, comprising an aerosol supply device and a consumable according to the second aspect of the present disclosure.

According to the sixth aspect of the present disclosure, there is provided a method for generating aerosol from a consumable according to the second aspect of the present disclosure using an aerosol generating device, wherein at least one aerosol generator is configured to heat without burning the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a receptor.

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 shows a schematic perspective view of a portion of a first embodiment of an article according to the present disclosure;

FIG2 shows a cross-sectional view of the product of FIG1 taken along the cross-sectional line A-A′;

FIG3 shows a perspective view of a first embodiment of a consumable product made from the article of FIG1 ;

FIG4 shows a schematic perspective view of a portion of a second embodiment of an article according to the present disclosure;

FIG5 shows a second schematic perspective view of the article of FIG4 ;

FIG6 shows a cross-sectional view of the product of FIG4 taken along the cross-sectional line B-B′;

FIG. 7 shows a schematic perspective view of a first embodiment of a consumable product made from the article of FIG. 4 ; and

FIG8 shows a schematic perspective view of a method of making a film of a cured or partially cured aerosol generating material.

DETAILED DESCRIPTION

The product of this specification may be a consumable, a component of a consumable, or a product that can be used to make a consumable.

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

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

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

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

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

In some embodiments, the non-flammable aerosol supply system is an aerosol generating 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-flammable aerosol supply system is a hybrid system for generating an aerosol using a combination of aerosol generating materials, one or more of which can be heated. Each of the aerosol generating materials can 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 includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material can include, for example, tobacco or non-tobacco products.

Generally, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

In some embodiments, the present disclosure is directed to a consumable product that includes an aerosol generating material and is configured for use with a non-flammable aerosol supply device.

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

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

In some embodiments, consumables for use with a non-flammable aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material conveying component, an aerosol generator, an aerosol generating area, a shell, a wrapping paper, a filter, a mouthpiece and/or an aerosol modifier.

According to a first aspect of the present disclosure, there is provided an article for use with a non-flammable aerosol supply device, wherein the article comprises an aerosol generating material and a support member having a first surface and a second surface relative to each other, at least one discrete portion of the aerosol generating material being supported on the first surface, and at least one discrete portion of the aerosol generating material being supported on the second surface.

In one of the above embodiments, the article is self-supporting in at least one direction along the first surface or the second surface of the support member, a length of the article can be fixed at one end of the length and the article can extend horizontally without support from the fixed position.

An advantage of the article of the present disclosure is that it allows the use of supports that are not rigid enough to be self-supporting. As described above, the combination of at least one discrete portion of aerosol generating material on the first surface, the support and at least one discrete portion of aerosol generating material on the second surface produces an article that is rigid enough to be self-supporting. Therefore, the support in the article can be thinner than is possible in known articles and will use less material than known articles, at least economically. Using thinner materials for the support also has the advantage that when a consumable made from the article of the present disclosure is heated during use, and in particular when the aerosol generating material supported on the support is heated, the support requires less energy to heat than a thicker support. This results in an aerosol supply device having increased energy efficiency and, for a battery or similar powered device, having a longer battery life or cycle between the need to recharge the power supply of the device.

Previously, the thickness of the article (and consumables made therefrom) was determined at least in part by the need for the article/consumable to be sufficiently rigid so that it could be handled by a user and inserted into a non-flammable aerosol supply device without damage. This placed a constraint on the support being too thin. The article/consumable of the present disclosure reduces the constraint on how thin the support can be. It should be noted that after the article/consumable has been used, i.e., after all aerosol-generating material supported on the support has been heated and no significant additional aerosol (or vapour subsequently converted to an aerosol) has been released, the need for rigidity in the support is reduced or ceases altogether. This is because the article/consumable will then be disposed of and any bending or damage to the used article/consumable is of no importance.

In one of the above embodiments, the article comprises an aerosol generating material and a support.

In one embodiment of any of the above embodiments, the article is self-supporting in a direction along the first surface or the second surface of the support member, and when the size of the article is designed to be a consumable product, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, up to 90% or up to 99% of the dimension of the article in that direction can extend horizontally without support from a fixed position to fix the article.

In one embodiment of any of the above embodiments, the position shape and size of each of the at least one discrete portion of the aerosol generating material on the first surface, and the position shape and size of each of the at least one discrete portion of the aerosol generating material on the second surface are such that the discrete portions on the first surface and the second surface at least partially correspond to each other. In such an embodiment, and when viewed from a direction perpendicular to one of the first surface and the second surface, the at least partial correspondence between each of the at least one discrete portion on the first surface and the second surface means that the discrete portions at least partially overlap each other. In some embodiments, for example, one of the discrete portions on one surface can have a larger size than the discrete portion on the other surface. Therefore, when viewed from a position perpendicular to one of the surfaces, the discrete portion on one surface can appear to be completely within the perimeter of the discrete portion on the other surface.

In one embodiment of any of the above embodiments, the position, shape and size of each of the at least one discrete portion of the aerosol generating material on the first surface, and the position, shape and size of each of the at least one discrete portion of the aerosol generating material on the second surface correspond to each other. In such an embodiment, and when viewed from a direction perpendicular to one of the first surface and the second surface, the correspondence between each of the at least one discrete portion on the first surface and the second surface means that the discrete portions completely overlap each other. In this case, the discrete portions on the first surface and the second surface have the same size and shape, and when viewed from a position perpendicular to one of the surfaces, the perimeters of the discrete portions on each surface are aligned with each other.

In one embodiment of any of the above embodiments, the position, shape and size of at least one of the discrete portions of the aerosol generating material on the first surface and the position, shape and size of at least one discrete portion of the aerosol generating material on the second surface are different. In such an embodiment, the arrangement of the discrete portions of the aerosol generating material on the first surface of the support may be slightly different to very different from the arrangement of the discrete portions of the aerosol generating material on the second surface of the support. For example, the discrete portions of the aerosol generating material on the first surface of the support may be arranged as at least one group of substantially parallel longitudinally extending strips. Such strips provide resistance to bending of the support around an axis substantially perpendicular to the longitudinally extending strips. On the second surface of the support, the aerosol generating material may be arranged in a rectangular array of a plurality of substantially circular portions. In some embodiments, the first surface may include a second group of substantially parallel longitudinally extending strips that intersect the first group of substantially parallel longitudinally extending strips at an angle between 0 degrees and 90 degrees (e.g., one of 30 degrees, 45 degrees, 60 degrees, or 90 degrees).

