US20220400754A1

US20220400754A1 - An article for use in a non-combustible aerosol provision system

Info

Publication number: US20220400754A1
Application number: US17/780,096
Authority: US
Inventors: Junior Kabirat
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2019-11-29
Filing date: 2020-11-27
Publication date: 2022-12-22
Also published as: KR20220121782A; EP4064888A1; GB201917457D0; JP2023505077A; WO2021105473A1

Abstract

An article for use in a non-combustible aerosol provision system and method of manufacturing a non-combustible aerosol provision system, including a support element having at least one cavity and an aerosol generating material disposed within the at least one cavity, wherein the aerosol generating material includes an amorphous solid material.

Description

RELATED APPLICATION INFORMATION

The present application is a National Phase entry of PCT Application No. PCT/EP2020/083795, filed Nov. 29, 2020, which claims priority from GB Patent Application No. 1917457.2, filed Nov. 29, 2019, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to an article for use in a non-combustible aerosol provision system, a method of producing such an article, and a non-combustible aerosol provision system including an article.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternative smoking articles produce an inhalable aerosol or vapor by releasing compounds from an aerosol generating material without burning. These articles may be referred to as non-combustible smoking articles or aerosol provision systems.

SUMMARY

In accordance with some embodiments described herein, there is provided an article for use in a non-combustible aerosol provision system, the article comprising a support element comprising at least one cavity, and an aerosol generating material disposed within the at least one cavity, wherein the aerosol generating material comprises an amorphous solid material.
One or more of the cavities may comprise an aperture which extends entirely through the thickness of the support element, and/or may comprise a recess comprising a cut out, depression or other formation extending partially through the thickness of the support element.
The support element may comprise a substantially planar body. The at least one cavity may extent at least partially through the thickness of the support element. The aerosol generating material may be off-set with respect to a thickness or plane of the support element or portion thereof and aligned with the at least one cavity so as to be accessible therethrough. The aerosol generating material may be disposed within the cavity within the thickness or plane of the support element or portion thereof. The aerosol generating material may be provided on a carrier layer or substrate. The carrier layer or substrate may comprise a sheet material. The carrier layer or substrate maybe attached to the at least one support element. The at least one cavity may comprise an aperture extending entirely through the thickness of the support element. The at least one cavity may comprise a recess extending partially through the thickness of the support element.
The support element may comprise at least two layers of sheet material. The aerosol generating material may be sandwiched between the at least two layers of sheet material.
The sheet material may have a weight of between 180 GSM and 210 GSM. The sheet material may have a thickness of between 150 pm and 400 pm.
The thickness of the support element may be between 300 pm and 800 pm.
The aerosol generating material may comprise an amorphous solid material having regions of different composition within the same body of material.
The article may comprise a plurality of discrete, spaced-apart cavities comprising aerosol generating material.
The aerosol generating material maybe perforated.
The aerosol generating material may be provided on a substrate. The substrate may comprise a metallic foil.
The material of the support element may comprise at least one of paper, cardboard, or foil.
The material of the support element may be a biodegradable material.
The article may comprise an identifying element. The identifying element may be a barcode, a QR code, or an RFID chip. The amorphous solid material may comprise a gelling agent. The gelling agent may comprise alginate, pectin and/or carrageenan.
The amorphous solid material may be a dried hydrogel.
The amorphous solid material may further comprises an aerosol generating agent, an active substance and/or a flavorant. The aerosol generating agent may be glycerol. The active substance may be nicotine. The amorphous solid material may have a thickness of around 0.015 mm and 0.5 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm.
The aerosol generating material may comprise a plurality of holes arranged to demarcate discrete regions of the aerosol generating material.
The article may comprise a plurality of distinct cavities comprising amorphous solid material, wherein each cavity comprises a different amorphous solid material.
In accordance with other embodiments described herein, there is provided a non-combustible aerosol provision system comprising an article as described above and a non-combustible aerosol provision device.
The aerosol generating device may be configured to provide a customizable heating profile such that amorphous solid material in distinct cavities of the article may be heated independently.
In accordance with other embodiments described herein, there is provided a method for producing an article as described above. The method may comprise providing a support element including at least one cavity in the support element, and providing an aerosol generating material comprising an amorphous solid material within the at least one cavity.
The method may comprise providing at least two layers of sheet material to form the support element, at least one of the layers including at least one cavity, and sandwiching the aerosol generating material between the at least two layers of sheet material. The method may comprise providing the aerosol generating material on a substrate. The method may comprise providing the substrate as comprising a metallic foil.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used to illustrate like features:

FIG. 1 is a perspective view of a first embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 2 is a front view of the article of FIG. 1 ;

FIG. 3 is a side view of the article of FIG. 1 ;

FIG. 4 is an exploded view of the article of FIG. 1 ;

FIG. 5 is a perspective view of an exemplary aerosol generating device for use with the article of FIG. 1 ;

FIG. 6 is a schematic cross sectional view of an aerosol generating assembly comprising the article of FIG. 1 received within the aerosol generating device of FIG. 5 ;

FIG. 7 is a schematic cross-sectional view of a second embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 8 is a is a schematic cross-sectional view of a third embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 9 is a schematic cross-sectional view of a fourth embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 10 is a schematic cross-sectional view of a fifth embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 11 is a schematic cross-sectional view of a sixth embodiment of an article for use with a non-combustible aerosol provision device;

FIG. 12 is an exploded perspective view of a seventh embodiment of an article for use with a non-combustible aerosol provision device; and

FIG. 13 is a flow chart of an exemplary method of manufacturing an article for use with a non-combustible aerosol provision device.

