KR20240114747A - Method for manufacturing consumables containing aerosol-generating materials - Google Patents

Abstract

A method of making a consumable (2) for use with a non-flammable aerosol delivery system is disclosed. Consumables 2 include aerosol generating material, support 4 and cover 6. In the method, a support (4), a cover (6), and a cover support (30) are provided, the cover support (30) having a portion of the first surface (8) of the support (4) and the cover (6) in the cover position. ) is positioned adjacent to the support 4 between. The cover (6) is fixed to the support (4). At least one individual portion 12 of aerosol-generating material is applied to the first surface 8 of the support 4 and, when placed in the cover position, the cover support 30 is configured to form at least one individual portion of the aerosol-generating material. It is placed on part (12).

Description

Method for manufacturing consumables containing aerosol-generating materials

The present disclosure relates to the field of non-flammable aerosol delivery systems, and particularly to methods of manufacturing products comprising aerosol-generating materials for use as consumables for use with an aerosol delivery device, and consumables for use with an aerosol delivery device. It relates to a method for manufacturing them, and an aerosol delivery system comprising consumables and an aerosol delivery device.

Aerosol-generating articles release compounds from the substrate material by heating rather than burning, thereby releasing an inhalable aerosol or vapor. These may be referred to as non-combustible articles, aerosol generating assemblies or aerosol providing devices.

One example of such a product is a heating device, which releases compounds by heating an aerosol-enabled material, which can be referred to as a solid aerosol-generating material. Heating typically volatilizes at least one component of the material to form an inhalable aerosol. These products may be referred to as heat-not-burn devices.

As another example, hybrid devices exist. These hybrid devices contain a liquid source (which may or may not contain an active substance) that is evaporated by heating to generate an inhalable vapor or aerosol. The device further contains an aerosol-generating solid material (which may or may not contain botanical material) whose components are entrained into an inhalable vapor or aerosol to generate an inhalable medium.

According to a first aspect of the present disclosure, a method of manufacturing a consumable for use with a non-flammable aerosol delivery system is provided, the consumable comprising an aerosol generating material, a support, and a cover, wherein the support is provided and the cover is provided. provided, and a cover support is provided. The cover support is positioned adjacent the support between a portion of the first surface of the support and the cover at the cover position, and the cover is secured to the support. At least one discrete portion of aerosol-generating material is applied to the first surface of the support, and when positioned in the cover position, the cover support overlies the at least one discrete portion of aerosol-generating material.

According to a second aspect of the disclosure, a consumable for use with a non-flammable aerosol delivery system is provided, the consumable being a product of the method of the first aspect of the disclosure.

According to a third aspect of the disclosure, there is provided an aerosol providing device for use with a consumable according to the second aspect of the disclosure, the device configured to heat at least a portion of an aerosol generating material supported on the consumable. Includes generator.

According to a fourth aspect of the disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable according to the second aspect of the disclosure.

According to a fifth aspect of the disclosure, a method of generating an aerosol from a consumable according to the second aspect of the disclosure using an aerosol generating device having at least one aerosol generator arranged to heat the consumable without burning it when in use. This is provided; At least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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

1 shows a schematic diagram of a first embodiment of a consumable manufactured according to the method of the present disclosure.
Figure 2 shows a cross-sectional view of the consumable of Figure 1;
Figure 3 shows a schematic exploded perspective view of the consumable of Figure 1 during manufacturing.
4A-4D show cross-sectional views of the consumable of FIG. 1 during different stages of manufacturing the consumable.
Figure 5 shows a schematic diagram of an alternative embodiment of a cover support for use in the manufacture of a second embodiment of a consumable manufactured according to the methods of the present disclosure.
Figure 6 shows a schematic diagram of a third embodiment of a consumable manufactured according to the method of the present disclosure.
Figure 7 shows a schematic diagram of a second method of manufacturing a consumable product according to the present disclosure.
Figure 8 shows a side view of the method of Figure 7;
9 shows a schematic diagram of a third method of manufacturing a consumable product according to the present disclosure.
Figure 10 shows a side view of the method of Figure 9.

Consumables in this description may alternatively be referred to as articles.

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

A device for heating aerosol-generating materials that can be used with consumables is part of a non-flammable aerosol delivery system. Non-flammable aerosol delivery systems release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials.

According to the present disclosure, a "non-combustible" aerosol delivery system comprises a component aerosol generating material of the aerosol delivery system (or a component thereof) to facilitate delivery of at least one substance to a user. It is a system that neither combusts nor burns.

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

In some embodiments, the non-flammable aerosol delivery system may be an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although the presence of nicotine in the aerosol-generating material is not a requirement. You should pay attention to this point.

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

In some embodiments, the non-flammable aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be in solid, liquid or gel form, for example, 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. Solid aerosol generating materials may include, for example, tobacco or non-tobacco products.

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

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with non-flammable aerosol presentation devices. These consumables are sometimes referred to as articles throughout this disclosure.

In some embodiments, a non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device thereof, can include a power source and a controller. The power source may be, for example, an electric power source or an exothermic power source. In some embodiments, the heating power source includes a carbon substrate capable of supplying energy to distribute power in the form of heat to an aerosol generating material or heat transfer material proximate to the heating power source.

In some embodiments, a non-flammable aerosol delivery system may include a region for receiving consumables, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use with a non-flammable aerosol delivery device include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, and a mouthpiece. and/or an aerosol modifier.

According to a first aspect of the present disclosure, a method of manufacturing a consumable for use with a non-flammable aerosol delivery system is provided, the consumable comprising an aerosol generating material, a support, and a cover, wherein the support is provided; A cover is provided and a cover support is provided. The cover support is positioned adjacent the support between a portion of the first surface of the support and the cover at the cover position, and the cover is secured to the support. At least one discrete portion of aerosol-generating material is applied to the first surface of the support, and when positioned in the cover position, the cover support overlies the at least one discrete portion of aerosol-generating material.

The consumable resulting from the method of the present disclosure forms an essentially tubular consumable with the outer surfaces of the consumable being formed by the support and the cover. In some embodiments, the tube has a square or rectangular or approximately square or rectangular cross-section. In some embodiments, the tube has a circular or approximately circular cross-section. In other embodiments, the tube has alternative cross-sections.

In an embodiment of the above embodiment, the cover support includes a first surface portion and a second surface portion, the first surface portion facing the support, and the second surface portion not facing the support when the cover support is in the cover position. and securing the cover to the support includes disposing at least a portion of the cover over at least a portion of the second surface portion of the cover support.

In any of the above embodiments, the cover may be disposed entirely over the second surface portion of the cover support.

In any of the above embodiments, the cover may be substantially rectangular, and the cover support may extend the cover from one edge of the cover to an opposite edge of the cover when the cover is placed on the second surface portion of the cover support. Dimensions are determined to support it. In alternative embodiments, the cover may have an alternative shape.

In any of the alternative embodiments of the above embodiments, the cover can be substantially rectangular and the cover support extends from one edge of the cover to an opposite edge of the cover when the cover is disposed on the second surface portion of the cover support. It is dimensioned to support the cover to a position between one edge of the cover. In alternative embodiments, the cover may have an alternative shape.