In one embodiment of any of the above embodiments, the article or a consumable to be made from the article is to be used in a non-flammable aerosol supply device configured to heat aerosol-generating material on a first surface and a second surface of a support. The device is configured to allow a user to inhale such vapor and aerosol that has been converted from vapor to aerosol, regardless of which surface of the support the vapor/aerosol comes from.

In one embodiment of any of the above embodiments, the support comprises a plurality of perforations or openings extending between the first and second surfaces of the support, the perforations or openings allowing aerosols and vapors to pass from one side of the support to the other.

In one embodiment of any of the above embodiments, the composition of the aerosol generating material of at least one discrete portion of the aerosol generating material on the first surface is different from the composition of the at least one discrete portion of the aerosol generating material on the second surface. This may result in an enhanced and/or altered user experience when using the consumable.

In one of any of the above embodiments, the thickness of at least one discrete portion of the aerosol generating material on the first surface is different from the thickness of at least one discrete portion of the aerosol generating material on the second surface.

In one of any of the above embodiments, the thickness of at least one discrete portion of the aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of the aerosol generating material on the second surface.

In one of the above embodiments, each discrete portion of the aerosol generating material on the surface of the support has substantially the same thickness.

In one embodiment of any of the above embodiments, the support has a thickness less than or equal to 0.025 mm. In some embodiments, the support has a thickness less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, about 0.020 mm, or about 0.007 mm.

In one embodiment of any of the above embodiments, the thickness of the article is between 0.100 mm and 0.610 mm. In some embodiments, the thickness of the support may be in the range of 0.005 mm to 0.020 mm, and the thickness of the aerosol generating material on each of the first surface and the second surface of the support is between 0.040 mm and 0.301 mm. In some other embodiments, the thickness of the support may be in the range of 0.005 mm to 0.020 mm, and the cumulative thickness of the aerosol generating material on the first surface and the second surface of the support is between 0.080 mm and 0.602 mm.

The thickness of the article is understood to be the maximum thickness of the article measured in a direction perpendicular to the first or second surface of the support at the location where the measurement is made.

According to a second aspect of the present disclosure, there is provided a consumable for use with a non-flammable aerosol supply device, wherein the consumable comprises a portion of the article according to the first aspect of the present disclosure, and the portion of the article has been configured into a shape and size suitable for use with the device.

According to a third aspect of the present disclosure, there is provided a method for manufacturing an article, wherein the article comprises an aerosol generating material and a support, wherein the method comprises:

Provide support,

applying an aerosol generating material to at least one predetermined area on the first surface of the support,

An aerosol generating material is applied to at least one predetermined area on the second surface of the support.

In one of the above embodiments, the article is self-supporting. The article is self-supporting in at least one direction along the first surface or the second surface of the support, a length of the article can be fixed at one end of the length and the article can extend horizontally without support from the fixed position.

In one embodiment of any of the above embodiments, the article is self-supporting in a direction along the first surface or the second surface of the support member, and when the size of the article is designed to be a consumable product, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, up to 90% or up to 99% of the size of the article in that direction can extend horizontally without support from a fixed position to fix the article.

In one embodiment of any of the above embodiments, the article comprises an aerosol generating material and a support.

In one embodiment of any of the above embodiments, applying the aerosol generating material comprises applying a slurry of the aerosol generating material.

In one embodiment of any of the above embodiments, the method further comprises: allowing or causing the aerosol generating material slurry applied to the first surface of the support to cure, and the aerosol generating material slurry cures into an aerosol generating material. As the aerosol generating material cures, it loses a significant portion of its volume, and therefore thickness, due to evaporation of a solvent used in forming the aerosol generating material slurry.

In one of any of the above embodiments, the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface of the support to cure or at least partially cure prior to applying the aerosol generating material slurry to the second surface of the support.

In one embodiment of any of the above embodiments, curing the aerosol-generating material slurry applied to the first surface of the support member includes using ultraviolet radiation. This helps to accelerate the curing of the aerosol-generating material slurry. In other embodiments, alternative or additional known techniques for increasing the curing speed of the aerosol-generating material slurry can be used.

In one embodiment of any of the above embodiments, applying the aerosol generating material to the first surface of the support and allowing or causing the aerosol generating material slurry applied to the first surface of the support to cure or at least partially cure is repeated one or more times. In such an embodiment, there may be a desired predetermined thickness of aerosol generating material. In such an embodiment, the aerosol generating material may be applied in two or more layers, as this allows for better control of the final thickness than a single application of the aerosol generating material. In addition, it has been found that thinner layers of aerosol generating material cure in a more uniform and consistent manner than thicker layers of aerosol generating material. It has also been found that the cumulative curing time of such thinner layers is lower than that of thicker layers that ultimately produce the same final thickness.

In one of any of the above embodiments, the method further comprises measuring a thickness of the cured or partially cured aerosol generating material applied to the first surface of the support.

In one embodiment of any of the above embodiments, the method further comprises: forming a cured or partially cured film of aerosol generating material on the film forming surface, and separating the cured or partially cured film of aerosol generating material from the film forming surface. Applying the aerosol generating material to the first surface of the support comprises: applying a cured or semi-cured film of aerosol generating material to the first surface of the support. In such an embodiment, the cured or partially cured film is formed on a separate surface, which has the advantage that the formation of the film can be performed separately from the manufacture of the article of the present disclosure. This is advantageous because using the cured or partially cured film in the manufacture of the article of the present disclosure may be faster than producing the cured or partially cured film.

