WO2023118204A2

WO2023118204A2 - A method of manufacturing a product comprising aerosol generating material

Info

Publication number: WO2023118204A2
Application number: PCT/EP2022/087082
Authority: WO
Inventors: Richard Hepworth; Robert Press; Joanna SOFFE
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29
Also published as: WO2023118204A3

Abstract

A method of manufacture of an aerosol generating material for use in aerosol provision devices is disclosed. The method comprises providing a surface (2S), applying an aerosol generating material slurry (142) to the surface (2S), allowing or causing the aerosol generating material slurry (142) to at least partially set, and separating the at least partially set aerosol generating material (18) from the surface (2S).

Description

A METHOD OF MANUFACTURING A PRODUCT COMPRISING AEROSOL GENERATING MATERIAL

Technical Field

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

Background

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

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

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

Summary According to a first aspect of the present disclosure there is provided a method of manufacture of an aerosol generating material for use in aerosol provision devices, in which the method comprises providing a surface, applying an aerosol generating material slurry to the surface, allowing or causing the aerosol generating material slurry to at least partially set, and separating the at least partially set aerosol generating material from the surface.

According to a second aspect of the present disclosure there is provided a method of manufacture of a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision device, in which the product comprises a cover material and an aerosol generating material, in which the method comprises providing a cover material, providing an aerosol generating material, and applying the aerosol generating material to the cover material.

According to a third aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision device, in which the product comprises a cover material and an aerosol generating material film, and the aerosol generating material is applied to the cover material.

According to a fourth aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision system, in which the consumable is a portion of a product according to the third aspect of the present disclosure which has been shaped and dimensioned to a desired configuration.

According to a fifth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable according to the fourth aspect of the present disclosure in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the support.

According to a sixth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable according to the fourth aspect of the present disclosure. According to a seventh aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the fourth aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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

Drawings

Figure 1 shows a schematic view of a first embodiment of a method of manufacture of an aerosol generating material according to the present disclosure;

Figure 2 shows a schematic view of a first embodiment of a method of use of the aerosol generating material made according to the method of Figure 1 ;

Figure 3 shows a schematic view of a second embodiment of a method of use of the aerosol generating material made according to the method of Figure 1;

Figure 4 shows a schematic view of a second embodiment of a method of manufacture of an aerosol generating material according to the present disclosure; Figure 5 shows a detail of the method of Figure 4; and

Figure 6 shows an embodiment of a consumable made using the aerosol generating material made according to the method of Figure 4.

Detailed Description

The consumable of the present description may be alternatively referred to as an article.

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

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

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

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

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

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

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

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

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

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

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

According to a first aspect of the present disclosure there is provided a method of manufacture of an aerosol generating material for use in aerosol provision devices, in which the method comprises providing a surface, applying an aerosol generating material slurry to the surface, allowing or causing the aerosol generating material slurry to at least partially set, and separating the at least partially set aerosol generating material from the surface. In an embodiment of the above embodiment, the aerosol generating material slurry is applied in a layer that is between 0.5 mm and 2.0 mm thick. In other embodiments the aerosol generating material slurry is applied in a layer that is between 0.5 mm and 2.5 mm, between 0.5 mm and 3.0 mm or between 0.5 mm and 3.5 mm thick. the method further comprises treating the surface with a release agent. A release agent is a chemical or composition used to prevent the aerosol generating material from bonding to the surface. This will assist in separating the aerosol generating material from the surface and minimise damage to the aerosol generating material when doing so.

In an embodiment of any of the above embodiments, the surface is a surface of a flexible sheet material. In some embodiments, the flexible sheet material is a laminate material.

In an embodiment of any of the above embodiments, the surface is supported on a rigid surface whilst the aerosol generating material slurry is applied to the surface. This provides a temporary rigidity to the surface and assists in both the accurate application of the aerosol generating material slurry to the surface, and avoiding distortions in the surface being reflected in the aerosol generating material slurry.

In an embodiment of any of the above embodiments, the surface is under tension in at least one direction whilst the aerosol generating material slurry is applied to the surface. In some embodiments, the tension is in one direction in the plane of the surface. Again, this assists in providing a temporary rigidity to the surface and assisting in both the accurate application of the aerosol generating material slurry to the surface, and avoiding distortions in the surface being reflected in the aerosol generating material slurry.