The use of a cover support has the advantage that the cover support supports the cover during manufacture of the consumable product, and potential damage to the consumable product and cover is particularly reduced during the manufacturing process. It has an additional advantage that the structural strength of the cover can be lower than in manufacturing methods that do not involve the use of a cover support.

In any of the above embodiments, the cover includes at least one contact portion, and securing the cover to the support includes causing at least one contact portion of the cover to contact the support and at least one contact portion of the cover to contact the support. It includes fixing the part to the support.

In any of the above embodiments, the cover includes two contact portions. In some embodiments, these two contact portions extend in substantially parallel directions.

In any of the above embodiments, the cover includes at least two contact portions. In some embodiments, these at least two contact portions extend in substantially parallel directions. In some embodiments, the cover includes three or four contact portions extending in substantially parallel directions. In such embodiments, one or two separate contact portions are secured to a first surface of the support and one or more contact portions are secured to a second surface of the support.

In any of the above embodiments, the cover includes three contact portions. In some embodiments, two of these contact portions extend in substantially parallel directions and a third contact portion extends between the other two contact portions.

In some embodiments, the contact portion or portions are integrated with the cover. In some embodiments, the contact portions are connected to the main portion of the cover by a fold line, and the contact portions are of sufficient size to enable the cover to be securely secured to the support.

In any one of the above embodiments, securing the cover relative to the support comprises forcing or pressing at least one contact portion of the cover against the support after the at least one contact portion of the cover has been secured to the support. (compressing) is included. This has the advantage of being able to increase the fixation strength of the cover to the support and reduce the possibility of the cover becoming separated from the support.

In any of the above embodiments, the cover support extends in a first direction, and the cover is secured to the support by first and second contact portions, the first and second contact portions having a long dimension and a short dimension. and the long dimension of at least one of the first and second contact portions is generally parallel to the first direction. In some embodiments, the long dimension of each of the first and second contact portions is generally parallel to the first direction.

In any of the above embodiments, at least one of the first and second contact portions of the cover is secured to the first surface of the support adjacent an edge of the support.

In any of the above embodiments, the support has a second surface, and at least a portion of at least one of the first and second contact portions of the cover is secured to the second surface of the support adjacent an edge of the support.

In any of the above embodiments, the support has a second surface, and at least a portion of at least one of the first and second contact portions of the cover is secured to the second surface of the support. In some embodiments, the cover at least partially covers the second surface of the support. In some embodiments, the cover covers more than 20%, more than 50%, more than 75%, or more than 90% of the surface area of the second surface of the support.

In any of the above embodiments, the support is a sheet material and the first surface of the support is one of the major surfaces of the sheet material.

In any of the above embodiments, the support is a sheet material, and the first and second surfaces of the support are the two major surfaces of the sheet material.

In any of the above embodiments, at least one contact portion of the cover is folded around an edge of the support, partially secured to a first surface of the support, and partially secured to a second surface of the support. This arrangement provides a secure fixation of the cover to the support. Folding of the or each contact portion around the edge of the support also results in increased rigidity for the edge of the or each support around which the contact portion is folded.

In any of the above embodiments, the first and second contact portions of the cover are spaced apart from each other, the cover is not secured to the support between the first and second contact portions of the cover, and the cover and the support are together. Defining a passageway having first and second ends.

In any of the above embodiments, the method comprises: at least one piece of air flow inhibiting material on the first surface of the support or cover at or adjacent to a position where the end of the passageway will be formed once the cover is secured to the support. It further includes the step of positioning the elements.

In any of the above embodiments, positioning the air flow restriction element is performed prior to positioning the cover in the cover position or on the cover support, and the cover support is secured to the support while the cover is secured to the support. At least partially retaining at least one element of the air flow inhibiting material in place.

In any of the above embodiments, the airflow inhibiting material may be a porous material, such as cellulose acetate, air-laid paper, cotton based material, shredded paper or cut rag tobacco (but , but not limited to).

In any of the above embodiments, the method further comprises fitting the mouthpiece or mouth piece on a first surface of the support or cover at or adjacent to a position at which the end of the passageway will be formed once the cover is secured to the support. It further includes the step of positioning the socket to be bitten. The mouthpiece will allow the user to draw the aerosol out from between the support and the cover when the consumable is in use.

In any of the above embodiments, positioning the mouthpiece or socket is performed prior to positioning the cover in or on the cover position, and the cover support is secured to the support. Maintains the mouthpiece or socket at least partially in place while

In any of the above embodiments, the method further includes placing the consumable product in packaging.

In any of the above embodiments, the method further includes sealing the consumable product in packaging.

In any of the above embodiments, the packaging is packaging that will be used in storage of the consumable product and subsequent sale to a user of the consumable product. The step of placing consumables in packaging serves to protect them from damage.

In any of the above embodiments, the method includes removing the cover support from between the cover and the support.

In any of the above embodiments, the method includes, once the cover support is removed from between the cover and the support, at least partially filling the passageway formed between the support and the cover with a porous or permeable material. do.

In any of the above embodiments, the porous or permeable material is disposed into the passageway at the same time the cover support is removed from between the cover and support. The porous or permeable material may be or include, for example, cellulose acetate, air-laid paper, cotton-based material, shredded paper, or cut rag tobacco, or mixtures of two or more of these materials. (but not limited to this).

In any of the above embodiments, the cover support has a structure that is permeable by aerosols, and the cover support is retained between the support and the cover.

In any of the above embodiments, the cover support is retained between the support and the cover, and the cover support is configured to be removed from between the support and the cover by the user prior to use of the consumable. This has the advantage that the cover will be supported and thus the consumable will not be damaged and/or pushed against the support until just before use.

In any of the above embodiments, the method further includes introducing at least one perforation in the cover material.

In any of the above embodiments, the passage between the cover and the support is a blind passage, with the cover secured to the support along one end and sides of the passage.

In any of the above embodiments, the passage between the cover and the support is a blind passage, wherein the cover is secured to the support along one end and sides of the passage, and the cover is attached to the blind end of the passage. or comprising one or more perforations in the cover adjacent the blind end of the passageway. The number of apertures in the cover will affect the pressure drop within the consumable while the consumable is in use and a user is drawing aerosols and air through the consumable. The number and/or size of apertures can be varied to provide a desired level of pressure drop.

In any of the above embodiments, the support is a longitudinally extending strip of material, the support supports at least two separate portions of aerosol-generating material, and the individual portions of aerosol-generating material are positioned on the support such that they are spaced apart from each other. is located in At least two cover supports and covers are provided, each cover support positioned adjacent a portion of the support in the cover position, the covers being secured to the support to form a passage between the support and each of the covers, and each The cover support of is positioned between a portion of the support and the cover once the covers are secured to the support.

In any of the above embodiments, the covers are provided as a single longitudinally extending strip of cover material, and a plurality of covers are formed during performance of the method.

In any of the above embodiments, the individual portions of the aerosol-generating material are bundled into two or more groups of portions, each group being such that each of the cover supports is a group of portions. It is positioned on the first surface of the support so as to rest on one of the supports.

In any of the above embodiments, the method further comprises separating the support into at least two portions of the support, each separation occurring in a space on the support between adjacent groups of aerosol generating material. .