DETAILED DESCRIPTION

As used herein, the term “delivery system” is intended to encompass systems that deliver a substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosolizable material without combusting the aerosolizable material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolizable materials; articles comprising aerosolizable material and configured to be used in one of these non-combustible aerosol provision systems; and aerosol-free delivery systems, such as lozenges, gums, patches, articles comprising inhalable powders, and smokeless tobacco products such as snus and snuff, which deliver a material to a user without forming an aerosol, wherein the material may or may not comprise nicotine.
According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosolizable material of the aerosol provision system (or component thereof) is combusted or burned in order to facilitate delivery to a user.
According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosolizable material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery to a user.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.
In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energized so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
FIGS. 1 to 3 illustrate a first embodiment of an article 10 for use with a non-combustible aerosol provision device. The article 10 comprises a consumable article for use with a non-combustible aerosol provision device, and is intended to be a replaceable component which, once depleted or spent, can be replaced with another article 10 for use with the non-combustible aerosol provision device. As referred to herein, a non-combustible aerosol provision system comprises a non-combustible aerosol provision device in combination with one or more articles 10 for use with the non-combustible aerosol provision device.
The article 10 comprises a support element 11 and a plurality of regions 12, each comprising a portion of an amorphous solid material 13, at least one of which comprises an aerosol generating material. In the embodiment shown, the article 10 comprises six regions 12 of substantially uniform size and shape, arranged in two rows of three. However any arrangement and/or number of regions may be provided within the scope of the invention, including one single region, and one or more of the regions 12 maybe of a uniform size/shape, or some or all regions 12 maybe of differing size/shape to other regions 12. The support element 11 includes a plurality of cavities in the form of apertures 14 extending entirely through the thickness of the support element 11 which define the regions 12 of the article 10 at which the portions of amorphous solid material 13 are located. The support element 11 comprises a two ply component, having a first layer 11 a and a second layer 11 b. The six discrete portions of the amorphous solid material 13 are spaced from one another and are sandwiched between the first and second layers 11 a, 11 b. The construction of the article 10 can be understood in more detail from the exploded view of FIG. 4 . Each of the first and second layers 11 a, 11 b includes a plurality of apertures 14 a, 14 b extending entirely through the thickness of the layer 11 a, 11 b which define the apertures 14 in the support element 11. The portions of amorphous solid material 13 are larger than the dimensions of their respective aperture 14 a, 14 b so that they overlie a region of the first and second layer 11 a, 11 b around the perimeter of the respective aperture 14 a, 14 b. The first and second layers 11 a, 11 b are bonded together to form the two-ply support element 11 and thereby secure the portions of amorphous solid material 13 in place within respective aperture 14. The layers na, nb may be bonded by any suitable bonding agent, such as PVA or other adhesive, or may be bonded by non-adhesive means, such as welding or any other method of mechanical securing. An advantage of the configuration of consumable article 10 comprising a plurality of discrete portions of amorphous solid material 13 being spaced from each other is that in embodiments in which two or more of the portions of amorphous solid material 13 are of a different substance or composition, for example, comprising a different chemical composition, differing flavorants or other aerosol-generating materials, then the tendency of one portion of amorphous solid material 13 in one region being tainted, or otherwise affected by a portion of amorphous solid material in an adjacent region, is reduced. For example, if adjacent portions of amorphous solid material were in contact, there may be a tendency for components of one portion to diffuse into an adjacent portion. In embodiments in which certain regions of the article 10 are selectively activated in use, this may make the composition of the resulting aerosol more difficult to accurately control.
In the example of consumable article 10 shown, the support element 11 is made from card. The card may be from too to 300 gsm basis weight, and may advantageously be from 150 to 250 gsm basis weight, and may advantageously be from 180 to 210 gsm basis weight, and may advantageously be around i95 gsm basis weight. The card may be of between 150 to 550 pm in thickness, and advantageously maybe of between 250 to 450 pm in thickness, and advantageously may be between 300 to 400 pm in thickness, and advantageously maybe around 350 pm in thickness.
The material of the support element 11 is advantageously heat resistant up to around 300° Celsius, and advantageously is heat resistant up to around 250° Celsius, and advantageously is heat resistant up to around 200° Celsius, and advantageously is heat resistant up to around 150° Celsius, and advantageously is heat resistant up to around 90° Celsius. This can help avoid degradation of the material of the support element 11 when exposed to heat during use with a non-combustible aerosol provision device too (described below).
The material of the support element 11 is advantageously biodegradable to enable or enhance recyclability of the consumable article 10 after use. The support element 11 being made of paperboard or card advantageously enhances the biodegradability of the article 10. Advantageously, the material of the support element 11 is compliant with European biodegradability standard EN 13430. Advantageously the material of the support element 11 is compostable and capable of being aerobically disintegrated through composting and is compliant with European biodegradation standard EN 13432.
Any suitable material may be used for the construction of the support element 11, and is not necessarily limited to card, and may instead comprise paper, paperboard, cardboard, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy metal, or any combinations thereof.
The material of the support element 11 is advantageously resistant to oil or grease penetration. This may advantageously help to prevent components of the portions of amorphous solid material 13 from leaching into the material of the support element 11, which could make the article 10 less effective in use, if the desired components of the portions of amorphous solid material 13 had been partially dispersed out of the amorphous solid material 13. Such oil or great penetration resistance maybe provided by the material of the support element 11 comprising a laminar construction, in which one layer of the material comprises a fluid-impermeable layer. In one embodiment, at least one of the first and second layers 11 a, 11 b may comprise a laminar construction including a fluid-impermeable layer, and in an embodiment, both of the first and second layers 11 a, 11 b may comprise a laminar construction including a fluid-impermeable layer. Advantageously, fluid-impermeable layer(s) are disposed on the side of the respective first and second layer 11 a, 11 b that faces and contacts the portions of amorphous solid material 13. In an embodiment, the fluid impermeable layer(s) may comprise plastic or metallic material, such as aluminum. In an embodiment, the first and second layers 11 a, 11 b may comprise paperboard or card having a fluid-impermeable layer. The consumable article 10 may be between 20 mm to 40 mm wide at its widest part, and preferably may be around 30 mm wide at its widest part. The consumable article 10 may be between 35 mm to 55 mm long, and preferably may be around 45 mm long. Each of the regions of amorphous solid material may be a quadrilateral with side edges of between 5 mm to 20 mm in length, and may be square with sides of around 6 mm to 10 mm in length, and may be square with sides around 8 mm in length. FIGS. 5 and 6 show a non-combustible aerosol provision device 100 (hereafter “device” 100 for brevity) with which the article 10 of FIGS. 1 to 4 may be used as a non-combustible aerosol provision system. The device 100 comprises a housing 101 having an inlet 102 and an outlet 103. The inlet 102 is provided at a first end of the device 100 and the outlet 103 is formed in a mouthpiece 104 at a second end of the device 100 opposite the first end. The first end of the device includes a slot 105 into which a consumable article 10 can be inserted to be received and retained within the device 100 for use of the device 100. FIG. 6 shows a schematic view of components within the housing 101 of the device 100. FIG. 6 also shows a consumable article 10 received and retained within the device 100 in a position for use of the device 100. The device 100 comprises a heater 106 comprising a plurality of heating elements 106 a. Each of the heating elements 106 a is positioned to correspond to a location of a respective region 12 of amorphous solid material 13 of a consumable article 10 when a consumable article 10 is received and retained within the device too. In use, the device too is configured such that the heater 106 can controllably heat at least one of the plurality of portions of amorphous solid material 13 to produce an aerosol for inhalation. Each heating element 106 a may directly contact a respective portion of amorphous solid material 13, or may be disposed closely adjacent to but spaced from a respective portion of amorphous solid material 13, in order to heat the respective portion of amorphous solid material 13.