In an embodiment of any of the above embodiments, the surface is a surface of a continuous loop of a sheet material. This allows the surface to be repeatedly reused which is both economically and environmentally beneficial. In an embodiment of any of the above embodiments, the application of aerosol generating material slurry to the surface comprises the application of at least one layer of aerosol generating material slurry over the whole of or substantially the whole of the area of application. In some embodiments the application of aerosol generating material slurry is the application of at least two layers of aerosol generating material slurry until a desired thickness of aerosol generating material has been achieved.

In an embodiment of any of the above embodiments, at least one layer of aerosol generating material slurry is of a substantially even thickness.

In an embodiment of any of the above embodiments, the method further comprises moving the surface and aerosol generating material slurry thereon relative to a blade spaced a predetermined distance from a rigid surface on which the surface is supported. The surface and aerosol generating material slurry thereon passes between the blade and the rigid surface on which the surface is supported, and the relative movement results in the surface and aerosol generating material slurry having a predetermined thickness. This is a result of the blade scraping excess aerosol generating material slurry from overly thick parts of the aerosol generating material slurry. In some embodiments, the blade redistributes any aerosol generating material slurry that is too thick onto thinner parts of the aerosol generating material slurry or to the edge of the aerosol generating material slurry.

In an embodiment of any of the above embodiments, the method further comprises measuring the thickness of the aerosol generating material slurry or the at least partially set aerosol generating material slurry. The measurement of the thickness occurs after the aerosol generating material slurry is applied to the surface and before or after allowing or causing the aerosol generating material slurry to at least partially set.

In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the surface and aerosol generating material slurry thereon to an environment in which the rate of setting of the aerosol generating material slurry can at least partially be controlled. In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to electromagnetic radiation.

In an embodiment of any of the above embodiments, the electromagnetic radiation is one or more of infrared, microwaves or a radio frequency.

In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to a source of radiant heat.

In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to a heated atmosphere.

In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to a partial or absolute vacuum.

In an embodiment of any of the above embodiments, allowing or causing the aerosol generating material slurry to at least partially set comprises indirectly heating the aerosol generating material slurry by heating the surface.

In an embodiment of any of the above embodiments, application of aerosol generating material slurry to the surface comprises application of one or more discrete portions of aerosol generating material slurry to the surface.

In an embodiment of any of the above embodiments, each discrete portion of aerosol generating material slurry has a predetermined shape and dimensions.

In an embodiment of any of the above embodiments, the method further comprises cutting the at least partially set aerosol generating material into one or more aerosol generating material portions, each aerosol generating material portion having a predetermined shape and dimensions. In an embodiment of any of the above embodiments, cutting the at least partially set aerosol generating material into one or more aerosol generating material portions is performed before the at least partially set aerosol generating material is separated from the surface. This is beneficial because it occurs before any possible distortion of the aerosol generating material that may occur on separation of the aerosol generating material from the surface with the result that aerosol generating material portions are of a known volume of the aerosol generating material. This assists in provide in constant experience to a user of a consumable made using the aerosol generating material of the first aspect of the present disclosure.

In an embodiment of any of the above embodiments, cutting the at least partially set aerosol generating material into one or more aerosol generating material portions is performed using a kiss cutting technique.

In an embodiment of any of the above embodiments, the surface is caused to have a waved, grooved or dimpled surface, the application of the aerosol generating material slurry is application of a sufficiently deep layer of aerosol generating material slurry that the surface is completely covered, the thickness of the aerosol generating material slurry is sufficient that the at least partial setting of the aerosol generating material slurry does not cause such shrinkage that any of the surface ceases to be covered by the aerosol generating material, and the separated aerosol generating material has areas of greater and areas of lesser thickness relative to the average thickness of the aerosol generating material. The aerosol generating material slurry layer is of uneven thickness because sufficient aerosol generating material slurry is applied in a layer such that the waves, troughs or dimples are filled with aerosol generating material slurry and the surface of the aerosol generating material slurry is substantially flat. It is known that aerosol generating material slurry undergoes significant dimensional change, typically up to a 90% reduction in thickness, on the setting of the aerosol generating material slurry. This is because the solvent that forms the aerosol generating material slurry evaporates allowing the aerosol generating material to at least partially set. When the aerosol generating material is at least partially set, the aerosol generating material is substantially dimensionally stable. In an embodiment of any of the above embodiments, the surface is caused to have a waved, grooved or dimpled surface with a predetermined pattern of waves, groves or dimples, and the separated aerosol generating material has the predetermined pattern of waves, groves or dimples.