In any of the above embodiments, separation is effected by cutting the support with a suitable cutting means, such as but not limited to a knife or a pair of blades.

In any of the above embodiments, at least one separation occurs after at least one cover has been secured to the support.

In any of the above embodiments, the at least one separation passes through an area where the cover material is secured to the support.

In any of the above embodiments, at least one separation occurs before the at least one cover is secured to the support.

In any of the above embodiments, each separation forms at least one edge of the support.

In any of the above embodiments, the support and the at least one cover support pass along a longitudinally extending manufacturing path, and the at least one cover overlies the at least one cover support and at least a portion of the support, while at least One cover support and the support travel along the manufacturing path.

In any of the above embodiments, the or each cover support is adjacent to, but not in contact with, the support, and the or each cover support is held in place by a support device, and the support device is As the support passes along the manufacturing path, the or each cover support is maintained in a substantially fixed position relative to the support.

In any of the above embodiments, each cover support has a longitudinal extent, and the longitudinal extent of each cover support is oriented in substantially the same direction as the direction of travel of the support along the manufacturing path.

In any of the above embodiments, each cover support has a longitudinal extent, and the longitudinal extent of each cover support is oriented at an angle with respect to the direction of travel of the support along the manufacturing path. In some embodiments, the angle is between 45 and 90 degrees. In some embodiments, the angle is about 90 degrees.

In any of the above embodiments, the method comprises measuring the temperature of one or both of the support and the aerosol-generating material, and wherein the temperature of one or both of the support and the aerosol-generating material exceeds a predetermined temperature. If so, it further includes cooling one or both of the support and the aerosol generating material.

In any of the above embodiments, temperature measurement and cooling, if they occur, are performed at fixed positions on the manufacturing path, and measurement and cooling, if they occur, occur at predetermined times.

In any of the above embodiments, temperature measurement and cooling, if they occur, are performed at fixed positions on the manufacturing path, and temperature measurement and cooling, if they occur, occur at intervals. The intervals are determined by the speed of the support along the manufacturing path, and temperature measurements and cooling, if they occur, occur at predetermined intervals along the support in the direction of the manufacturing path.

In any of the above embodiments, temperature measurement and cooling, if they occur, are performed respectively at first and second fixed positions on the manufacturing path, and the temperature measurement is continuous or substantially continuous and the measured temperature is Cooling occurs whenever a predetermined temperature is exceeded.

In any of the above embodiments, the temperature measurement is made in a first position on the support, and cooling, if this occurs, is performed before at least one cover is fixed to the support in the first position on the support. .

In any of the above embodiments, the or each cover is formed from a sheet material.

In any of the above embodiments, the sheet material includes one or more of card, paper, and plastic materials.

In any of the above embodiments, the cover is formed of a laminate material, and the laminate includes two or more layers of sheet material.

In any of the above embodiments, the cover includes a composite material, and the composite material includes one or more stiffening elements.

In any of the above embodiments, when the support is removed from between the support and the cover, the cover is self-supporting.

In any of the above embodiments, the cover is sufficiently rigid that the consumable can be inserted into and removed from the aerosol-providing device without damage.

In any of the above embodiments, the material forming the or each cover is a foldable material.

In any of the above embodiments, the material forming the or each cover is a permeable or porous material.

In any of the above embodiments, the material forming the or each cover includes one or more fold lines.

In any of the above embodiments, the material forming the or each cover includes one or more corrugations.

In any of the above embodiments, the material forming the or each cover includes one or more folds or structural features that reinforce all or part of the cover.

The advantage of a cover material that includes one or more corrugations or other structural features that reinforce all or part of the cover is that it provides more strength to achieve the degree of reinforcement required for the cover than is possible for a cover that does not include any reinforcing features. This means that thin materials can be used.

In any of the above embodiments, fold lines, creases or other structural features are formed while performing the method.

In any of the above embodiments, the aerosol-generating material is an aerosol-generating membrane.

In any of the above embodiments, the support comprises metallic foil.

In any of the above embodiments, the support includes a susceptor.

In any of the above embodiments, the support includes a laminate material, and the laminate material includes at least two layers.

In any of the above embodiments, at least one cover is secured to the support using an adhesive.

In any of the above embodiments, the adhesive is an aerosol generating material slurry.

In any of the above embodiments, the at least one cover is secured to the support using ultrasonic welding techniques.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when energized, irradiated or heated in any other way. Aerosol-generating materials may be in the form of solids, liquids or semi-solids (such as gels), which may or may not contain, for example, active substances and/or flavoring agents.

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

Aerosol-generating materials may include binders such as gelling agents and aerosol formers. Optionally, substances and/or fillers to be delivered may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol generating material is substantially free of botanical material. In particular, in some embodiments, the aerosol generating material is substantially free of tobacco.

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

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

The aerosol-generating membrane combines a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol former, and one or more substances to be delivered to form a slurry and then heats the slurry to release at least a portion of the solvent. It can be formed by volatilizing to form an aerosol-generating film.

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

In some embodiments, the aerosol-generating material may be or include an “amorphous solid.” In some embodiments, the aerosol-generating material includes an aerosol-generating membrane that is an amorphous solid. Amorphous solids may be “monolithic solids.” Amorphous solids may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid, such as a liquid, inside them. In some embodiments, the amorphous solid may comprise, for example, from about 50%, 60%, or 70% by weight of the amorphous solid to about 90%, 95%, or 100% by weight of the 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 by a changing magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that its transmission by a changing magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor material may be a magnetic material, whereby penetration by a changing magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor can be both electrically conductive and magnetic, so that the susceptor can be heated by both heating mechanisms. A device configured to generate a changing magnetic field is referred to as a magnetic field generator.

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

In any of the above embodiments, the aerosol generating material comprises an active agent.

As used herein, the active agent may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substances may be selected from, for example, nutraceuticals, nootropics, and psychoactives. The active substances may occur naturally or be obtained synthetically. The active substances are, for example, nicotine, caffeine, taurine, terpenes from non-cannabinoids, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or It may include constituents, derivatives, or combinations thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other botanicals.

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

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

The active substance may comprise or be derived from one or more herbal medicines or their components, derivatives or extracts. As used herein, the term "herbal medicine" means extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk. , shells, etc., and any material derived from plants. Alternatively, the material may contain active compounds naturally present in herbal medicines obtained synthetically. This material may be in the form of liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, etc. Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, and flax. ), ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin ), papaya, rose, sage, tea (e.g. green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaf. (bay leaves), cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elder. Elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom. blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm ), lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine ( theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v. (Mentha piperita citrata c.v.), Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suablens Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is tobacco.

In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from rooibos and fennel.

In some embodiments, the aerosol generating material includes a flavor or flavoring agent.

As used herein, the terms “flavour” and “flavourant” refer to the taste, aroma, or aroma desired in a product for adult consumers, when local regulations permit. ) or other somatosensorial sensations. These include naturally occurring flavoring ingredients, plants, extracts of plants, synthetically obtained ingredients, or combinations thereof (e.g. tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen. , cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumbers, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery. , cascarilla, nutmeg, sandalwood oil, bergamot, geranium, khat, naswar, betel nut, hookah, pine, honey essence, rose oil, vanilla, lemon. Oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, Coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnuts, hibiscus. , bay, mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano. ), paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, cassis, valerian. , pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena. (verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or irritants, sugars and/or Sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives , such as charcoal, chlorophyll, minerals, herbal medicines, or breath fresheners. These may be imitation, synthetic or natural components or blends thereof. These may be in any suitable form, for example liquids such as oils, solids such as powders or gases.