Each of the heating elements 106 a may provide thermal energy to a specific portion of amorphous solid material 13 to enable aerosolization of the respective portion of amorphous solid material 13, or to release one or more volatiles from the portion of amorphous solid material 13, to form or for entrainment within, an aerosol. During use of the device too, one or more of the heating elements 106 a may be activated so as to produce aerosol/release volatiles from one or more of the portion of amorphous solid material 13.
The device too comprises a power source 107 for supplying power to the heater 106.
The device too also comprises a controller 108 connected to the power source 107 and to the heater 106 which is operable to control operation of the heating elements 106 a.
A user interface 109 is provided on the housing 101 and is connected to the controller 108. A user is able to input operational commands to the device controller 108 to selectively control operation of the device too, via the user interface 109. The user command(s) may be received by the controller 108 via a wired or wireless interface, such that the device 100 may be operated via e.g. Bluetooth® or a LAN or via a smartphone or other such device. The user interface 109 may include one or more manually operable actuators, for example buttons or regions of a touch-sensitive screen, for manual operation of the device 100, and for the user to select the desired operation of the device 100.
In an example, the controller 108 is arranged to control the activation of specific heating elements 106 a of the heater 106 so as to produce an aerosol. Selective activation of the heating elements 106 a results in selective heating of portions of amorphous solid material 13 such that a personalized aerosol is produced. The user may therefore select the contributory materials to heat to produce an aerosol, thereby providing a personalized aerosol. “Personalized aerosol” is therefore used herein to mean user-selected or, at least in some way, tailored to the desires of the user.
An airflow passage 110 extends through the device too from the inlet 102 to the outlet 103 and is in fluid communication with the region within the housing 101 occupied by the consumable article 10 when the consumable article 10 is received and retained within the device too.
To use the non-combustible aerosol provision system 1 described herein, a user inserts a consumable article 10 into the slot 105 of the device too until the article 10 is fully received and retained within the device too. In the fully inserted position, the portions of amorphous solid material 13 lie against or closely adjacent to a respective heating element 106 a of the heater 106. The user then actuates the device too via the user interface 109 to provide operational commands to the controller 108 to effect activation of specific heating elements 106 a of the heater 106. The heating elements 106 a heat one or more of the regions of amorphous solid material 13 of the article 10 to produce an aerosol and to release one or more volatiles from the portion(s) of amorphous solid material 13 for entrainment within the aerosol. A user inhales on the mouthpiece 104 and ambient air is drawn into the airflow passage 110 through the inlet 102, through the airflow passage 110 and into the user's mouth to be inhaled through the outlet 103. The aerosol generated from the portion(s) of amorphous solid material 13 is entrained within the airflow to be inhaled by a user. In some embodiments, some or all of the portions amorphous solid material 13 may include one or more perforations 15, as illustrated in an exemplary second embodiment of consumable article 10 illustrated in FIG. 7 . In embodiments of non-combustible aerosol provision systems 1 in which the portions of amorphous solid material 13 are in contact, or closely disposed adjacent to, the heating elements 106 a, it may be possible for gas and/or vapor to be generated from the surface of the amorphous solid material 13 adjacent the respective heating element 106 a. This may create, or enlarge, a gap between the surface of the heating element 106 a and the respective portion of amorphous solid material 13. Such a gap may be detrimental to the efficiency of heating of the amorphous solid material 13 by the respective heating element 106 a. The perforations 15 may advantageously help to enable any gas and/or vapor generated between the surface of the heating element 106 a and the adjacent surface of the portion of amorphous solid material 13, to vent through the portion of amorphous solid material 13 away from the heating element 106 a and thereby prevent the portion of amorphous solid material 13 from being forced away from the heater element 106 a.
The perforations maybe of any appropriate size and number, and may comprise a single perforation, advantageously disposed substantially centrally on the portion(s) of amorphous solid material 13, or may comprise a plurality of perforations disposed in an array across the portion(s) of amorphous solid material 13, as illustrated in FIG. 7 .
The amorphous solid material 13 may be perforated by means of a dermoabrasion roller or any other suitable means, and may be perforated during manufacture of the amorphous solid material or during manufacture of the consumable article 10. In the embodiment of article 10 shown in FIGS. 1 to 4 , the apertures 14 extend all of the way through the support element. This may be advantageous for heating efficiency as the heat from the heating elements 106 a passes directly to the amorphous solid material 13, without other parts of the article 10 being significantly heated or absorbing heat energy. This configuration may be additionally advantageous since the material of the support element 11 is not significantly heated, or less material of the support element 11 is heated, in use. The can help reduce or avoid unwanted aerosol, scent or flavor being imparted by the material of the support element, for example avoiding detectable cardboard scent if the support material is made of cardboard. However, the scope of the invention is not intended to be limited to this configuration of article 10 in which apertures 14 extend entirely through the support element 11. An alternative configuration of consumable article 10 of a third embodiment is illustrated in the cross-sectional view of FIG. 8 . The article 10 of FIG. 8 appears similar in front view to that of the first embodiment shown in FIG. 2 , and includes six regions 12 of substantially uniform size and shape, arranged in two rows of three (although as mentioned with reference to the embodiment of article in FIGS. 1 to 4 , any arrangement/number/size of regions maybe provided within the scope of the invention).
A difference with the article 10 of FIG. 8 is that the support element 11 is a one ply component, comprising a single layer 11 c. The six regions 12 of amorphous solid material 13 are provided within cavities in the form of recesses 14 c which are formed in the thickness of the single layer 11 c. The recesses 14 c extend partially but not entirely through the thickness of the single layer 11 c. The recesses 14 c may be formed by any suitable method, for example by laser or mechanical cutting, milling, reaming, or by compressing selected areas of the layer 11 c that are to be the regions 12 of amorphous solid material. The amorphous solid material maybe provided in the recesses 14 c by a sheet of solid material being cut to appropriately sized sections and the sections placed within the recesses 14 c, or maybe provided in the recesses 14 c in liquid form, for example by being pipetted into the recesses 14 c, and subsequently solidified within the recesses 14 c. The solidifying step may comprise applying a setting agent to the liquid material within the recesses 14 c.
Use of the article 10 of the third embodiment in a non-combustible aerosol provision system 1 would be the same as that described above with reference to the first embodiment of consumable article 10. The heating elements 106 a heat the selected areas of the single layer 11 c corresponding to the recesses 14 c, and the heat transferred through the material of the single layer 11 c to the respective regions of amorphous solid material 13. Although the heating elements 106 a have to transfer heat through the material of the single layer 11 c instead of directly heating the amorphous solid material 13, the single layer 11 c is thinner in the regions of the recesses 14 c, and so there is less resistance to the transfer of heat through the thickness of the single layer 11 c than would be the case if heat had to transfer through the entire thickness of the single layer 11 c. Accordingly, the recesses 14 c of the third embodiment of consumable article 10 help avoid reduced efficiency of heat transfer to the amorphous solid material. A consumable article 10 of a fourth embodiment is shown in schematic cross-section in FIG. 9 , and appears similar in front view to that of the first embodiment shown in FIG. 2 , and includes six regions 12 of substantially uniform size and shape, arranged in two rows of three (although as mentioned with reference to the embodiment of article in FIGS. 1 to 4 , any arrangement/number/size of regions may be provided within the scope of the invention).
The support element 11 of the article 10 of FIG. 9 comprises a two ply component, comprising a first layer 11 a and a second layer nd. The first layer 11 a includes a plurality of apertures 14 a extending entirely through the thickness of the first layer 11 a.
A difference with the consumable article 10 of the fourth embodiment is that the second layer nd does not include apertures extending through its thickness. Instead, the second layer nd comprises a carrier or substrate upon which discrete regions 12 of amorphous solid material 13 are formed. The first and second layers 11 a, nd are bonded together to form the two-ply support element 11 and the portions of amorphous solid material 13 are located within a respective aperture 14 a in the first layer 11 a. The layers 11 a, nd may be bonded by any suitable bonding agent, such as PVA or other adhesive, or may be bonded by non-adhesive means, such as welding or other method of mechanical securing.