In an embodiment of any of the above embodiments, the surface is caused to have a waved, grooved or dimpled surface, the application of the aerosol generating material slurry is application of a sufficiently deep layer of aerosol generating material slurry that the surface is completely covered, the thickness of the aerosol generating material slurry is sufficiently small that the at least partial setting of the aerosol generating material slurry causes such shrinkage of the aerosol generating material that portions of the surface cease to be covered by the aerosol generating material, and the separated aerosol generating material has the form of a plurality of separate portions which correspond to the areas on the surface that had the form of depressions which were located between the portions of the surface that ceased to have a covering of aerosol generating material.

In an embodiment of any of the above embodiments, the surface is a surface of one of a plastics film, a plastics sheet, a metallic film, a metallic foil, or an aluminium foil.

In an embodiment of any of the above embodiments, the method further comprises placing a metallic foil on a free surface of the aerosol generating material slurry, in which the placing of the metallic foil is performed after the application of aerosol generating material slurry to the surface or once the aerosol generating material slurry is at least partially set. The free surface of the aerosol generating material slurry is the surface of the slurry which is furthest from the surface.

In an embodiment of any of the above embodiments, the method further comprises introducing at least one perforation into the metallic foil. The at least one perforations will allow aerosol to pass through the perforations in the foil. This will make the aerosol generated by the aerosol generating material, once incorporated into a consumable, more easily accessed and transmissible to a user of that consumable. In an embodiment of any of the above embodiments, the aerosol generating material slurry is non-fibrous.

In an embodiment of any of the above embodiments, the aerosol generating material slurry is free from or substantially free from tobacco.

In an embodiment of any of the above embodiments, the aerosol generating material slurry is free from or substantially free from any substance obtained from tobacco.

In an embodiment of the above embodiment the aerosol generating material is made using the method according to the first aspect of the present disclosure.

In an embodiment of any of the above embodiments, providing the aerosol generating material comprises making the aerosol generating material using the method according to the first aspect of the present disclosure.

In an embodiment of any of the above embodiments, the application of the aerosol generating material to the cover material comprises application of an adhesive to one or both of the cover material and the aerosol generating material.

In an embodiment of any of the above embodiments, the adhesive comprises aerosol generating material slurry. The aerosol generating material slurry is sticky and forms an adhesive when it sets. This is advantageous because the components of the aerosol generating material are known and acceptable for use in the manufacture of consumables. In an embodiment of any of the above embodiments, the method further comprises providing a second cover material, and applying the second cover material to the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material. In this embodiment the method comprises forming a product that is a laminate material with at least some of the product being a laminate comprising layers of cover material, aerosol generating material, and second cover material with the aerosol generating material being located between the cover material and second cover material.

In an embodiment of any of the above embodiments, the application of the aerosol generating material to the cover material, and the application of the second cover material to the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material occurs sequentially or at approximately the same time. In this embodiment, the cover material, aerosol generating material, and second cover material are all fed into the location where they are fixed to each other.

In an embodiment of any of the above embodiments, the application of the second cover material to the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material comprises application of an adhesive to one or all of the cover material, the aerosol generating material, and the second cover material. In an embodiment of the above embodiment the adhesive comprises aerosol generating material slurry.

In an embodiment of any of the above embodiments, the aerosol generating material is sufficiently set to be handleable.

In an embodiment of any of the above embodiments, one or both of the cover material and the second cover material is a material which undergoes a dimensional change if an aerosol generating material slurry is applied to the cover material and I or second cover material. As such the application of aerosol generating material to the cover material and or second cover material avoids causing that dimensional change. Such a material may be, without limitation, paper. In an embodiment of any of the above embodiments, one or both of the cover material and the second cover material comprises a first material, and a physical property of the first material changes if an aerosol generating material slurry is applied to the first material. That physical property may be, without limitation, strength, flatness, or colour.