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

In some embodiments, flavor is a sensation intended to achieve a somatosensory sensation that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the scent or taste nerves. These may include agents that provide heating, cooling, tingling, and numbing effects. A suitable thermogenic agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

Aerosol-generating materials include aerosol-generating agents. In some embodiments, an aerosol generating agent may include one or more ingredients capable of forming an aerosol. In some embodiments, the aerosol generating agent is glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillatate, ethyl lau. One or more of nitrate, diethyl subrate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. It can be included. In particular examples, the aerosol generating agent includes glycerol.

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

In some embodiments, the aerosol generating material is from about 0.1%, 0.5%, 1%, 3%, 5%, 7% or 10% to about 50%, 45%, 40% by weight. , may contain 35%, 30% or 25% by weight of aerosol generating agent (all calculated on a dry weight basis). Aerosol generating agents can act as plasticizers. For example, the aerosol-generating material may include 0.5 to 40%, 3 to 35%, or 10 to 25% by weight of aerosol generating agent.

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

In some embodiments, the aerosol generating material comprises up to about 80% by weight of aerosol generating agent, such as about 40 to 80%, 40 to 75%, 50 to 70%, or 55 to 65% by weight. You can do it (DWB).

Aerosol-generating materials may also include gelling agents. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, gelling agents include alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. It contains one or more compounds selected from the group comprising: For example, in some embodiments, the gelling agent is alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, gum acacia, fumed Contains one or more of silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin and can be combined with a curing agent (eg, a calcium source) while forming the aerosol-generating material. In some cases, the aerosol generating material may include calcium-crosslinked alginate and/or calcium-crosslinked pectin.

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

In some embodiments, the cellulose gelling agent is hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CAB), It is selected from the group consisting of cellulose acetate butyrate (CAP), 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 methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent is agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan. , starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

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

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

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

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

In examples, the aerosol-generating material includes a gelling agent and a filler, wherein the gelling agent and filler comprise from about 10%, 20%, 25%, 30% or 35% to about 60% by weight of the aerosol-generating material; Taken together in amounts of 55%, 50% or 45% by weight. In examples, the aerosol-generating material includes a gelling agent and a filler, the gelling agent and filler being in an amount of about 20 to 60%, 25 to 55%, 30 to 50%, or 35 to 45% by weight of the aerosol-generating material. are taken together as

In some examples, the aerosol-generating material (i.e., without considering the amount of filler) is about 5%, 10%, 15%, 20%, 25%, 30%, or 35% by weight of the aerosol-generating material. % to about 60%, 55%, 50% or 45% by weight of gelling agent. In examples, the aerosol-generating material (i.e., without considering the amount of filler) is about 5 to 60%, 20 to 60%, 25 to 55%, 30 to 50%, or 35 to 35% by weight of the aerosol-generating material. It contains a gelling agent in an amount of 45% by weight.

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

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

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

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

The aerosol-generating material can (a) form a slurry comprising the components of the aerosol-generating material or their precursors, (b) form a layer of the slurry, (c) cure the slurry to form a gel, and (d) dry. It can be formed in a way to form an aerosol generating material.

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

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

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

In examples, the slurry includes a gelling agent, an aerosol former material, and an active agent. The slurry may include these ingredients in any of the ratios given herein in relation to the composition of the aerosol generating material. For example, the slurry may include (on a dry weight basis):

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

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

Optionally, the active material in an amount of up to about 20% by weight of the slurry.

c) Curing the gel may include adding a setting agent to the slurry. For example, the slurry can include sodium, potassium, or ammonium alginate as a gel-precursor, and a curing agent comprising a calcium source (e.g., calcium chloride) can be added to the slurry to form a calcium alginate gel. there is.

In examples, the curing agent is calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, Or it includes or consists of a combination thereof. In some examples, the curing agent includes or consists of calcium formate and/or calcium lactate. In certain instances, the curing agent includes or consists of calcium formate. The present inventors have found that, typically, using calcium formate as a curing agent results in an aerosol-generating material with greater tensile strength and greater resistance to elongation.

The total amount of hardener, such as calcium source, may be 0.5 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 discovered that adding too little curing agent may result in an aerosol-generating material in which the aerosol-generating material components are not stabilized and these components are shed from the aerosol-generating material. The inventors have discovered that adding too much curing agent makes the aerosol-generating material very sticky and consequently poor handling.

If the aerosol-generating material does not contain tobacco, larger amounts of hardener may need to be applied. Accordingly, in some cases the total amount of curing agent may be 0.5 to 12 wt%, such as 5 to 10 wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol generating material will generally not contain any tobacco.

In examples, supplying the curing agent to the slurry includes spraying the curing agent onto the slurry, such as the top surface of the slurry.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10 to 600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. am. By adding calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with high G monomer content form gels more easily upon addition of a calcium source. Accordingly, in some cases, the gel-precursor is an 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. May contain salt.

In examples, d) drying 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 water from the slurry. do.

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

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

In instances where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol-generating material. Accordingly, the discussion herein regarding solid compositions is explicitly disclosed in combination with the slurry embodiment of the invention.

Aerosol-generating materials may include flavors. Suitably, the aerosol generating material may comprise up to about 80%, 70%, 60%, 55%, 50% or 45% by weight of flavor. In some cases, the aerosol-generating material contains at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% (all calculated on a dry weight basis) of flavoring agent. It can be included. For example, the aerosol generating material may include 1 to 80%, 10 to 80%, 20 to 70%, 30 to 60%, 35 to 55%, or 30 to 45% by weight of flavor. . In some cases, the flavor includes, consists essentially of, or consists essentially of menthol.

Aerosol-generating materials may include fillers.

In some embodiments, the aerosol-generating material is less than 60% by weight, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 10% by weight. Contains 20% by weight of filler.

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

In some such cases, the aerosol-generating material contains at least 1% filler, such as at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, or at least 50% by weight. Contains % filler. In some embodiments, the aerosol-generating material includes 5 to 25 weight percent filler.

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

In certain embodiments involving filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

Without being bound by theory, it is believed that including fibrous fillers in an aerosol generating material can increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided in a sheet, for example where the sheet of aerosol-generating material surrounds a rod of aerosolizable material.

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

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

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

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

In some cases, the aerosol-generating material includes an active agent such as tobacco extract. In some cases, the aerosol-generating material may include 5 to 60% tobacco extract by weight (calculated on a dry weight basis). In some cases, the aerosol generating material is from about 5%, 10%, 15%, 20% or 25% by weight to about 60%, 50%, 45%, 40%, 35% by weight. or 30% by weight tobacco extract (calculated on dry weight basis). For example, the aerosol-generating material may include 10 to 50 weight percent, 15 to 40 weight percent, or 20 to 35 weight percent tobacco extract. Tobacco extracts may be used wherein the aerosol-generating material comprises from 1% 1.5%, 2% or 2.5% to about 6%, 5%, 4.5% or 4% nicotine by weight (calculated on a dry weight basis). ) may contain nicotine in concentration. In some cases, the aerosol generating material may be free of nicotine other than the nicotine produced from 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 from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% nicotine by weight. (Calculated on dry weight basis). For example, the aerosol-generating material may include 1 to 20%, 2 to 18%, or 3 to 12% nicotine by weight.