The amorphous solid material 13 may be provided on the substrate second layer nd before the first and second layers 11 a, nd are bonded together. In such an embodiment, the amorphous solid material 13 may be sandwiched between the substrate second layer nd and the first layer 11 a. Alternatively, the amorphous solid material 13 may be provided within the apertures 14 a after the first and second layers 11 a, nd are bonded together. In the latter case, the amorphous solid material 13 may be provided by a sheet of solid material being cut to appropriately sized sections and the sections placed within the apertures 14 a, or maybe provided in the apertures 14 a in liquid form and subsequently solidified within the apertures 14 a. The solidifying step may comprise applying a setting agent to the liquid material within the apertures 14 a.
Use of the article 10 of the fourth embodiment in a non-combustible aerosol provision system 1 would be the same as that described above with reference to the first embodiment of consumable article 10. The heating elements 106 a heat the selected areas of the second substrate layer nd corresponding to the regions 12 of solid amorphous material 13, and the heat transferred through the material of the second substrate layer nd to the respective regions of amorphous solid material 13. Although the heating elements 106 a have to transfer heat through the material of the second substrate layer nd instead of directly heating the amorphous solid material 13, second layer nd is thinner than the total thickness of the support element 11 and so there is less resistance to the transfer of heat through the thickness of the single second layer nd than would be the case if heat had to transfer through the entire thickness of the support element. The second substrate layer nd may also be formed of a material having good thermal conductivity, for example, a metal, in order to increase heating efficiency and heat transfer from the heating elements 106 a to the amorphous solid material 13. In some embodiments, the second, substrate or carrier layer nd may comprise metal foil, such as aluminum foil.
A consumable article 10 of a fifth embodiment is shown in schematic cross-section in FIG. 10 , and appears similar in front view to that of the first embodiment shown in FIG. 2 , and includes six regions 12 of substantially uniform size and shape, arranged in two rows of three (although as mentioned with reference to the embodiment of article in FIGS. 1 to 4 , any arrangement/number/size of regions maybe provided within the scope of the invention). The consumable article 10 of the fifth embodiment is similar to that of the fourth embodiment, and comprises a support 11 having a first layer 11 a having a plurality of apertures 14 a extending entirely through the thickness of the first layer 11 a, and a second layer lid comprising a carrier or substrate upon which discrete regions 12 of amorphous solid material 13 are formed. However, the article 10 of the fifth embodiment further includes a third support layer lie, which has a plurality of apertures 14 e extending entirely through the thickness of the third layer lie. As such, the third layer lie of the fifth embodiment is similar in configuration to the second layer 11 b of the first embodiment described above. The first, second and third layers 11 a, nd, lie are bonded together to form the support element 11 and the portions of amorphous solid material 13 are located within a respective aperture 14 a in the first layer 11 a. The layers 11 a, nd, lie may be bonded by any suitable bonding agent, such as PVA or other adhesive, or may be bonded by non-adhesive means, such as welding or other method of mechanical securing. As with the article io of the fourth embodiment, the amorphous solid material 13 may be provided on the substrate second layer nd before the first, second and third layers 11 a, nd, lie are bonded together. In such an embodiment, the amorphous solid material 13 may be sandwiched between the substrate second layer nd and the first layer 11 a. Alternatively, the amorphous solid material 13 may be provided within the apertures 14 a after the first, second and third layers 11 a, nd, lie are bonded together, in the same manner as described previously.
Use of the article 10 of the fifth embodiment in a non-combustible aerosol provision system 1 would be the same as that described above with reference to the fourth embodiment of consumable article 10. As the third layer lie comprises apertures 14 e in the regions 12 of the solid amorphous material 13, the heat from the heating elements 106 a heats the selected areas of the second substrate layer nd corresponding to the regions 12 of solid amorphous material 13, just as with the article 10 of the fourth embodiment. The heat is transferred through the material of the second substrate layer nd to the respective regions of amorphous solid material 13. Again, advantageously, the second layer nd maybe thinner than the total thickness of the support element 11 and so there is less resistance to the transfer of heat through the thickness of the single second layer nd than would be the case if heat had to transfer through the entire thickness of the support element 11. The second substrate layer nd may also be formed of a material having good thermal conductivity, for example, a metal, in order to increase heating efficiency and heat transfer from the heating elements 106 a to the amorphous solid material 13. In some embodiments, the second, substrate or carrier layer lid may comprise metal foil, such as aluminum foil.
A consumable article 10 of a sixth embodiment is shown in schematic cross-section in FIG. 11 , and appears similar in front view to that of the first embodiment shown in FIG. 2 , and includes six regions 12 of substantially uniform size and shape, arranged in two rows of three (although as mentioned with reference to the embodiment of article in FIGS. 1 to 4 , any arrangement/number/size of regions may be provided within the scope of the invention).
The consumable article 10 of the sixth embodiment is similar to that of the fourth embodiment, and comprises a support 11 having a first layer 11 a having a plurality of apertures 14 a extending entirely through the thickness of the first layer 11 a, and a second layer lid comprising a carrier or substrate upon which discrete regions 12 of amorphous solid material 13 are formed. However, a difference with the article 10 of the sixth embodiment is that the substrate layer nd comprises a multi-ply material, including a primary substrate layer lid′ and a secondary substrate layer nd″. The first and second layers 11 a, nd are bonded together as described above to form the support element 11 and the portions of amorphous solid material 13 are located within a respective aperture 14 a in the first layer 11 a. The amorphous solid material 13 is disposed on the primary substrate layer lid′. The substrate layer nd may comprise a two-layer material such as foil-backed card, and the primary substrate layer lid′ may comprise a metallic foil layer, such as an aluminum layer, and the secondary substrate layer nd″ may comprise a layer of other material, such as card or paperboard. This may provide increased structural strength to the article 10.
Use of the article 10 of the sixth embodiment in a non-combustible aerosol provision system 1 would be the same as that described above with reference to the fourth embodiment of consumable article 10. Heat from the heating elements 106 a heats the selected areas of the second substrate layer nd corresponding to the regions 12 of solid amorphous material 13, just as with the article 10 of the fourth embodiment. The heat is transferred through the material of the second substrate layer nd to the respective regions of amorphous solid material 13. Again, advantageously, the second layer nd maybe thinner than the total thickness of the support element 11 overall and so there is less resistance to the transfer of heat through the thickness of the single second layer nd than would be the case if heat had to transfer through the entire thickness of the support element 11. In embodiments in which the second substrate layer nd includes a layer formed of a material having good thermal conductivity, for example, a metal, heating efficiency and heat transfer from the heating elements 106 a to the amorphous solid material 13 may be increased. Also, in a system which may employ inductive heating (described in more detail below), the primary substrate layer lid′ may be formed of a material suitable as a susceptor such that the regions 12 of amorphous solid material 13 may be directly heating by inductively heating the respective regions 12 of the primary substrate layer lid′. However, in a variant of the sixth embodiment, the secondary substrate layer nd″ may comprise a metallic layer, and the primary substrate layer lid′ may comprise another material, for example, card or paperboard.
The consumable articles 10 of the second to sixth embodiments comprises a plurality of discrete portions of amorphous solid material 13 spaced from each other, with the advantages described above with respect to the article 10 of the first embodiment. A consumable article 10 of a seventh embodiment is shown in exploded perspective view in FIG. 12 , and appears similar in front view to that of the first embodiment shown in FIG. 2 , and includes six regions 12 of substantially uniform size and shape, arranged in two rows of three (although as mentioned with reference to the embodiment of article in FIGS. 1 to 4 , any arrangement/number/size of regions may be provided within the scope of the invention).