In an embodiment of any of the above embodiments, one or both of the cover material and the second cover material comprises a susceptor.

In an embodiment of any of the above embodiments, the method further comprises introducing at least one perforation into one or both of the cover material and the second cover material. The at least one perforation will allow aerosol to pass through the perforations in the cover material and I or the second cover material. This will make the aerosol generated by the aerosol generating material, once incorporated into a consumable, more easily accessed and transmissible to a user of that consumable.

According to a third aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision device, in which the product comprises a cover material and an aerosol generating material, and the aerosol generating material is applied to the cover material.

In an embodiment of the above embodiment, the aerosol generating material is the product of the method according to the first aspect of the present disclosure.

In an embodiment of any of the above embodiments, the aerosol generating material is fixed to the cover material using an adhesive.

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

In an embodiment of any of the above embodiments, the product further comprises a second cover material, and the second cover material is applied to the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material.

In an embodiment of any of the above embodiments, the application of the second cover material to the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material comprises use of an adhesive.

In an embodiment of any of the above embodiments, one or both of the cover material and the second cover material comprises a material which undergoes a dimensional change if an aerosol generating material slurry is applied to the material.

In an embodiment of any of the above embodiments, one or both of the cover material and the second cover material comprises a first material, and a physical property of the first material changes if an aerosol generating material slurry is applied to the first material.

According to a fourth aspect of the present disclosure there is provided consumable for use with a non-combustible aerosol provision system, in which the consumable is a portion of a product according to the third aspect of the present disclosure which has been shaped and dimensioned to a desired configuration.

In an embodiment of any of the above embodiments, the consumable is a portion of a product comprising a cover material and a second cover material which has been shaped and dimensioned to a desired configuration, and at least one edge of the portion of the product has been sealed. The sealing of the at least one edge of the portion of a material over the at least one edge that assists in holding the edges together and preventing the entry or exit of anything between the cover material and the second cover material.

In an embodiment of any of the above embodiments, the at least one edge of the portion of the product has been sealed using an adhesive.

According to a sixth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable according to the fourth aspect of the present disclosure.

According to a seventh aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the fourth aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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

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

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

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

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

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

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically- conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator.

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

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

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

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

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

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

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

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

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

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

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

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

The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular examples, the aerosol generating agent comprises glycerol. In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

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

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

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

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

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

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

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

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

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

In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent. In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.

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

In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.

In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.

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

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

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

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

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

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

In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially. In some examples, the slurry is applied to a support. The layer may be formed on a support.

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

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

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

The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.

When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case the aerosol generating material will not generally contain any tobacco.

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

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

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

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

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

In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.

The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35- 55wt% or 30-45wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.

The aerosol generating material may comprise a filler.

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

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

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

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

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

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

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

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

In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.

In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.

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

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

The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition in order to achieve a physiological and/or olfactory response.

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

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

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

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

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

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

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

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

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

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

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

1-60 wt% of a gelling agent;

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

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

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

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

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

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

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

1-60 wt% of a gelling agent;

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

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

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent; 20-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

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

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

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

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

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

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

A material having a thickness of 0.1mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

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

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.

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

The aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m² to 120 g/m². In some cases, the sheet may have a mass per unit area of 80-120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m², or suitably about 100 g/m² (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m², 40 to 60 g/m², or 25-60 g/m² and may be used to wrap an aerosolisable material such as tobacco.

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

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

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

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

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

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

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

All references to above, below, beneath, up, down and similar language in the following specific description are to be understood to relate to the orientation of the apparatus for the manufacture of the aerosol generating material as shown in Figures 1 or 4 unless the context of the use of that language indicates otherwise.