In one embodiment of any of the above embodiments, the method further comprises: providing a cured or partially cured film of aerosol generating material, wherein applying the aerosol generating material to the first surface of the support comprises: applying the cured or partially cured film of aerosol generating material to the first surface of the support. In such an embodiment, the cured or partially cured film is formed on a separate surface, which has the advantage that the formation of the film is performed separately from the manufacture of the article of the present disclosure. This is advantageous because using the cured or partially cured film in the article of the present disclosure may be faster than producing the cured or partially cured film.

In one embodiment of any of the above embodiments, the method further comprises measuring the thickness of the cured or partially cured aerosol generating material film.

In one embodiment of any of the above embodiments, applying the film of cured or partially cured aerosol generating material is repeated one or more times.

In one of any of the above embodiments, applying the aerosol generating material to the second surface of the support comprises applying a slurry of the aerosol generating material.

In one embodiment of any of the above embodiments, the method further comprises: allowing or causing the aerosol generating material slurry applied to the second surface of the support to cure or at least partially cure, and the aerosol generating material slurry cures into the aerosol generating material.

In one embodiment of any of the above embodiments, curing or at least partially curing the aerosol generating material slurry applied to the second surface of the support member includes: using ultraviolet radiation. This helps to accelerate the curing of the aerosol generating material slurry. In other embodiments, alternative or additional known techniques for increasing the curing speed of the aerosol generating material slurry can be used.

In one embodiment of any of the above embodiments, applying the aerosol generating material to the second surface of the support and allowing or causing the aerosol generating material slurry applied to the second surface of the support to cure or at least partially cure is repeated one or more times. This has the advantages described above.

In one embodiment of any of the above embodiments, the method further comprises measuring a thickness of the cured or at least partially cured aerosol generating material applied to the second surface of the support.

In one embodiment of any of the above embodiments, the method further comprises: forming a film of a solidified or partially solidified aerosol generating material on the film-forming surface, and separating the film of a solidified or partially solidified aerosol generating material from the film-forming surface, wherein applying the aerosol generating material to the second surface comprises: applying the film of a solidified or partially solidified aerosol generating material to the second surface of the support. Advantages of the method are as described above.

In one embodiment of any of the above embodiments, the method further comprises: providing a cured or partially cured aerosol generating material film, wherein applying the aerosol generating material to the second surface comprises: applying the cured or partially cured aerosol generating material film to the second surface of the support. The advantages of this method are as described above.

In one embodiment of any of the above embodiments, the method further comprises measuring the thickness of the cured or partially cured aerosol generating material film.

In one embodiment of any of the above embodiments, applying the aerosol generating material to the second surface of the support is repeated one or more times.

In one embodiment of any of the above embodiments, the support is less than 0.025 mm thick. In some embodiments, the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, about 0.020 mm, or about 0.007 mm.

In one embodiment of any of the above embodiments, the support is a metal foil. In some embodiments, the support is an aluminum foil.

In one of any of the above embodiments, applying the aerosol generating material to one or both of the first and second surfaces of the support is applying discrete portions of the aerosol generating material to two or more predetermined areas on one or both surfaces of the support.

In one embodiment of any of the above embodiments, the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the first surface, and the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the second surface make the discrete portions on the first surface and the second surface at least partially correspond to each other.

In one embodiment of any of the above embodiments, the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the first surface, and the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the second surface correspond to each other.

In one of any of the above embodiments, the position shape and size of at least one of the discrete portions of aerosol generating material on the first surface and the position shape and size of at least one discrete portion of aerosol generating material on the second surface are different.

In one of any of the above embodiments, the composition of at least one discrete portion of the aerosol generating material on the first surface is different from the composition of at least one discrete portion of the aerosol generating material on the second surface.

In one of any of the above embodiments, the thickness of at least one discrete portion of the aerosol generating material on the first surface is different from the thickness of at least one discrete portion of the aerosol generating material on the second surface.

In one of any of the above embodiments, the thickness of at least one discrete portion of the aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of the aerosol generating material on the second surface.

In one embodiment of any of the above embodiments, the article has a thickness between 0.085 mm and 0.610 mm.

In one embodiment of any of the above embodiments, two or more fold lines are formed in the support member.

In one embodiment of any of the above embodiments, two or more predetermined areas are located on one or both of the first surface and the second surface of the support member, so that a fold line can be formed between the predetermined areas on one or both of the first surface and the second surface of the support member.

In one embodiment of any of the above embodiments, the fold lines may be spaced apart so that the article may be folded in an accordion fashion. This allows the article to be stored in a compact form.

In one of any of the above embodiments, the article is larger than a size required for compatible use with the non-flammable aerosol delivery system, wherein the method further comprises configuring the article for storage.

In one embodiment of any of the above embodiments, the article is larger than a size required for compatible use with a non-flammable aerosol supply system, wherein the method further comprises: dividing the article into two or more article portions, wherein each article portion is shaped and sized to be used as a consumable for use with a non-flammable aerosol supply system.

Aerosol generating materials are materials that are capable of generating an aerosol, for example when heated, irradiated or energized in any other way. Aerosol generating materials may for example be in the form of a solid, liquid or semi-solid (such as a gel), which may or may not contain an active substance and/or a flavorant.

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

The aerosol generating material can include a binder (such as a gelling agent) and an aerosol forming agent. Optionally, there can also be a substance to be delivered and/or a filler. Optionally, there is also a solvent (such as water), and one or more other components of the aerosol generating material can be dissolved in the solvent or can be insoluble in the solvent. In some embodiments, the aerosol generating material is substantially free of plant material. Specifically, in some embodiments, the aerosol generating material is substantially free of tobacco.

The aerosol generating material may include an aerosol generating film or the form of an aerosol generating film. The aerosol generating film may include an adhesive (such as a gelling agent) and an aerosol forming agent. Optionally, there may also be material to be delivered and/or filler. The aerosol generating film may be substantially free of plant material. Specifically, in some embodiments, the aerosol generating material is substantially free of tobacco.