The support element 11 of the article 10 of FIG. 11 is similar to the article 10 of the first embodiment shown in FIGS. 1 to 4 , and like features retain the same reference numerals. A difference with the consumable article 10 of the seventh embodiment is that the amorphous solid material 13 is provided as a single sheet that is sandwiched between the first and second layers 11 a, 11 b. This may enable a simpler and more cost-effective method of article manufacture as only one single portion of amorphous solid material is required per consumable article 10. The single sheet of amorphous solid material 13 may be of a uniform composition, or may comprise different compositions in different regions of the sheet such that different composition of aerosol may be produced by selective activation of the respective heating elements 106 a.
The sheet of amorphous solid material 13 may optionally include an array of dividing holes 16 demarcating discrete regions 12 of the amorphous solid material. Such dividing holes are illustrated in FIG. 11 . These dividing holes may serve to reduce heat transfer by conduction through the amorphous solid material 13 from one region 12 to an adjacent region. This may be advantageous, for example, when one region 12 of the amorphous solid material 13 is selectively heating by one heating element 106 a, but an adjacent region 12 of the amorphous solid material 13 is not intended to be heated. This may be beneficial to accurately control the composition of the personalized aerosol being produced by the device 100 by avoiding aerosol or volatile generation from regions 12 not intended to be activated.
The dividing holes 16 may additionally, or alternatively, help reduce unwanted transfer of components of one region 12 of the amorphous solid material 13 into adjacent regions 12 of the amorphous solid material 13, in an embodiment where different regions 12 of the amorphous solid material 13 comprise different compositions. The different compositions may tend to diffuse to adjacent regions 12 due to a concentration gradient within the amorphous solid material 13, and the dividing holes 16 may prevent or at least reduce the ability for such diffusion to occur.
Use of the article 10 of the seventh embodiment in a non-combustible aerosol provision system 1 would be the same as that described above with reference to the first embodiment of consumable article 10 and so will not be repeated. It is intended within the scope of the invention that embodiments of consumable article
10 are provided which may comprise some discrete separate regions of amorphous solid material of a uniform composition, and at least one region of amorphous solid material which comprises different compositions in different areas of the same body of amorphous solid material. Such regions maybe of similar or different size, shape and area.
The embodiments of consumable article 10 shown and described comprise an enlarged end region 17 at one end of the support element 11. The enlarged end region 17 is shown wider than the remaining portion of the support element 11. Such enlarged end region 17 may facilitate handling by a consumer, by providing a grip region of greater area to make insertion into, and removal from, a device too easier, particularly for users with limited dexterity. The enlarged end region 17 may also serve to ensure the correct fully-inserted position of the article 10 within the device too. For example, the article 10 may be configured such that the correct fully-inserted position is reached when the enlarged end region 17 contacts the edges of the slot 105 or other portion of the housing 101 and cannot be inserted any further into the device too.
A method of manufacturing the consumable article 10 of the first embodiment may be understood with reference to the flow chart of FIG. 13 . The method comprises providing first and second layers 11 a, 11 b of sheet material with apertures 14 a, 14 b respectively in each layer 11 a, 11 b of sheet material (Si), providing discrete portions of amorphous solid material, at least one of which comprises an aerosol generating material (S2), locating the discrete portions of amorphous solid material over the apertures I4 a/i4 b on one of the layers of sheet material na/iib (S3), and bonding the two layers 11 a, 11 b of sheet material together to sandwich the discrete portions of amorphous solid material between the two layers of sheet material 11 a, 11 b (S4). The step S4 of bonding the two layers 11 a, 11 b together may include providing PVA adhesive to at least one of the layers 11 a, 11 b, which may be my means of a roller or other suitable adhesive applicator. The step Si of providing first and second layers 11 a, 11 b of sheet material with apertures 14 a, 14 b may comprise laser cutting the first and second layers from a blank of sheet material, or stamp or press cutting.
The consumable article 10 of the various embodiments described herein may optionally comprise an identifying element 18 (see FIG. 1 ). Such identifying element may comprise, for example, a bar code, QR code, RFID tag or other optically, electrically or wirelessly detectable and/or readable identifying element.
The device 100 may include a sensor 111 configured to detect, read or otherwise interact with the identifying element 18. Such sensor 111 is connected to the controller 108. In use, the identifying element 18 may include information about the article 10 and the composition of the amorphous solid material 13, including the aerosol generating material it comprises.
In the non-combustible aerosol provision system 1, different consumable articles 10 may be provided that include different compositions of amorphous solid material 13, for example, different ingredients, flavorants, volatiles, and aerosol generating compounds. It will be appreciated that in this case, applying the same heating patterns to different consumable articles 10 may result in different aerosols mixes being generated, not all of which may be desirable, and so optionally the composition of the current consumable article 10 should be notified to the controller 108 which controls heating so that an appropriate mix can be generated.
Hence in an embodiment of the present invention, the composition of portions of a given consumable article 10 can be obtained via the identifying element 18 and sensor 111. Once identified, the composition of the portions on the consumable article 10 can be obtained from either local or remote storage, together with any other configuration information regarding for example preset mixes, vaporization temperatures for different portion materials, and/or any limits or correlations between portions (for example to avoid undesirable mixes), and the like. The embodiments of consumable articles 10 illustrated and described herein comprise flat planar elements. This may be advantageous for simplicity and therefore ease and cost of manufacture, and also space efficiency of packaging. However, the invention is not intended to be limited to such configuration. For example, the article 10 maybe “V” or “U” shaped in cross-section, or any other appropriate configuration, and the slot 105 in the device correspondingly shaped to receive the article 10. In such alternative embodiments, it will be appreciated that the heater 106 within the device 100 may advantageously be appropriately configured to align with the regions 12 of amorphous solid material 13 of the associated consumable article 10.
As used herein, the term “cavity” is intended to encompass an aperture which extends entirely through the thickness of an element, and also a recess comprising a cut-out, depression or other formation extending partially through the thickness of an element. In the embodiments of article 10 described herein, the aerosol generating material is described as being within the at least one cavity. This is intended to include the aerosol generating material being off-set with respect to a thickness or plane of the support element or portion thereof but aligned with the at least one cavity so as to be accessible therethrough, and also the aerosol generating material being disposed within the cavity within the thickness or plane of the support element or portion thereof.
The heater 106 in the described examples maybe an electrically resistive heater 106. However, in other examples, the heater 106 may be a chemically activated heater which may or may not operate via exothermic reactions or the like. The heater 106 may be part of an inductive heating system, wherein the heater 106 is the source of energy for inductive heating, such as a coil of copper wire, and the support element 11, including one or more of the layers 11 a, 11 b, 11 c, 11 d thereof, or other component within the device too may be or may contain a susceptor or the like. The susceptor may for example be a metallic sheet, for example a sheet of aluminum foil or the like. In an example, the heating elements 106 a are not all the same type of heating element. In an example, at least one heating element 106 a of the heater 106 is an electrically resistive heater, another heating element 106 is optionally a chemically activated heater and another heating element 106 a is optionally an inductive heater. The heater may comprise one or more electrically resistive heaters, including for example one or more ni chrome resistive heater(s) and/or one or more ceramic heater(s). The heater may comprise one or more induction heaters which includes an arrangement comprising one or more susceptors which may form a chamber into which an article comprising aerosolizable material is inserted or otherwise located in use. Alternatively or in addition, one or more susceptors may be provided in the aerosolizable material. Other heating arrangements may also be used.
The power source 107 may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the heater 106 to supply electrical power when required and under control of the controller 108.