With reference to Figure 1, a continuous belt 2 is provided. The continuous belt 2 travels in the direction indicated by arrows 4 and passes around the rollers 6A and 6B. The part of the belt that is travelling from the roller 6A to the roller 6B is the active belt part 2T and the aerosol generating material is formed on belt part 2T as described further below. The part of the belt that travels from the roller 6B to the roller 6A is the passive belt part 2B. The belt 2 is tensioned by the rollers 6A, 6B and as such is pulled flat. The surface of the belt that does not make contact with the rollers 6A, 6B and that is, when passing around the rollers 6A or 6B, substantially parallel to the rollers 6A or 6B is the surface 2S. The continuous belt may be of a single material such a plastics sheet, or may be a composite material or a laminated material with a surface 2S that is formed by one of a plastics film, a plastics sheet, a metallic film, a metallic foil, or an aluminium foil.

Starting at the roller 6A, the belt part 2T starts to pass over and across the surface of a bed 8. The bed 8 is flat and the belt part 2T slides across the surface of the bed 8 closest to the belt part 2T. The bed 8 helps prevent the belt part 2T moving downwards in a direction approximately perpendicular to the direction of travel 4 of the belt part 2T.

Shortly after the belt part 2T starts to pass across the surface of the bed 8 the belt part 2T passes beneath an aerosol generating material applicator 10. The aerosol generating material is applied to the surface 2S of the belt part 2T as an aerosol generating material slurry by any suitable application means. The aerosol generating material slurry will set to become an aerosol generating film.

Optionally, after the aerosol generating material applicator 10 a metallic foil, for example aluminium foil, is placed onto the surface of the aerosol generating material slurry. The stickiness of the aerosol generating material slurry will cause the foil to adhere to the aerosol generating material once it is at least partially set.

The belt part 2T with the slurry applied thereto next moves along the surface of the bed 8 until it passes beneath a setting station 12. The setting station 12, in the illustrated embodiment, includes a source of ultraviolet radiation, exposure of the aerosol generating material slurry to the ultraviolet helps to minimise the time the aerosol generating material slurry takes to set or at least partially set into an aerosol generating material film. In other embodiments the setting station may include one or more other means for enhancing the speed of setting of the aerosol generating material slurry.

Next the belt part 2T continues to pass along the bed 8 and the aerosol generating material slurry continues to set until it passes beneath a cooling station 14. The cooling station 14 forcibly cools the aerosol generating material so that further setting of the aerosol generating material (by the evaporation of solvent from the aerosol generating material slurry) is slowed down or stopped.

The belt part 2T next passes beneath a separation station 16 where the aerosol generating material is caused to separate from the surface 2S. The aerosol generating material 18 is subsequently moved away from the belt 2 for use or storage.

The belt part 2T passes around the roller 6B and becomes belt part 2B and starts to travel back towards roller 6A. On its way to roller 6A, the belt part 2B passes trough a cleaning and preparation station 20. In the cleaning and preparation station 20, any aerosol generating material that remains on the surface 2S is removed from the surface 2S for disposal. Thereafter a release agent, not shown, is applied to the surface 2S. The belt part 2B next continues to travel towards the roller 6A until it passes around the roller 6A and becomes belt part 2T again.

With reference to Figure 2, a support 22 is supplied from a bobbin 24 of the support 22. The support 22 is, in the illustrated embodiment, an aluminium foil. In other embodiments the support may be other materials.

Shortly after the support 22 comes off the bobbin 24, the support 22 passes an adhesive applicator 26. The adhesive application applies a layer of adhesive, not shown, to the surface 22T of the support 22. The adhesive may be any appropriate adhesive, for example, an aerosol generating material slurry. The support 22 then passes around a first support surface 28 to bring the support 22 into alignment with a second support surface 30.

As the support 22 passes over the second support surface 30, aerosol generating material 18 is applied to the surface 22T of the support 22. The aerosol generating material 18 is fixed to the surface 22T by the adhesive. The combined support 22 and aerosol generating material 18 next reaches a processing station 32. At the processing station 32 the support 22 and aerosol generating material 18 are compressed to form a continuous bond between them, and the support 22 and aerosol generating material are cut into a plurality of portions 34. The portions 34 are of a size suitable for use as consumables for an aerosol provision device.

With reference to Figure 3, a support 22 is supplied from a bobbin 24 of the support 22. The support 22 is, in the illustrated embodiment, an aluminium foil. In other embodiments the support may be other materials.