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

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

The aerosol-generating component may include one or more active substances. In examples, the aerosol-generating material includes one or more active substances, for example, up to about 20% by weight of the aerosol-generating material. In examples, the aerosol-generating material comprises the active agent in an amount from about 1%, 5%, 10%, or 15% to about 20%, 15%, 15%, or 5% by weight of the aerosol-generating material. It can be included.

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 of about 50 to 95 wt%, or about 60 to 90 wt%, or about 70 to 90 wt%, or about 75 to 85 wt%.

Tobacco material can be in any form but is typically fine-cut (e.g., cut into narrow shreds). The finely chopped tobacco material can advantageously be blended with the aerosol-generating material to provide an aerosol-generating composition in which the tobacco material and aerosol-generating material are evenly dispersed throughout the aerosol-generating composition.

In examples, the tobacco material is one of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and/or tobacco extract. It may include more. Surprisingly, the inventors have found that it is possible to use relatively large amounts of lamina tobacco in an aerosol generating composition and also provide an acceptable aerosol when heated by a non-flammable aerosol delivery system. Lamina tobacco typically provides excellent organoleptic properties. In examples, the tobacco material includes lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material includes cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

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

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

In some cases, the aerosol generating material may further include an emulsifying agent to emulsify the molten flavor during manufacturing. For example, the aerosol-generating material may comprise from about 5% to about 15% by weight emulsifier (calculated on a dry weight basis), suitably about 10% by weight. Emulsifiers may include acacia gum.

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

The aerosol-generating material may have any suitable moisture content, for example, from 1% to 15% by weight. Suitably, the moisture content of the aerosol-generating material is from about 5%, 7% or 9% by weight to about 15%, 13% or 11% by weight (WWB), most suitably about 10%. The moisture content of the aerosol-generating material can be determined, for example, by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

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

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

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

In examples, the aerosol-generating material does not include flavoring agents; In certain instances, the aerosol-generating material does not include an active agent.

In some embodiments, the aerosol-generating material includes an aerosol-generating material, and the aerosol-generating material includes:

- 1 to 60% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol generating agent; and

- 0.1 to 80% by weight of flavor;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material includes 1 to 80% flavor by weight (dry weight basis).

In some embodiments, the aerosol generating material includes:

- 1 to 50% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol generating agent; and

- 30 to 60% by weight of flavor;

These weights are calculated on a dry weight basis.

In alternative embodiments of the aerosol-generating material, the aerosol-generating material includes an aerosol-generating material, and the aerosol-generating material includes:

- 1 to 60% by weight of gelling agent;

- 5 to 60% by weight of aerosol generator; and

- 10 to 60% by weight of tobacco extract;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material includes:

- 1 to 60% by weight of gelling agent;

- 20 to 60% by weight of aerosol generator; and

- 10 to 60% by weight of tobacco extract;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material includes 20 to 35 weight percent of a gelling agent; 10 to 25% by weight of aerosol former material; Filler comprising 5 to 25% by weight of fibers; and 35 to 50% by weight of flavoring agent and/or active substance.

In some cases, the aerosol-generating material may consist or consist essentially of a gelling agent, an aerosol-generating agent, tobacco extract, water and, optionally, flavor. In some cases, the aerosol generating material may consist or consist essentially of glycerol, alginates and/or pectins, tobacco extract and water.

In some embodiments, the aerosol-generating material may have the following composition (DWB): about 5 wt% to about 40 wt%, or about 10 wt% to about 30 wt%, or about 15 wt% to about 25 wt%. A positive gelling agent (preferably comprising alginate); Tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%; An aerosol generator (preferably comprising glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

In one embodiment, the aerosol generating material includes about 20% alginate gelling agent, about 48% Virginia tobacco extract, and about 32% glycerol by weight (DWB).

The “thickness” of an aerosol-generating material refers to the shortest distance between the first and second surfaces. 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 range 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 can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

Materials with a thickness of 0.2 mm are particularly suitable. The aerosol-generating material may include more than one layer, and the thickness described herein refers to the collective thickness of these layers.

It has been found that if the aerosol generating material is too thick, in this case the heating efficiency is reduced. This adversely affects power consumption during use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; Very thin materials are difficult to cast and brittle, which can adversely affect aerosol formation when used.

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

In some examples, the aerosol-generating material in sheet form can have a tensile strength of about 200 N/m to about 900 N/m. In some instances, for example where the aerosol-generating material does not include filler, the aerosol-generating material has a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. It may be N/m.

These tensile strengths may be particularly suitable for embodiments where the aerosol-generating material is formed into a sheet and then broken and incorporated into the aerosol-generating article. In some instances, such as when the aerosol-generating material includes a filler, the aerosol-generating material has a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m. You can. These tensile strengths may be particularly suitable for embodiments in which the aerosol-generating solid is included in the 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 can have a tensile strength of about 200 N/m to about 2600 N/m. In some examples, the aerosol-generating material can have a tensile strength of 600 N/m to 2000 N/m, or 700 N/m to 1500 N/m, or about 1000 N/m. These tensile strengths may be particularly suitable for embodiments where the aerosol-generating material comprising the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

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

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

As used herein, the term “sheet” refers to an element having a width and length that is substantially greater than its thickness. If the major surface of a sheet is a surface extending in both the width and length dimensions, the sheet is flat. The sheet may be, for example, a strip.

Aerosol-generating materials may include colorants. The addition of colorants can change the visual appearance of the aerosol-generating material. The presence of colorants in the aerosol-generating material can 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 can be color-matched with other components of the aerosol-generating material or with other components of the article comprising the aerosol-generating material.

Various colorants can be used depending on the desired color of the aerosol generating material. The color of the aerosol-generating material can be, for example, white, green, red, purple, blue, brown or black. Other colors are also envisioned. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which can impart the aerosol generating material with a brown appearance. In these embodiments, the color of the aerosol-generating material may be similar to the color of the other ingredients (e.g., tobacco materials). In some embodiments, the addition of a colorant to the aerosol-generating material renders the aerosol-generating material visually indistinguishable from other components of the aerosol-generating material.

The colorant may be incorporated during forming the aerosol-generating material (e.g., when forming a slurry comprising the materials forming the aerosol-generating material) or while forming the aerosol-generating material (e.g., by spraying onto the aerosol-generating material). It may later be applied to aerosol-generating materials.

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

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

1 and 2, the consumable product 2 includes a support 4 and a cover 6.