In an example, a plurality of regions 12 of amorphous solid material 13, and a plurality of heating elements 106 a, may be different in number. For example, one heating element 106 a may heat two regions 12 of amorphous solid material 13 if it is desired for these to always be heated together. Conversely, two heating elements 106 a may be used for respective regions 12 of amorphous solid material 13 in one instance, but may be used in concert to heat a larger region 12 of amorphous solid material 13 (for example for a major component of the aerosol, or one that is consumed more frequently) in another instance. Alternatively or in addition, the support element may be physically moveable with respect to the heater 106 to newly position one or more different regions 12 of amorphous solid material 13 over a respective heater element 106 a, thereby enabling a new mixing palette. In an example, the plurality of regions 12 of amorphous solid material 13 may be a sample or reservoir of aerosolizable substance, which may include nicotine and nicotine-containing substances.
In use, heating elements 106 a may be activated at the same time or maybe operated with a delay between operation. This may be used to enable particular notes of an aerosol to be more or less prevalent in the overall aerosol or smoking session. In an example, a particular heating element 106 a may heat a particular region 12 of amorphous solid material 13 e.g. a tobacco portion, at a first time to produce a tobacco aerosol for inhalation. This may be shortly followed by a different heating element 106 a heating a menthol region 12 of amorphous solid material 13 at a second time to follow the tobacco aerosol with a menthol aerosol with which the user desires to conclude the smoking session. Varying heating profiles may be supplied to a plurality of regions 12 of amorphous solid material 13 to provide a personalized aerosol. Complex combinations of profiles may be utilized to produce a highly specific combination of blends and release time so that the aerosol is highly personalizable.
In an example, a first heating element 106 a heats a first region 12 of amorphous solid material 13 for a first amount of time and a second heating element 106 a heats a second region 12 of amorphous solid material 13 for a second amount of time, wherein the first amount of time and the second amount of time are different. This enables greater personalization of aerosol. This also enables production of aerosol with different notes during the smoking session.
In an example, a first heating element 106 a heats a first region 12 of amorphous solid material 13 at a first power level and a second heating element 106 a heats a second region 12 of amorphous solid material 13 at a second power level, wherein the first power level and the second power level are different power levels. This further enables greater personalization of a produced aerosol. As the aerosol released maybe related to the power at which the heater 106 a operates, flavors can be released at different times in the session which, as above, leads to a level of control over the production of different notes within the smoking session.
In examples, the amorphous solid material 13 has a thickness of imm. In alternative embodiments the amorphous solid sheet material may have a thickness of between 0.2 mm to 2 mm, or between 0.4 mm to 1.8 mm, or between 0.8 mm to 1.2 mm. However, the amorphous solid material may have any suitable thickness as described herein.
In embodiment in which the support element comprises aluminum foil, the aluminum foil may comprise a layer having a thickness of about 6 pm. However, in alternative arrangements, the aluminum foil can be other thicknesses, for instance between 4 pm and 16 pm in thickness.
The amorphous solid material 13 may comprise an aerosol generating material comprising an aerosolizable material, also called an aerosol forming material. The aerosolizable material may be present on or in a support or carrier, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, such as aluminum, or a metal alloy. In some embodiments, the support or carrier comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.
An aerosol modifying agent is a substance that is able to modify aerosol in use. The agent may modify aerosol in such a way as to create a physiological or sensory effect on the human body. Example aerosol modifying agents are flavorants and sensates. A sensate creates an organoleptic sensation that can be perceived through the senses, such as a cool or sour sensation.
An aerosol forming material may promote the generation of an aerosol by promoting an initial vaporization and/or the condensation of a gas to an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol forming material may improve the delivery of flavor from the aerosol generating material. In general, any suitable aerosol forming material or agents may be included in the aerosol generating material of the invention, including those described herein. Other suitable aerosol forming materials include, but are not limited to: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of from 10 to 20% by weight of the composition, for example 13 to 16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, if present, maybe present in an amount of from 0.1 to 0.3% by weight of the composition.
In some embodiments, the aerosol forming material comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Embodiments of consumable articles 10 described herein are intended for use with a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. Embodiments of a non-combustible aerosol provision system described herein comprise a non-combustible aerosol provision device and an article for use with such a device.
Aerosolizable material, which also may be referred to herein as aerosol generating material, is material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosolizable material may or may not contain nicotine and/or flavorants.
Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavorants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50 wt %, 6owt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or ioowt % of amorphous solid.
The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
In some embodiments, the aerosol-former material or the amorphous solid comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
In one embodiment, the non-combustible aerosol provision device includes a heater capable of interacting with the aerosol generating material is able material so as to release one or more volatiles from the aerosolizable material to form an aerosol. In one embodiment, the aerosol generating component is capable of generating an aerosol from the aerosolizable material without heating. For example, the aerosol generating component may be capable of generating an aerosol from the aerosolizable material without applying heat thereto, for example via one or more of vibrational, mechanical, pressurization or electrostatic means. In one embodiment, the aerosolizable material may comprise an active material, an aerosol forming material and optionally one or more functional materials. The active material may comprise nicotine (optionally contained in tobacco or a tobacco derivative) or one or more other non-olfactory physiologically active materials. A non-olfactory physiologically active material is a material which is included in the aerosolizable material in order to achieve a physiological response other than olfactory perception.
In some cases, the amorphous solid sheet material may have a mass per unit area of 30-120 g/m². In some embodiments, the amorphous solid sheet material may have an area density of from about 30 to 70 g/m², or about 40 to 60 g/m². In some embodiments, the amorphous solid may have an area density of from about 80 to 120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m².
In some examples, the amorphous solid in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.
In some examples, such as where the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. The support element may be any suitable material which can be used to support an amorphous solid. In some cases, the support element may be formed from materials selected from metal, for example metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the support element maybe a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the support element may also function as a flavor carrier, for example, the support element may be impregnated with a flavorant or with tobacco extract.
In one case, the surface of the support element that abuts the amorphous solid may be porous. For example, in some cases, the support element comprises paper. A porous support element maybe particularly suitable in making a strong bond with the amorphous solid material. The amorphous solid maybe formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed may partially impregnate the porous support element so that when the gel sets and forms cross-links, the support element is partially bound into the gel. In alternative embodiments however, the support element may comprise a non-porous material as described above.
Additionally, surface roughness may contribute to the strength of bond between layers of the support element and/or the amorphous solid material. Paper roughness may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the “Bekk smoothness”.) In one particular case, the support element may comprise a paper-backed foil; the paper layer may abut the amorphous solid and the properties discussed in the previous paragraphs are afforded by this abutment. Alternatively, the foil layer may abut the amorphous solid. The foil backing is substantially impermeable, and may also serve to conduct heat to the amorphous solid. The foil may also prevent water provided in the amorphous solid to be absorbed into the paper which could weaken its structural integrity. In another case, a paper and greaseproof paper laminate has also been found to be particularly useful for the present invention. The paper layer abuts the amorphous solid and the tacky amorphous solid does not stick readily to the greaseproof paper carrier backing.
In some cases, one or more of the surfaces of the support element, other than the surface other than the layer attached to the first surface of the amorphous solid, maybe treated to prevent adhesion of the tacky amorphous solid once the amorphous solid has set and dried. For example, the surfaces may be treated with PTFE (polytetrafluoroethylene) and/or other non-stick materials.