A cover material 34 is supplied from a bobbin 40 of cover material 34. The cover material 34 is, in the illustrated embodiment, an aluminium foil. In other embodiments the cover material may be other materials.

Shortly after the cover material 34 comes off the bobbin 40, the cover material 34 passes an adhesive applicator 38. The adhesive application applies a layer of adhesive, not shown, to the surface 36B of the cover material 34. The adhesive may be any appropriate adhesive, for example, an aerosol generating material slurry. The cover material 34 then passes around a third support surface 42 to bring the cover material 34 into alignment with a second support surface 30. As the support 22 and cover material 34 pass over the second and third support surfaces 30, 42 aerosol generating material 18 is introduced between the surface 22T of the support 22 and the surface 36B of the cover material 34. The portions of the surfaces 22T and 36B of the support 22 and cover material 34 respectively that are not in contact with the aerosol generating material 18 are adhered to each other.

The combined support 22, aerosol generating material 18, and cover material 34 next reaches a processing station 32. At the processing station 32 the support 22, aerosol generating material 18, and cover material 34 are compressed to form a continuous bond between them, and the support 22, aerosol generating material 18, and cover material 34 are cut into a plurality of portions 134. The portions 134 are of a size suitable for use as consumables for an aerosol provision device. One or more of the edges of the portions 134 may be sealed using an adhesive to increase the integrity of the portions 134 and to stop entry or exit of anything between the cover material and the second cover material.

With reference to Figures 4 and 5, as in Figure 1, a continuous belt 2 is provided. The continuous belt 2 travels in the direction indicated by arrows 4 and passes around the rollers 6A and 6B. The part of the belt that is travelling from the roller 6A to the roller 6B is the active belt part 2T and the aerosol generating material is formed on belt part 2T as described further below. The part of the belt that travels from the roller 6B to the roller 6A is the passive belt part 2B. The belt 2 is tensioned by the rollers 6A, 6B and as such is pulled flat. The surface of the belt that does not make contact with the rollers 6A, 6B and that is, when passing around the rollers 6A or 6B, substantially parallel to the rollers 6A or 6B is the surface 2S.

Shortly after the belt part 2T starts to pass across the surface of the bed 8 the belt part 2T passes beneath a first aerosol generating material applicator 110. The aerosol generating material is applied to the surface 2S of the belt part 2T as an aerosol generating material slurry 142 by any suitable application means.

The belt part 2T with the slurry 142 applied thereto next moves along the surface of the bed 8 until it passes beneath a blade 144. The blade 144 is rigidly held a predetermined distance D from the surface of the bed 8. The blade 144 can be set to create a layer of slurry 142 of a predetermined thickness D. Excess slurry 142A is removed from the blade 144 by means not shown.

The belt part 2T and slurry 142 next moves along the surface of the bed 8 until it passes beneath a first setting station 112. The setting station 112, in the illustrated embodiment, includes a source of ultraviolet radiation, and helps to minimise the time the aerosol generating material slurry 142 takes to set or at least partially set into an aerosol generating material film. In other embodiments the setting station may include on or more other means for enhancing the speed of setting of the aerosol generating material slurry.

Next, the belt 2T continues to pass across the surface of the bed 8 with the slurry 142 continuing to set until the belt part 2T passes beneath a second aerosol generating material applicator 146. The aerosol generating material is applied to the previously applied aerosol generating material which is now a set or at least partially set aerosol generating material film. The slurry 142 is applied by any suitable application means.

The belt part 2T with the second layer of slurry 142 applied thereto next moves along the surface of the bed 8 until it passes beneath a second blade 148. The blade 148 is as the blade 144 shown in Figure 5 with the exception that D for the blade 148 is greater than D for the blade 144.

The belt part 2T and slurry 142 next moves along the surface of the bed 8 until it passes beneath a second setting station 150. The second setting station 150, in the illustrated embodiment, includes a source of ultraviolet radiation, and helps to minimise the time the aerosol generating material slurry 142 takes to set or at least partially set into an aerosol generating material film. In other embodiments the setting station may include on or more other means for enhancing the speed of setting of the aerosol generating material slurry.