The support 4 is a sheet material with a first surface 8 and a second surface 10 . On the first surface 8 , one or more individual parts 12 of aerosol-generating material are supported (for clarity, not all parts 12 are labeled). The portion or portions 12 of aerosol-generating material are applied to the support in a suitable manner and with predetermined dimensions and configurations in a predetermined pattern on the first surface 10 . Collectively, parts 12 may be described as a group of parts 12 . The number of portions 12 of the aerosol-generating material shown in FIGS. 1 and 2, their shape and position relative to each other, are exemplary, and other numbers of portions 12, portions 12 relative to each other, are exemplary. Other positioning and/or other configurations of parts 12 are within the scope of the present disclosure.

The cover 6 is fixed to the support 4 adjacent the edges 14A, 14B of the support 4. The fixing means for fixing the cover 6 to the support is an adhesive 16 (not shown in FIGS. 1 and 2). In other embodiments, the fastening means may be the use of an aerosol-generating material slurry, which can act as an adhesive if fastening occurs before the aerosol-generating material has hardened. An alternative means of fastening is the use of melting or welding (eg ultrasonic welding) techniques.

Once cover 6 is secured to support 4, cover 6 and support 4 collectively define a passageway 28. Passageway 28 contains a group of portions 12 of aerosol-generating material and a volume through which air or aerosol can flow.

3 and 4A-4D, to make the consumable product 2 shown in FIGS. 1 and 2, the cover support 30 is placed in the cover position. In the cover position, the cover support 30 lies over most of the first side 8 of the support 4 . The cover support 30 has a first surface portion 32 facing the first surface 8 of the support 4 and a second surface facing away from the first surface 8 of the support 4. It has part 34.

The cover 6 is formed by nine rectangular parts 18, 20A, 20B, 22A, 22B, 24A, 24B, 26A, 26B, each part corresponding to the edges 14A of the support 4. It has a long axis (longitudinal axis) substantially parallel to 14B). Each portion of the cover is adjacent to at least one other portion of the cover, and at least one longitudinally extending side of each cover portion has one or two of the fold lines 18F, 20F, 22F, 24F formed from the material of the cover. Defined by the dog.

During the manufacture of the consumable product 2, and as shown in FIGS. 4A to 4D, the cover 6 is folded around the fold lines 18F, 20F, 22F, 24F so that the cover portion 18 is folded around the cover portions 20A. , 20B), the cover portions 22A, 24A, 26A, and 22B, 24B, 26B wrap the edges 14A, 14B of the support 4, respectively. Cover portions 22A, 24A, 26A, and 22B, 24B, 26B may be collectively referred to as first and second contact portions of cover 6, respectively. The surfaces of the cover portions 22A, 24A, 26A, and 22B, 24B, 26B that are in contact with or close to the surface of the support 4 are the first and second contact surfaces of the cover 6. Prior to folding of cover portions 22A, 24A, 26A, and 22B, 24B, 26B around edges 14A, 14B, adhesive 16 is applied to the first and second contact surfaces.

After the cover portions 22A, 24A, 26A and 22B, 24B, 26B and the adhesive 16 are folded around the edges 14A, 14B of the support 4, the cover portions 22A, 24A, 26A and The parts of the consumable consisting of edges 14A and 22B, 24B, 26B and edge 14B are supported by a pair of compression rollers (not shown) or equivalent to maximize the fixation of cover 6 to support 4. Passes between means of compression.

Once adhesive 16 has cured, packaging (not shown) is partially placed around consumable product 2. Subsequently, the cover support 30 is removed from between the cover 6 and the support 4, and the packaging is sealed around the consumable product.

In an alternative embodiment, the cover support 30 is held between the cover 6 and the support 4 and the consumable and packaging that is sealed around the cover support 30. In such an embodiment, the cover support 30 can be operated by a user prior to use of the consumable, for example allowing the user to grab a tag and pull the cover support 30 out between the cover 6 and the support 4. By including a tag that is not shown, it is configured to be removed.

In an alternative embodiment, the cover support 30 is configured to remain between the cover 6 and the support 4 while the consumable is in use. In this embodiment, the cover support 30 is made of cellulose acetate, air-laid paper, cotton-based material, shredded paper, or cut rag tobacco. It is formed of a porous or permeable material, such as a mixture of two or more of these materials.

5, an alternative cover support 130 is shown. The cover support 130 includes a recess 136 in the cover support first side 132 adjacent the first end 138 of the cover support 130 . The recess is configured to retain a portion of the porous or permeable material 140 relative to the first surface 108 of the support 4 when the cover support 130 is in the cover position. When the cover support 130 is moved to the cover position the porous or permeable material 140 is placed in the desired position on the support 4, resulting in the porous or permeable material 140 being pressed in the position shown in Figure 5. The cover support is used in a manner similar to that discussed with respect to cover support 30 and FIGS. 3 and 4A-4D, except that.

In this embodiment, the porous or permeable material 140 is an elastically deformable material, which causes the cover 6 to be fixed to the support 4 and when the cover support 130 is removed from the cover position. It will remain in approximately the same position relative to the cover and expand into contact with the cover 6 and the support 4, thereby extending over the passage 28 formed between the cover 6 and the support 4.

6, an alternative configuration of consumable 202 is shown. Consumable product 202 is similar to consumable product 2 described in connection with Figures 1-4D, except for the following differences. Cover 206 is configured to be formed of seven rectangular portions 218, 220A, 220B, 222A, 222B, 242, 244. Each of the portions 218, 220A, 220B, 222A, and 222B has a major axis (longitudinal axis) that is substantially parallel to another portion of the portions 218, 220A, 220B, 222A, and 222B. Each of the portions 218, 220A, 220B, 222A, and 222B of the cover 206 has at least one other portion of the portions 218, 220A, 220B, 222A, and 222B of the cover 206 and each portion 218, At least one longitudinally extending side of 220A, 220B, 222A, 222B is defined by one or two of the fold lines 218F, 220F formed from the material of the cover. Portions 242 and 244 have a major axis (longitudinal axis) that is substantially perpendicular to the major axis (longitudinal axis) of portions 218, 220A, 220B, 222A, and 222B. At least one longitudinally extending side of each of portions 242 and 244 is defined by one or two of fold lines 218EF, 242F formed from the material of the cover. Portion 242 includes one or more apertures 246 extending through the cover material. Although four apertures 246 are illustrated in FIG. 6, the present disclosure includes other numbers of apertures.

7 and 8, support 304 is a longitudinal strip of material fed in direction D from feed roll 304R. The support 304 then passes through zone 350 where the aerosol generating material 12 is applied to the support 304. The aerosol-generating material is applied as a group 312 of individual parts 12. Each consumable 302 holds one group 312 of aerosol generating material portions 12.

Once the aerosol-generating material has cured, the support passes through zone 352, where the temperatures of the support 304 and the aerosol-generating material are measured by temperature measuring means (not shown), where the measured temperature reaches a predetermined value. If exceeded, the support 304 and aerosol generating material are cooled by cooling means (not shown).

Next, the cover support 330 is moved to the cover position where the cover support 330 rests over the group 312 of aerosol generating material. The cover support 330 is supported on the cover support device, which maintains the cover support device a predetermined distance from the support first surface 308 and moves the cover support 330 at the same speed as the support 304 in the direction D ).