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-forming film can 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 evaporate at least some of the solvent to form an aerosol-forming 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 include or may be an "amorphous solid". In some embodiments, the aerosol generating material includes an aerosol generating film, which is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that may retain some fluid (such as a liquid) inside it. In some embodiments, the amorphous solid may, for example, include from about 50wt%, 60wt% or 70wt% amorphous solid to about 90wt%, 95wt% or 100wt% amorphous solid.

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

A susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. A susceptor may be a conductive material such that its penetration with a varying magnetic field causes inductive heating of the susceptor through resistive heating as a result of eddy currents. A susceptor may be a magnetic material such that its penetration with a varying magnetic field causes hysteresis heating of the susceptor. A susceptor may be both conductive and magnetic such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is called a magnetic field generator.

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

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

Active substance as used herein can be a physiologically active material, which is a material intended to achieve or enhance physiological reactions. Active substance can be, for example, selected from a nutrient, a nootropic, a psychoactive substance. Active substance can be naturally occurring, or synthetically obtained. Active substance can include, for example, nicotine, caffeine, taurine, terpenes, caffeine, vitamins (such as B6 or B12 or C), melatonin, or a composition, derivative or combination thereof. Active substance can include one or more components, derivatives or extracts of tobacco or another plant.

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

The active substance may include or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, husks, etc. Alternatively, the material may include an active compound naturally present in a plant, which is obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Exemplary plants are tobacco, eucalyptus, star anise, hemp, cocoa, fennel, lemongrass, mint, spearmint, red tea tree, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, cloves, cinnamon, coffee, anise (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, The mint may be selected from the following mint varieties: wild mint, mint cultivar, Egyptian mint, peppermint, basil cultivar, peppermint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, spearmint cultivar, and apple mint.

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

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

In some embodiments, the active ingredient comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from the group consisting of red leaf tea tree and fennel.

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

As used herein, the terms "flavoring" and "flavor" refer to materials that can be used to produce a taste, aroma or other physical sensation desired by adult consumers in a product, where permitted by local regulations. They can include naturally occurring flavoring materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese magnolia leaves, chamomile, fenugreek, cloves, maple, matcha, menthol, Japanese mint, aniseed (fennel), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, cranberry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape , Durian, Pitaya, Cucumber, Blueberry, Mulberry, Citrus Fruit, Durian, Bourbon, Scotch, Whiskey, Gin, Tequila, Rum, Spearmint, Mint, Lavender, Aloe, Cardamom, Celery, Sophora flavescens, Nutmeg, Sandalwood, Bergamot, Geranium, Arabic Tea, Sorghum, Betel Leaf, Coriander, Pine, Honey Essence, Rose Oil, Vanilla, Lemon Oil, Orange Oil, Orange Blossom, Cherry Blossom, Cinnamon, Coriander, Cognac, Jasmine, Ylang Ylang, Sage, Fennel , mustard, green pepper, ginger, coriander, coffee, mint oil from any species of the mint family, eucalyptus, star anise, cocoa, lemongrass, red beans, flax, ginkgo biloba, hazelnuts, hibiscus, laurel, mate, orange peel, rose, tea (e.g., green or black), thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, chili pepper, rosemary, saffron, lemon peel, mint, beefsteak, turmeric, coriander, myrtle, black currant, valerian, Spanish bell pepper, mace, dami The invention relates to a novel composition comprising a composition comprising a balm, ...

In some embodiments, flavorings include menthol, spearmint and/or peppermint. In some embodiments, flavorings include flavoring components of cucumber, blueberry, citrus fruit and/or cranberry. In some embodiments, flavorings include eugenol. In some embodiments, flavorings include flavoring components extracted from tobacco.

In some embodiments, in addition to or in lieu of aroma or taste nerves, flavoring agents may include sensates that are intended to achieve somatic sensations that are typically chemically induced and sensed by stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

The aerosol generating material includes an aerosol generating agent. In some embodiments, the aerosol generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetyl glycerol mixture, benzyl benzoate, benzylphenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In a specific example, the aerosol generating agent includes glycerol.

In some embodiments, the aerosol generator includes one or more polyols, such as propylene glycol, triethylene glycol, 1,3-butylene glycol, and glycerol; esters of polyols, such as glycerol monoacetate, diacetate, 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 include from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt% or 10 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 25 wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the aerosol generating material may include 0.5 wt% to 40 wt%, 3 wt% to 35 wt% or 10 wt% to 25 wt% of an aerosol generating agent.

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

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

Aerosol generating material can also include gelling agent.In some embodiments, gelling agent includes hydrocolloid.In some embodiments, gelling agent includes one or more compounds, and this compound includes the group selected from including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silicon dioxide or silicone compound, clay, polyvinyl alcohol and combination thereof.For example, in some embodiments, gelling agent includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.In some cases, gelling agent includes alginate and/or pectin, and can be combined with curing agent (such as calcium source) during forming aerosol generating material.In some cases, aerosol generating material can include calcium cross-linked alginate and/or calcium cross-linked pectin.

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

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

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

In some embodiments, the gelling agent comprises (or is) one or more non-cellulose 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 a preferred embodiment, the non-cellulose based gelling agent is alginate or agar.

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

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

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

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

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

In an example, the aerosol-generating material includes a gelling agent (i.e., without regard to the amount of filler) in an amount from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt% or 35wt% to about 60wt%, 55wt%, 50wt% or 45wt% of the aerosol-generating material. In an example, the aerosol-generating material includes a gelling agent (i.e., without regard to the amount of filler) in an amount from about 5wt% to 60wt%, 20wt% to 60wt%, 25wt% to 55wt%, 30wt% to 50wt% or 35wt% to 45wt% of the aerosol-generating material.

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

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

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

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

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

(b) Forming the slurry layer generally includes spraying, pouring or extruding the slurry. In an example, the slurry layer is formed by electrospraying the slurry. In an example, the slurry layer is formed by pouring the slurry.