In some cases, the amorphous solid may have a thickness of about 0.005 mm to about 1.0 mm Suitably, the thickness may be in the range of about 0.05 mm to about 0.2 mm, and may be around 0.09 mm. In some embodiments, the thickness may be around
0.06 mm to around 0.09 mm, and may be around 0.077 mm. In some embodiments, the thickness may be in the range of around 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
The thickness stipulated herein is a mean thickness for the material. In some cases, the amorphous solid thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%. In some cases, the amorphous solid may comprise i-6owt % of a gelling agent wherein these weights are calculated on a dry weight basis.
Suitably, the amorphous solid may comprise from about iwt %, 5 wt %, iowt %, I5 wt %, 20 wt % or 25 wt % to about 6owt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, 30 wt % or 27 wt % of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise i-50 wt %, 5-40 wt %, io-30 wt % or i5-27 wt % of a gelling agent.
In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin. In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from io-30 wt % of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin. The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof. In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum. In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar. In some embodiments the amorphous solid may include gelling agent comprising carrageenan. The aerosol-generating material or the amorphous solid may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may be an alpha-keto acid.
In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.
Suitably the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some embodiments, the acid is levulinic acid.
In certain embodiments, the aerosol-generating material or the amorphous solid comprises a gelling agent comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active substance and an acid.
Suitably, the amorphous solid may comprise from about 5 wt %, iowt %, I5 wt %, or 20 wt % to about 8owt %, 70 wt %, 6owt %, 55 wt %, 50 wt %, 45 wt % 40 wt %, or 35 wt % of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise 5-6owt %, io-50 wt % or 20-40 wt % of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol. The inventors have established that if the content of the plasticizer is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. The inventors have established that if the plasticizer content is too low, the amorphous solid may be brittle and easily broken. The plasticizer content specified herein provides an amorphous solid flexibility which allows the amorphous solid sheet to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles.
In some cases, the amorphous solid additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. For example, the amorphous solid may additionally comprise powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the amorphous solid may comprise from about iwt %, 5 wt %, iowt %, I5 wt %, 20 wt % or 25 wt % to about 70 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) of active substance. In some cases, the amorphous solid may comprise from about iwt %, 5 wt %, iowt %, I5 wt %, 20 wt % or 25 wt % to about 70 wt %, 6owt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) of a tobacco material and/or nicotine.
In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-6owt % (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5 wt %, iowt %, I5 wt %, 20 wt % or 25 wt % to about 55 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 5-6owt %, io-55 wt % or 25-55 wt % of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises iwt % i.5 wt %, 2 wt % or 2.5 wt % to about 6 wt %, 5 wt %, 4-5 wt % or 4 wt % (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract. In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about iwt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, i5 wt %, iowt % or 5 wt % (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20 wt % or 2-5 wt % of nicotine.
In some cases, the amorphous solid may comprise a flavor. Suitably, the amorphous solid may comprise up to about 6owt %, 50 wt %, 40 wt %, 30 wt %, 20 wt %, iowt % or 5 wt % of a flavor. In some cases, the amorphous solid may comprise at least about 0-5 wt %, iwt %, 2 wt %, 5 wt % iowt %, 20 wt % or 30 wt % of a flavor (all calculated on a dry weight basis). For example, the amorphous solid may comprise o.i-6owt %, 1-6owt %, 5-6owt %, io-6owt %, 20-50 wt % or 30-40 wt % of a flavor. In some cases, the flavor (if present) comprises, consists essentially of or consists of menthol. In some cases, the amorphous solid does not comprise a flavor.
In some cases, the total content of active substance and flavor may be at least about o.iwt %, iwt %, 5 wt %, iowt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and flavor may be less than about 8owt %, 70 wt %, 6owt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).
In some embodiments, the amorphous solid may comprise a colorant. The addition of a colorant may alter the visual appearance of the amorphous solid. The presence of colorant in the amorphous solid may enhance the visual appearance of the amorphous solid and the aerosol-generating material. By adding a colorant to the amorphous solid, the amorphous solid may be color-matched to other components of the aerosol generating material or to other components of an article comprising the amorphous solid.
A variety of colorants may be used depending on the desired color of the amorphous solid. The color of amorphous solid may be, for example, white, green, red, purple, blue, brown or black. Other colors are also envisaged. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants and pharmaceutical-grade colorants may be used. In certain embodiments, the colorant is caramel, which may confer the amorphous solid with a brown appearance. In such embodiments, the color of the amorphous solid maybe similar to the color of other components (such as tobacco material) in an aerosol-generating material comprising the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid renders it visually indistinguishable from other components in the aerosol-generating material.
The colorant maybe incorporated during the formation of the amorphous solid (e.g. when forming a slurry comprising the materials that form the amorphous solid) or it may be applied to the amorphous solid after its formation (e.g. by spraying it onto the amorphous solid).
In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about i5 wt %, i2 wt % or 10 wt % of water calculated on a wet weight basis (WWB). In some cases, the hydrogel may comprise at least about iwt %, 2 wt % or at least about 5 wt % of water (WWB). The amorphous solid comprises from about iwt % to about i5 wt % water, or from about 5 wt % to about i5 wt % calculated on a wet weight basis. Suitably, the water content of the amorphous solid maybe from about 5 wt %, 7 wt % or 9 wt % to about I5 wt %, I3 wt % or iiwt % (WWB), most suitably about iowt %.
The amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at o.i-50 wt %. However, the inventors have established that the inclusion of a solvent in which the flavor is soluble may reduce the gel stability and the flavor may crystallize out of the gel. As such, in some cases, the gel does not include a solvent in which the flavor is soluble.
In some embodiments, the amorphous solid comprises less than 6owt % of a filler, such as from iwt % to 6owt %, or 5 wt % to 50 wt %, or 5 wt % to 30 wt %, or iowt % to 20 wt %. In other embodiments, the amorphous solid comprises less than 20 wt %, suitably less than iowt % or less than 5 wt % of a filler. In some cases, the amorphous solid comprises less than iwt % of a filler, and in some cases, comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In some cases, the amorphous solid comprises less than iwt % of a filler, and in some cases, comprises no filler. In particular, in some cases, the amorphous solid comprises no calcium carbonate such as chalk. In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, an aerosol generating agent, water, and optionally a flavor and/or an active substance (such as tobacco material and/or a nicotine source).
A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.
Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating. An object that is capable of being inductively heated is known as a susceptor.
Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.
When an object is both electrically-conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating. In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower. The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn though an article or device in use.
As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.
In some embodiments, the substance to be delivered comprises an active substance.
The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, thein, vitamins such as B6 or Bi2 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin Bi2. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint maybe chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
In some embodiments, the aerosol-generating material or the amorphous solid comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).
The aerosol-generating material or the amorphous solid may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol). The aerosol-generating material or the amorphous solid may comprise cannabidiol (CBD).
The aerosol-generating material or the amorphous solid may comprise nicotine and cannabidiol (CBD).
The aerosol-generating material or the amorphous solid may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).
In some embodiments, the substance to be delivered comprises a flavor.
As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.
In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. An article for use in a non-combustible aerosol provision system, the article comprising:

a support element comprising at least one cavity; and

an aerosol generating material disposed within the at least one cavity, wherein

the aerosol generating material comprises an amorphous solid material.

2. An article according to claim 1 wherein the at least one cavity comprises an aperture extending entirely through the thickness of the support element.

3. An article according to claim 1 wherein the at least one cavity comprises a recess extending partially through the thickness of the support element.

4. An article according to claim 1 wherein the support element comprises at least two layers of sheet material.

5. An article according to claim 4 wherein the aerosol generating material is sandwiched between the at least two layers of sheet material.

6. An article according to claim 4, wherein the sheet material has a weight of between 180 GSM and 210 GSM.

7. An article according to claim 4, wherein the sheet material has a thickness of between 150 μm and 400 μm.

8. An article according to claim 1, wherein the thickness of the support element is between 300 μm and 800 μm

9. An article according to claim 1 wherein the aerosol generating material comprises an amorphous solid material having regions of different composition within the same body of material.

10. An article according to claim 1 comprising a plurality of discrete, spaced-apart cavities comprising aerosol generating material.

11. An article according to claim 1 wherein the aerosol generating material is perforated.

12. An article according to claim 1 wherein the aerosol generating material is provided on a substrate.

13. An article according to claim 12 wherein the substrate comprises a metallic foil.

14. An article according to claim 1 wherein the material of the support element comprises at least one of paper, cardboard, or foil.

15. An article according to claim 1, wherein the material of the support element is a biodegradable material.

16. An article according to claim 1, wherein the article comprises an identifying element.

17. An article according to claim 16, wherein the identifying element is a barcode, a QR code, or an RFID chip.

18. An article according to claim 1 7, wherein the amorphous solid material comprises a gelling agent.

19. An article according to claim 18, wherein the gelling agent is alginate, pectin and/or carrageenan.

20. An article according to of claim 1, wherein the amorphous solid material is a dried hydrogel.

21. An article according to of claim 1, wherein the amorphous solid material further comprises an aerosol generating agent, an active substance and/or a flavorant.

22. An article according to claim 21, wherein the aerosol generating agent is glycerol.

23. An article according to claim 21, wherein the active substance is nicotine.

24. An article according to claim 1, wherein the amorphous solid material has a thickness of around 0.015 mm and 0.5 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm.

25. An article according to claim 1 wherein the aerosol generating material comprises a plurality of holes arranged to demarcate discrete regions of the aerosol generating material.

26. An article according to claim 1, wherein the support element comprises a substantially planar body.

27. An article according to claim 1, wherein the at least one cavity extends at least partially through a thickness of the support element.

28. An article according to claim 1, wherein the article comprises a plurality of distinct cavities comprising amorphous solid material, wherein each cavity comprises a different amorphous solid material.

29. An aerosol generating system comprising an aerosol generating device and an article according to claim 1.

30. An aerosol generating system according to claim 29, comprising an article according to claim 28, and wherein the aerosol generating device is configured to provide a customizable heating profile such that amorphous solid material in the distinct cavities of the article may be heated independently.

31. A method of manufacturing an article for use in a non-combustible aerosol provision system, the method comprising:

providing a support element including at least one cavity in the support element; and

providing an aerosol generating material comprising an amorphous solid material within the at least one cavity.

32. A The method of claim 31 comprising providing at least two layers of sheet material to form the support element, at least one of the layers including at least one cavity, and sandwiching the aerosol generating material between the at least two layers of sheet material.

33. A The method of claim 31, comprising providing the aerosol generating material on a substrate, wherein the substrate may comprise a metallic foil.