Cover material 306M is supplied from feed roll 306R (by means not shown) over and in contact with the second cover support surface 334 of cover support 330 and between adjacent cover supports 330. It lies over and is in contact with the first surface 308 of the support 304. After the cover material 306M leaves the feed roll 306R and before the cover material 306M comes into contact with the support 304, the cover material 306M is placed in contact with the support 304. It has adhesive 316 applied to portions of the surface. The adhesive is an aerosol-generating material, a gel slurry, or another suitable adhesive.

Support 304, cover material 306M and cover support 330 continue in direction D to cutting zone 354 where cover material 306M and support 304 are cut through. Cuts are made at the portions where cover material 306M is adhered to support 304. This forms a consumable 302 having a support 304, a cover 306 and a passageway 28 at that point substantially occupied by the cover support 330.

Next, consumable 302 is partially surrounded by packaging 356 (not shown in FIG. 7 for clarity) in such a way that packaging 356 does not contact cover support 330.

Next, the cover support 330 is pulled out between the support 304 and the cover 306 and the packaging that is sealed around the consumable product 302.

9 and 10, support 404 is a longitudinal strip of material fed in direction D from a feed roll (not shown). The support 404 then passes through a zone (not shown) where the aerosol generating material 12 is applied to the support 404. The aerosol-generating material is applied as a group 412 of individual parts 12. Each consumable 402 holds one group 412 of aerosol generating material portions 12.

Once the aerosol-generating material has cured, the support passes through a zone (not shown) where the temperatures of the support 404 and the aerosol-generating material are measured by temperature measuring means (not shown), where the measured temperature is determined at a predetermined temperature. If this value is exceeded, the support 404 and aerosol generating material are cooled by cooling means (not shown).

The support 404 passes under the first surface 432 of the cover support 430 with a longitudinal extent oriented in direction D. The cover support 430 is in a fixed position and the support 404 moves relative to the cover support 404 .

Cover material 406M is supplied from a feed roll (not shown) and is brought into contact with and over the second cover support surface 434 of cover support 430. Cover material 406M begins to advance in direction D.

Cover material 406M and support 404 enter folding zone 458, where folding means (not shown) cause cover material 406M to fold as shown in FIGS. 3 and 4A-4D. Wrap around the side edges 414A and 414B of support 404 in a manner similar to that discussed in connection with . The adhesive for securing cover material 306M to support 404 is an aerosol generating material slurry or other suitable adhesive.

The support 404 and cover material 406M continue in direction D and a compression zone 460 where the edges of the support 414A, 414B and cover material 406M are pressed between a pair of pressure rollers. Enter.

Support 404 and cover material 406M reach end 430E of cover support 430 and enter cutting zone 454, where cover material 406M and cover material 404 are grouped with aerosol generating material. It is cut through the portions between the fields 412. This forms a consumable 402 having a support 404, a cover 406, and a passageway 28.

Next, the consumable product 402 is partially surrounded by packaging 456 (not shown in Figure 9 for clarity), and the packaging is then sealed around the consumable product 402.

The above description is meant to be 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. Further modifications that fall within the scope of the invention will become apparent to those skilled in the art upon consideration of this disclosure.

Various aspects of the methods, products, and consumables disclosed in the various embodiments may be used alone, in combination, or in various arrangements, unless specifically discussed in the foregoing embodiments. Accordingly, the present disclosure does not limit its application to the details and arrangement of components presented in the previous description or illustrated in the drawings. For example, 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 changes and modifications may be made without departing from the invention in its broader aspects. The scope of the following claims is not to be limited by the embodiments set forth in the Examples, but is to be given the broadest reasonable interpretation consistent with the description as a whole.

Claims (59)