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

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

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

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

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

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

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

In examples, the curing agent includes calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof, or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the curing agent includes calcium formate and/or calcium lactate, or consists of calcium formate and/or calcium lactate. In a specific example, the curing agent includes calcium formate, or consists of calcium formate. The inventors have determined that, typically, the use of calcium formate as a curing agent results in an aerosol-generating material having greater tensile strength and greater resistance to elongation.

The total amount of curing agent (such as a calcium source) may be 0.5 wt% to 5 wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1 wt%, 2.5 wt% or 4 wt% to about 4.8 wt% or 4.5 wt%. The inventors have found that adding too little curing agent may result in the aerosol-generating material being unable to stabilize the aerosol-generating material components and causing these components to fall off the aerosol-generating material. Too much curing agent may result in the aerosol-generating material being very viscous and therefore having poor workability.

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

Supplying the curing agent to the slurry may include spraying the curing agent on the slurry, such as on a top surface of the slurry, or combining the curing agent with the slurry prior to pouring the slurry.

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

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

In an example, drying (d) reduces the thickness of the cast material by at least 80%, suitably 85% or 87%.For example, the slurry is cast to have a thickness of 2 mm and the resulting dried aerosol-forming material has a thickness of 0.2 mm.

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

In the example where the solvent consists of water, the dry weight content of the slurry can match the dry weight content of the aerosol generating material.Thus, the discussion herein regarding solid composition is explicitly disclosed in conjunction with the slurry aspect of the present invention.

The aerosol generating material may include flavoring agents. Suitably, the aerosol generating material may include up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of flavoring agents. In some cases, the aerosol generating material may include at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of flavoring agents (all calculated based on dry weight). For example, the aerosol generating material may include 1wt% to 80wt%, 10wt% to 80wt%, 20wt% to 70wt%, 30wt% to 60wt%, 35wt% to 55wt%, 30wt% to 45wt% or 1wt% to 30wt% of flavoring agents. In some cases, the flavoring agent includes menthol, is essentially composed of menthol or is composed of menthol.

The aerosol generating material may comprise a filler.

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

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

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

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

In embodiments that include a filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material such as wood pulp, cellulose, or a cellulose derivative such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC).

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

In some embodiments, the aerosol generating material does not include tobacco fibers. In some embodiments, the aerosol generating material does not include fibrous material.

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

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

In some cases, aerosol generating material includes active substance, such as tobacco extract.In some cases, aerosol generating material can include the tobacco extract of 5wt% to 60wt% (calculated based on dry weight).In some cases, aerosol generating material can include the tobacco extract from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt% or 30wt% (calculated based on dry weight).For example, aerosol generating material can include the tobacco extract of 10wt% to 50wt%, 15wt% to 40wt% or 20wt% to 35wt%.Tobacco extract can include the nicotine of certain concentration, so that aerosol generating material includes the nicotine of 1wt%, 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated based on dry weight). In some cases, there may be no nicotine in the aerosol generating material other than that produced by the tobacco extract.

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

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

The aerosol-generating composition may include one or more active substances. In examples, the aerosol-generating material includes one or more active substances, such as up to about 20 wt % of the aerosol-generating material. In examples, the aerosol-generating material includes the active substance in an amount from about 1 wt %, 5 wt %, 10 wt % or 15 wt % to about 20 wt %, 15 wt %, 15 wt % or 5 wt % of the aerosol-generating material.

Active substances may include physiologically and/or olfactory active substances that are included in the aerosol-generating composition to achieve a physiological and/or olfactory response.

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

The tobacco material may be present in any form, but is typically finely chopped (eg shredded). The finely chopped tobacco material may advantageously be mixed with an aerosol-generating material to provide an aerosol-generating composition having the tobacco material and aerosol-generating material uniformly dispersed throughout the aerosol-generating composition.

In an example, tobacco material comprises one or more of ground tobacco, tobacco fiber, tobacco shred, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly, the inventor has found that relatively large amounts of sheet cigarettes can be used in aerosol generating compositions and acceptable aerosols are still provided when heated by a non-flammable aerosol supply system. Sheet cigarettes provide outstanding organoleptic properties conventionally. In an example, tobacco material comprises a sheet cigarette that is at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt% or 95wt% of tobacco material in amount. In a specific example, tobacco material comprises a sheet cigarette that is at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt% or 95wt% of tobacco material in amount.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grades or blends, cut rags or whole leaf, including Virginia and/or Burley and/or Oriental tobaccos.

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

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

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

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

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

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

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

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

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

- 1 wt% to 60 wt% of a gelling agent;

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

- 0.1 wt% to 80 wt% of flavoring agent; wherein these weights are calculated on a dry weight basis.

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

In some embodiments, the aerosol generating material comprises:

- 1 wt% to 50 wt% of a gelling agent;

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

- 30 to 60 wt% of flavoring agents;

Among them, these weights are calculated based on dry weight.

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

- 1 wt% to 60 wt% of a gelling agent;

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

- 10 wt % to 60 wt % of tobacco extract;

Among them, these weights are calculated based on dry weight.

In some embodiments, the aerosol generating material comprises:

- 1 wt% to 60 wt% of a gelling agent;

- 20 wt% to 60 wt% of an aerosol generating agent; and

- 10 wt % to 60 wt % of tobacco extract;

Among them, these weights are calculated based on dry weight.

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

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

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

The "thickness" of an 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 opposite the first planar surface of the sheet.

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

In some cases, the aerosol generating material may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, 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.

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

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

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

In some examples, the aerosol-generating material in sheet form can have a tensile strength of from about 200 N/m to about 900 N/m. In some examples, such as where the aerosol-generating material does not include a filler, the aerosol-generating material can 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 strength may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet and then cut 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 about 800 N/m. Such tensile strength may be particularly suitable for embodiments in which 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 about 200 N/m to about 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 about 1000 N/m. Such tensile strengths may be particularly suitable for embodiments in which an aerosol generating material including the aerosol generating material is formed and incorporated into an aerosol generating consumable as a sheet.