1. A method of manufacturing a consumable product comprising an aerosol-generating material, a support, and a cover for use with a non-flammable aerosol delivery system, comprising:
A support is provided,
Cover is provided,
A cover support is provided,
the cover support is positioned adjacent the support between a portion of a first surface of the support and the cover at the cover position,
The cover is fixed to the support,
At least one individual portion of the aerosol-generating material is applied to the first surface of the support,
When positioned in the cover position, the cover support overlies at least one individual portion of aerosol-generating material.
How to manufacture consumables. According to claim 1,
The cover support includes a first surface portion and a second surface portion, the first surface portion facing the support, and the second surface portion not facing the support when the cover support is in the cover position. , and securing the cover to the support comprises disposing at least a portion of the cover over at least a portion of a second surface portion of the cover support,
How to manufacture consumables. According to claim 1 or 2,
The cover includes at least one contact portion, and fixing the cover to the support includes causing at least one contact portion of the cover to contact the support and fixing the at least one contact portion of the cover to the support. Including telling,
How to manufacture consumables. According to any one of claims 1 to 3,
Fixing the cover to the support includes colliding at least one contact portion of the cover against the support after the at least one contact portion of the cover is secured to the support.
How to manufacture consumables. According to any one of claims 1 to 4,
The cover support extends in a first direction, the cover is fixed to the support by first and second contact portions, the first and second contact portions having a long dimension and a short dimension, and the first and a long dimension of at least one of the second contact portions is generally parallel to the first direction.
How to manufacture consumables. According to clause 5,
wherein at least a portion of at least one of the first and second contact portions of the cover is secured to the first surface of the support adjacent an edge of the support.
How to manufacture consumables. According to claim 5 or 6,
wherein the support has a second surface, and at least a portion of at least one of the first and second contact portions of the cover is secured to the second surface of the support adjacent an edge of the support.
How to manufacture consumables. According to claim 5 or 6,
the support has a second surface, and at least a portion of at least one of the first and second contact portions of the cover is secured to the second surface of the support,
How to manufacture consumables. According to clause 8,
wherein the cover covers more than 20%, more than 50%, more than 75% or more than 90% of the surface area of the second surface of the support,
How to manufacture consumables. The method according to any one of claims 1 to 9,
wherein the support is a sheet material, and the first surface of the support is one of the major surfaces of the sheet material,
How to manufacture consumables. The method according to any one of claims 1 to 10,
The first and second contact portions of the cover are spaced apart from each other, the cover is not fixed to the support between the first and second contact portions of the cover, and the cover and support are together connected to the first and second contact portions. defining a passageway having ends,
How to manufacture consumables. According to claim 11,
The method includes, once the cover is secured to the support, at least one of an air flow inhibiting material on the first surface of the support or the cover at or adjacent to the position where the end of the passageway is to be formed. Further comprising the step of positioning one element,
How to manufacture consumables. According to claim 12,
Positioning the air flow restriction element is performed prior to positioning the cover support in the cover position or on the cover support, and the cover support is configured to remove air while the cover is secured to the support. at least partially maintaining at least one element of the flow-inhibiting material in place,
How to manufacture consumables. The method according to any one of claims 11 to 13,
The method includes, once the cover is secured to the support, positioning a mouthpiece or a socket into which the mouth piece will engage on the first surface of the support or the cover at or adjacent to a position where the end of the passageway will be formed. further comprising steps,
How to manufacture consumables. According to claim 14,
Positioning the mouthpiece or socket is performed prior to positioning the cover in the cover position or on the cover support, and the cover support is positioned at the cover while the cover is secured to the support. At least partially keeping the mouthpiece or socket in place,
How to manufacture consumables. The method according to any one of claims 1 to 15,
The method further comprises placing the consumable product in packaging,
How to manufacture consumables. According to claim 16,
The method further comprises sealing the consumable product in the packaging,
How to manufacture consumables. The method according to any one of claims 1 to 17,
The method includes removing the cover support from between the cover and the support,
How to manufacture consumables. The method according to any one of claims 1 to 18,
The cover support has a structure that is permeable by aerosol, and the cover support is held between the support and the cover,
How to manufacture consumables. The method according to any one of claims 1 to 19,
The cover support is maintained between the support and the cover, and the cover support is configured to be removed from between the support and the cover by a user before use of the consumable.
How to manufacture consumables. The method according to any one of claims 1 to 20,
The support is a longitudinally extending strip of material,
the support supports at least two separate portions of the aerosol-generating material,
the individual portions of the aerosol-generating material are positioned on the support so as to be spaced apart from each other,
At least two cover supports and covers are provided,
Each cover support is positioned adjacent a portion of the support in the cover position,
The covers are fixed to the support to form a passage between the support and each cover,
Each cover support is positioned between a portion of the support and the cover once the covers are secured to the support.
How to manufacture consumables. According to claim 21,
wherein the covers are provided on a single longitudinally extending strip of cover material, and a plurality of covers are formed during performance of the method.
How to manufacture consumables. The method of claim 21 or 22,
The individual parts of the aerosol-generating material are bundled into two or more groups of parts, each group having a support such that each of the cover supports rests on one of the groups of parts. Located on the first surface of
How to manufacture consumables. The method according to any one of claims 21 to 23,
The method further comprises separating the support into at least two portions of the support, each separation occurring in a space between adjacent groups of the aerosol-generating material.
How to manufacture consumables. According to clause 24,
wherein at least one separation occurs after at least one cover is secured to the support,
How to manufacture consumables. According to clause 25,
wherein the at least one separation passes through a region where the cover material is secured to the support.
How to manufacture consumables. According to clause 24,
at least one separation occurs before the at least one cover is secured to the support,
How to manufacture consumables. According to clause 27,
When subject to any one of claims 5 to 11, each separation forms at least one edge of said support,
How to manufacture consumables. The method according to any one of claims 1 to 28,
The support and the at least one cover support are passed along a longitudinally extending manufacturing path, the at least one cover overlying the at least one cover support and at least a portion of the support, while the at least one cover support and the support extend along the manufacturing path. moving along,
How to manufacture consumables. According to clause 29,
When subject to claim 18, the or each cover support is adjacent to the support, but does not rest on the support, and the or each cover support is held in place by a support device, and the support device is said to be causing the or each cover support to remain in a substantially fixed position relative to the support as the support passes along the manufacturing path.
How to manufacture consumables. The method according to any one of claims 1 to 30,
The method includes measuring the temperature of one or both of the support and the aerosol-generating material, and if the temperature of one or both of the support and the aerosol-generating material exceeds a predetermined temperature, the support and the aerosol further comprising cooling one or both of the resulting materials,
How to manufacture consumables. According to claim 31,
When subject to claim 29 or 30, the temperature measurement and the cooling, if this occurs, are carried out at fixed positions on the manufacturing route, and the measurement and the cooling, if this occurs, are carried out at a predetermined time. Occurring in the fields,
How to manufacture consumables. The method of claim 31 or 32,
the temperature measurement is made in a first position on the support, and the cooling, if this occurs, is performed before at least one cover is fixed to the support in a first position on the support.
How to manufacture consumables. The method according to any one of claims 1 to 33,
wherein the or each cover is formed from a sheet material,
How to manufacture consumables. The method according to any one of claims 1 to 34,
wherein the sheet material includes one or more of card, paper, and plastic materials,
How to manufacture consumables. The method according to any one of claims 1 to 35,
wherein the cover is formed of a laminate material, the laminate comprising two or more layers of the sheet material,
How to manufacture consumables. The method according to any one of claims 1 to 36,
the cover comprising a composite material, and the composite material comprising one or more reinforcing elements,
How to manufacture consumables. The method according to any one of claims 1 to 37,
When the support is removed from between the support and the cover, the cover is self-supporting.
How to manufacture consumables. The method according to any one of claims 1 to 38,
wherein the cover is sufficiently rigid to allow the consumable to be inserted into and removed from the aerosol presentation device without damage.
How to manufacture consumables. The method according to any one of claims 1 to 39,
The material forming the or each cover is a foldable material,
How to manufacture consumables. The method according to any one of claims 1 to 40,
wherein the material forming the or each cover is a permeable material,
How to manufacture consumables. The method according to any one of claims 1 to 41,
The material forming the or each cover comprises one or more fold lines,
How to manufacture consumables. The method according to any one of claims 1 to 42,
The material forming the or each cover comprises one or more corrugations,
How to manufacture consumables. The method according to any one of claims 1 to 42,
The material forming the or each cover includes one or more folds or structural features that reinforce all or part of the cover.
How to manufacture consumables. The method according to any one of claims 42 to 44,
The fold lines, creases or other structural features are formed during performance of the method,
How to manufacture consumables. The method according to any one of claims 1 to 45,
The aerosol-generating material is an aerosol-generating membrane,
How to manufacture consumables. The method according to any one of claims 1 to 46,
The support includes a metallic foil,
How to manufacture consumables. The method according to any one of claims 1 to 47,
The support includes a susceptor,
How to manufacture consumables. The method according to any one of claims 1 to 47,
wherein the support comprises a laminate material, the laminate material comprising at least two layers,
How to manufacture consumables. The method according to any one of claims 1 to 49,
wherein the at least one cover is fixed to the support using an adhesive,
How to manufacture consumables. According to claim 50,
The adhesive is an aerosol-generating material slurry,
How to manufacture consumables. The method according to any one of claims 1 to 51,
wherein the at least one cover is fixed to the support using ultrasonic welding techniques,
How to manufacture consumables. As a consumable for use with a non-flammable aerosol delivery system,
The consumable is a product of the method according to any one of claims 1 to 52,
Consumables for use with non-flammable aerosol delivery systems. As a consumable for use with a non-flammable aerosol delivery system,
The consumable includes an aerosol generating material, a support, a cover and a cover support, the cover support being positioned adjacent the support between a portion of a first surface of the support and the cover at a cover position, the cover being secured to the support. wherein the at least one individual portion of the aerosol-generating material is supported on the first surface of the support, and the cover support overlies the at least one individual portion of the aerosol-generating material.
Consumables for use with non-flammable aerosol delivery systems. According to claim 54,
The cover support is removed to leave a void,
Consumables for use with non-flammable aerosol delivery systems. According to claim 54,
The cover support has a structure that can be permeated by aerosol,
Consumables for use with non-flammable aerosol delivery systems. An aerosol delivery device for use with a consumable according to any one of claims 53 to 56, comprising:
wherein the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.
Aerosol delivery device. Comprising an aerosol delivery device according to claim 47 and a consumable according to any one of claims 53 to 56,
Aerosol delivery system. 57. A method of generating an aerosol from a consumable according to any one of claims 53 to 56 using an aerosol generating device having at least one aerosol generator arranged to heat the consumable without burning it during use,
wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor,
How to create an aerosol from consumables.