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

Unless otherwise expressly stated, all weight percentages (expressed as wt%) described herein are calculated on a dry weight basis. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis refer to the entire extract or slurry or material excluding water, and may include components that are themselves liquid at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis refer to all components, including water.

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

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

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

Depending on the desired color of the aerosol generating material, a variety of colorants can be used. The color of the aerosol generating material can be, for example, white, green, red, purple, blue, brown or black. Other colors are also contemplated. Natural or synthetic colorants can be used, such as natural or synthetic dyes, food grade colorants and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which can give the aerosol generating material a brown appearance. In such embodiments, the color of the aerosol generating material can be similar to the color of other components (such as tobacco material). In some embodiments, a colorant is added to the aerosol generating material so that it cannot be visually distinguished from other components in the aerosol generating material.

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

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

In the following discussion of the drawings, when the same element is present in more than one embodiment, the same reference numeral is used throughout for that element, and when similar elements are present, like reference numerals are used (the same numeral plus multiples of 100).

1 to 3, an article 2 for making a consumable product 4 for use with a non-flammable aerosol supply device comprises an aerosol generating material and a support 8. The support 8 has opposing first and second surfaces 10, 12. The support 8 is a sheet material, and the opposing surfaces 10, 12 are major surfaces of the sheet.

A plurality of discrete portions 6 of aerosol generating material are supported on a first surface 10, and a plurality of discrete portions 6 of aerosol generating material are supported on a second surface 12. In Figures 1 and 2, three discrete portions 6 of aerosol generating material are supported on each of the first surface 10 and the second surface 12 of the support 8. Other numbers of discrete portions from one to more than one may be supported on the support, depending on the size of the article 2.

The positions of the plurality of portions 6 on the first and second surfaces 10 and 12 correspond to each other because the portions 6 completely overlap or align with each other when viewed from a position perpendicular to the surface 10 or 12 and the peripheries of the portions 6 align with each other.

The support 8 is made of aluminum foil of approximately 0.007 mm thickness. Such foil is not rigid enough to be self-supporting. However, the combination of the support and the discrete portions 6 of aerosol generating material on the first surface 10 and the second surface 12 of the support 8 together provide an article 2 that is rigid enough to be self-supporting in at least one direction along the first surface 10 or the second surface 12 of the support 8. For the purposes of the present disclosure, the article 2 is self-supporting in at least one direction along the first surface or the second surface of the support, a length of the article 2 can be fixed at one end of the length, and when the article 2 is sized as a consumable 4, the article can be extended horizontally from the fixed position without support.

To form the consumable product 4 from the product 2 , the product 2 is cut along the cutting lines 16 .

4 to 7, an article 102 for making a consumable product 104 for use with a non-flammable aerosol supply device comprises an aerosol generating material and a support 8. The support 8 has first and second surfaces 10 and 12 that are opposed.

A plurality of discrete portions 106A of aerosol generating material are supported on the first surface 10. A plurality of discrete portions 106B of aerosol generating material are supported on the second surface 12. In Figures 4 to 6, three discrete portions 106A of aerosol generating material are shown as supported on the first surface 10, and seven discrete portions 106B of aerosol generating material are shown as supported on the second surface 12 of the support 8. Other numbers of discrete portions, from one to more than one, may be supported on either the first surface and the second surface of the support 8, depending on the size of the article 102.

The discrete portions 106A of aerosol-generating material are longitudinally extending strips of material with their longitudinal axes oriented in a first direction. The discrete portions 106B of aerosol-generating material are longitudinally extending strips of material with their longitudinal axes oriented in a second direction. In FIGS. 4 to 7 , the second direction is substantially perpendicular to the first direction. In other embodiments, the discrete portions 106A and 106B of aerosol-generating material may be oriented at different angles relative to each other.

In the embodiments shown in Figures 4 to 7, the discrete portions 106A of the aerosol generating material on the first surface 10 correspond to the discrete portions 106B of the aerosol generating material on the second surface 12, so that when viewed from a position perpendicular to the surface 10 or 12, the portions 106A/106B are aligned with each other.

The support 8 includes a plurality of apertures 118 (shown only in FIG. 4 and not all labeled for clarity) extending between the first surface 10 and the second surface 12 of the support 8. The apertures 118 allow aerosol or vapor to travel from one side of the support 8 to the other.

The support 8 is made of aluminum foil of approximately 0.020 mm thickness. Such foil is not rigid enough to be self-supporting. However, the combination of the support and the discrete portions 106A and 106B of aerosol generating material on the first surface 10 and the second surface 12 of the support together provide an article 102 that is rigid enough to be self-supporting in at least one direction along the first surface or the second surface of the support.

To form the consumable product 104 from the article 102 , the article 102 is cut along the cut lines 116 .

In embodiments of the article 2 or 102 , the composition of the portion 6 / 106A of the aerosol-generating material on the first surface 10 is different from the composition of the portion 6 / 106B of the aerosol-generating material on the second surface 12 .

In embodiments of the article 2 or 102 , the thickness of the portion 6 / 106A of the aerosol-generating material on the first surface 10 is different from the thickness of the portion 6 / 106B of the aerosol-generating material on the second surface 12 .

In alternative embodiments of the article 2 or 102 , the thickness of the portion 6 / 106A of the aerosol-generating material on the first surface 10 is substantially the same as the thickness of the portion 6 / 106B of the aerosol-generating material on the second surface 12 .

In one embodiment of any of the above embodiments, the support member 8 has a thickness less than or equal to 0.025 mm. In some embodiments, the support member has a thickness less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, about 0.020 mm, or about 0.007 mm.

The method of making the article 2/102 comprises providing a support 8, applying discrete portions 6/106A of an aerosol-generating material to a first surface 10 of the support 8, and applying discrete portions 6/106B of an aerosol-generating material to a second surface 12 of the support 8.

In some embodiments, applying the portion 6 , 106A, 106B of the aerosol generating material comprises applying a slurry of the aerosol generating material to the surface 10 / 12 of the support 8 .

In such embodiments, the method further comprises: allowing or causing the aerosol generating material slurry applied to the first surface 10 of the support 8 to cure or at least partially cure. In some embodiments, the aerosol generating material slurry cures or partially cures into an aerosol generating film.

Prior to applying the discrete portions 6 / 106B of the aerosol generating material slurry to the second surface 12 of the support 8 , the discrete portions 6 / 106A of aerosol generating material applied to the first surface 10 of the support 8 are allowed or caused to cure or at least partially cure.

In order to cure or at least partially cure the discrete portions 6/106A/106B of the aerosol-generating material slurry, the portions are exposed to ultraviolet radiation which accelerates the curing of the aerosol-generating material slurry.

In some embodiments of any of the foregoing embodiments, applying the discrete portions 6/106A/106B of aerosol-generating material to the first surface 10 or the second surface 12 of the support 8 and allowing or causing the aerosol-generating material slurry to cure or at least partially cure is repeated one or more times. In other words, the discrete portions 6/106A/106B of aerosol-generating material are composed of two or more layers of aerosol-generating material. The thickness of the cured or at least partially cured aerosol-generating material can be measured after applying each layer.

In an alternative embodiment, and with reference to Figure 8, a cured or partially cured aerosol generating material film 6 is formed on a film forming surface 20. The cured or partially cured film 6 is separated from the film forming surface and applied to a surface 10, 12 of a support 8. The thickness of the cured or partially cured film of aerosol generating material is then measured. Applying the cured or partially cured aerosol generating material film may be repeated one or more times.

In an embodiment not shown in the embodiments of Figures 1 to 3 and/or 4 to 7, two or more fold lines are formed in the support 8. The fold lines are spaced apart so that the article 2/102 is folded like an accordion. This allows the article 2/102 to be stored in a compact form.

When the article 2/102 is larger than the size required for compatible use with the non-flammable aerosol supply system, the article 2/102 can be configured for storage. Suitable configurations are folding in the form of an accordion, forming the article 2/102 into a roll for winding a bobbin, or cutting into sheets for storage in a stacked manner. Suitable barrier materials can be placed between the layers of the article to prevent the layers from possibly adhering to each other.

When the article 2/102 is larger than the size required for compatible use with the non-flammable aerosol supply system, the article 2/102 is separated into two or more article portions that are shaped and sized to function as consumables 4/104 for use with the non-flammable aerosol supply system.

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

Various aspects of the methods, articles, and consumables disclosed in various embodiments may be used alone, in combination, or in various arrangements not specifically discussed in the embodiments described above. Therefore, the present disclosure is not limited in application to the details and arrangements of the components described in the foregoing description or illustrated in the accompanying drawings. For example, various aspects described in one embodiment may be combined in any way with aspects described in other embodiments. Although specific embodiments have been shown and described, it will be apparent to those skilled in the art that various changes and modifications may be made in its broader aspects without departing from the scope of the invention. The scope of the appended claims should not be limited to the embodiments described in the examples, but should be given the broadest reasonable interpretation consistent with the entire specification.

Claims (51)

1. An article for use with a non-flammable aerosol supply device, wherein the article includes an aerosol generating material and a support member, the support member having a first surface and a second surface relative to each other, at least one discrete portion of the aerosol generating material being supported on the first surface, and at least one discrete portion of the aerosol generating material being supported on the second surface. 2. The article of claim 1 , wherein the article is self-supporting in at least one direction along the first surface or the second surface of the support member, a length of the article being capable of being fixed at one end of the length and the article being capable of extending horizontally without support from the fixed position. 3. The article according to claim 1 or 2, wherein the article comprises an aerosol generating material and the support. 4. The article according to any one of claims 1 to 3, wherein the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the first surface and the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the second surface make the discrete portions on the first surface and the discrete portions on the second surface at least partially correspond to each other. 5. The article according to any one of claims 1 to 3, wherein the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the first surface and the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the second surface correspond to each other. 6. The article according to any one of claims 1 to 3, wherein the position, shape and size of the aerosol generating material in at least one discrete portion on the first surface and the position, shape and size of the aerosol generating material in at least one discrete portion on the second surface are different. 7. The article of any one of claims 1 to 6, wherein the composition of the aerosol generating material of at least one discrete portion of the aerosol generating material on the first surface is different from the composition of the at least one discrete portion of the aerosol generating material on the second surface. 8. The article of any one of claims 1 to 7, wherein the thickness of the aerosol generating material of at least one discrete portion of the aerosol generating material on the first surface is different from the thickness of the aerosol generating material of at least one discrete portion of the aerosol generating material on the second surface. 9. The article of any one of claims 1 to 8, wherein the thickness of the aerosol generating material of at least one discrete portion of the aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of the aerosol generating material on the second surface. 10. The article of any one of claims 1 to 9, wherein the support member has a thickness less than or equal to 0.025 mm. 11. The article of any one of claims 1 to 10, wherein the article has a thickness between 0.085 mm and 0.610 mm. 12. A consumable for use with a non-flammable aerosol supply device, wherein the consumable comprises a portion of an article according to any one of claims 1 to 11 and the portion of the article has been configured to a shape and size suitable for use with the device. 13. A method of manufacturing an article, wherein the article comprises an aerosol generating material and a support, wherein the method comprises: Provide support, applying an aerosol generating material to at least one predetermined area on the first surface of the support, An aerosol generating material is applied to at least one predetermined area on the second surface of the support. 14. A method according to claim 13, wherein the article is self-supporting in at least one direction along the first surface or the second surface of the support member, a length of the article can be fixed at one end of the length and the article can extend horizontally without support from the fixed position. 15. A method according to claim 13 or 14, wherein the article comprises an aerosol generating material and the support. 16. The method of any one of claims 13 to 15, wherein applying the aerosol generating material comprises applying a slurry of the aerosol generating material. 17. The method of claim 16, wherein the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface of the support to cure, and the aerosol generating material slurry cures into an aerosol generating material. 18. A method according to claim 16 or 17, wherein the method further comprises: allowing or causing the aerosol generating material slurry applied to the first surface of the support to cure or at least partially cure before applying the aerosol generating material slurry to the second surface of the support. 19. The method of claim 17 or 18, wherein curing the aerosol generating material slurry applied to the first surface of the support comprises using ultraviolet radiation. 20. The method according to any one of claims 17 to 19, wherein applying an aerosol generating material to the first surface of the support and allowing or causing the aerosol generating material slurry applied to the first surface of the support to solidify or at least partially solidify is repeated one or more times. 21. A method according to any one of claims 17 to 20, wherein the method further comprises measuring the thickness of the cured or at least partially cured aerosol generating material applied to the first surface of the support. 22. The method according to any one of claims 13 to 15, wherein the method further comprises: forming a cured or partially cured aerosol-generating material film on the film-forming surface, and A cured or partially cured aerosol generating material film is separated from the film-forming surface, wherein applying the aerosol generating material to the first surface of the support comprises applying a cured or semi-cured aerosol generating material film to the first surface of the support. 23. The method according to any one of claims 13 to 15, wherein the method further comprises: providing a cured or partially cured aerosol generating material film, Wherein, applying the aerosol generating material to the first surface of the support comprises applying a cured or partially cured aerosol generating material film to the first surface of the support. 24. A method according to claim 22 or 23, wherein the method further comprises measuring the thickness of the film of solidified or partially solidified aerosol generating material. 25. A method according to any one of claims 22 to 24, wherein applying the film of cured or partially cured aerosol generating material is repeated one or more times. 26. The method of any one of claims 13 to 25, wherein applying an aerosol generating material to the second surface of the support comprises applying an aerosol generating material slurry. 27. The method of claim 26, further comprising allowing or causing the aerosol generating material slurry applied to the second surface of the support to cure or at least partially cure, and the aerosol generating material slurry cures into an aerosol generating material. 28. The method of claim 26 or 27, wherein curing or at least partially curing the aerosol generating material slurry applied to the second surface of the support comprises using ultraviolet radiation. 29. A method according to claim 27 or 28, wherein applying an aerosol generating material to the second surface of the support and allowing or causing the aerosol generating material slurry applied to the second surface of the support to cure or at least partially cure is repeated one or more times. 30. A method according to any one of claims 27 to 29, wherein the method further comprises measuring the thickness of the cured or at least partially cured aerosol generating material applied to the second surface of the support. 31. The method according to any one of claims 13 to 25, wherein the method further comprises: forming a cured or partially cured aerosol-generating material film on the film-forming surface, and The cured or partially cured film of aerosol generating material is separated from the film-forming surface, wherein applying the aerosol generating material to the second surface comprises applying the cured or partially cured film of aerosol generating material to the second surface of the support. 32. The method according to any one of claims 13 to 25, wherein the method further comprises: providing a cured or partially cured aerosol generating material film, Wherein applying the aerosol generating material to the second surface comprises applying a cured or partially cured aerosol generating material film to the second surface of the support. 33. A method according to claim 31 or 32, wherein the method further comprises measuring the thickness of the cured or semi-cured aerosol generating material film. 34. A method according to any one of claims 31 to 33, wherein applying an aerosol generating material to the second surface of the support is repeated one or more times. 35. A method according to any one of claims 13 to 34, wherein the support is less than 0.025 mm thick. 36. A method according to any one of claims 13 to 35, wherein the support is a metal foil. 37. A method according to any one of claims 13 to 36, wherein applying the aerosol generating material to one or both of the first surface and the second surface of the support member is applying discrete portions of the aerosol generating material to two or more predetermined areas on one or both surfaces of the support member. 38. A method according to any one of claims 13 to 37, wherein the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the first surface and the position, shape and size of each discrete portion of at least one discrete portion of the aerosol generating material on the second surface make the discrete portions on the first surface and the discrete portions on the second surface at least partially correspond to each other. 39. A method according to any one of claims 13 to 37, wherein the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the first surface and the position, shape and size of each discrete portion of the at least one discrete portion of the aerosol generating material on the second surface correspond to each other. 40. A method according to any one of claims 13 to 37, wherein the position, shape and size of at least one discrete portion of the aerosol generating material on the first surface and the position, shape and size of at least one discrete portion of the aerosol generating material on the second surface are different. 41. A method according to any one of claims 13 to 41, wherein the composition of at least one discrete portion of aerosol generating material on the first surface is different from the composition of at least one discrete portion of aerosol generating material on the second surface. 42. A method according to any one of claims 13 to 41, wherein the thickness of at least one discrete portion of the aerosol generating material on the first surface is different from the thickness of at least one discrete portion of the aerosol generating material on the second surface. 43. A method according to any one of claims 13 to 42, wherein the thickness of at least one discrete portion of the aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of the aerosol generating material on the second surface. 44. A method according to any one of claims 13 to 43, wherein the article has a thickness between 0.085 mm and 0.610 mm. 45. A method according to any one of claims 13 to 44, wherein two or more fold lines are formed in the support member. 46. The method of claim 45, wherein a plurality of said fold lines are spaced apart such that the article can be folded in an accordion fashion. 47. The method of any one of claims 13 to 46, wherein the article is larger than a size required for compatible use with a non-flammable aerosol delivery system, wherein the method further comprises configuring the article for storage. 48. A method according to any one of claims 13 to 47, wherein the article is larger than a size required for compatible use with a non-flammable aerosol delivery system, wherein the method further comprises: dividing the article into two or more article portions, Each of the article portions is shaped and sized to be used as a consumable item for use with a non-flammable aerosol supply system. 49. An aerosol supply device for use with a consumable according to claim 12, wherein the device comprises an aerosol generator configured to heat at least a portion of an aerosol generating material supported on the consumable. 50. An aerosol supply system comprising an aerosol supply device according to claim 49 and a consumable according to claim 12. 51. A method of generating an aerosol from a consumable product according to claim 12 using an aerosol generating device having at least one aerosol generator; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.