Next the belt part 2T continues to pass along the bed 8 and continues to set until it passes beneath a cooling station 114. The cooling station 114 forcibly cools the aerosol generating material so that further setting of the aerosol generating material (by the evaporation of solvent from the aerosol generating material slurry) is slowed down or stopped.

The belt part 2T next passes beneath a cutting station 152 at which the aerosol generating material is cut into two or more portions of aerosol generating material 118 each of a desired configuration and dimensions by a kiss cutting technique.

The belt part 2T next passes beneath a separation station 116 where at least the portions of aerosol generating material 118 are caused to separate from surface 2S. The aerosol generating material 18 is subsequently moved away from the belt 2 for use or storage.

The belt part 2T passes around the roller 6B and becomes belt part 2B and starts to travel back towards roller 6A. On its way to roller 6A, the belt part 2B passes trough a cleaning and preparation station 120. In the cleaning and preparation station 120, any aerosol generating material that remains on the surface 2S is removed from the surface 2S for disposal. Thereafter a release agent, not shown, is applied to the surface 2S. The belt part 2B next continues to travel towards the roller 6A until it passes around the roller 6A and becomes belt part 2T again.

Optionally, in this method the thickness of the at least partially set aerosol generating material slurry is measured after the first setting station 112. The measurement of the thickness determines the position of the blade 148 relative to the bed 8 so as to achieve a desired thickness.

With reference to Figure 6, the portions of aerosol generating material 118 are fixed to a support 122 in a predetermined pattern during the process of manufacturing of consumables 50 a suitable adhesive, for example aerosol generating material slurry, is used to fix the portions of aerosol generating material 118 to the support 122.

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

Various aspects of the method, film, product, and consumable disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects. The scope of the following claims should not be limited by the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

- 44 -

Claims

1 A method of manufacture of an aerosol generating material for use in aerosol provision devices, in which the method comprises providing a surface, applying an aerosol generating material slurry to the surface, allowing or causing the aerosol generating material slurry to at least partially set, and separating the at least partially set aerosol generating material from the surface.

2 A method according to claim 1 in which the aerosol generating material slurry is applied in a layer that is between 0.5 mm and 2.0 mm thick.

3 A method according to claim 1 or 2 in which the method further comprises treating the surface with a release agent.

4 A method according to any of claims 1 to 3 in which the surface is a surface of a flexible sheet material.

5 A method according to claim 4 in which the surface is supported on a rigid surface whilst the aerosol generating material slurry is applied to the surface.

6 A method according to claim 4 or 5 in which the surface is under tension in at least one direction whilst the aerosol generating material slurry is applied to the surface.

7 A method according to any of claims 4 to 6 in which the surface is a surface of a continuous loop of sheet material.

8 A method according to any of claims 1 to 7 in which the application of aerosol generating material slurry to the surface comprises the application of at least one layer of aerosol generating material slurry over the whole of or substantially the whole of the area of application. - 45 -

9 A method according to claim 8 in which at least one layer of aerosol generating material slurry is of substantially even thickness.

10 A method according to any of claims 1 to 9 in which the method further comprises moving the surface and aerosol generating material slurry thereon relative to a blade spaced a predetermined distance from a rigid surface on which the surface is supported, in which the surface and aerosol generating material slurry thereon passes between the blade and the rigid surface on which the surface is supported, and the relative movement results in the surface and aerosol generating material slurry having a predetermined thickness.

11 A method according to any of claims 1 to 10 in which the method further comprises measuring the thickness of the aerosol generating material slurry or the at least partially set aerosol generating material slurry, in which measurement of the thickness occurs after the aerosol generating material slurry is applied to the surface and before or after allowing or causing the aerosol generating material slurry to at least partially set.

12 A method according to any of claims 1 to 11 in which allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the surface and aerosol generating material slurry thereon to an environment in which the rate of setting of the aerosol generating material slurry can be at least partially controlled.

13 A method according to any of claims 1 to 12 in which allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to one or more of electromagnetic radiation, a source of radiant heat, a heated atmosphere, a partial or absolute vacuum or indirect heating.

14 A method according to claim 13 in which the electromagnetic radiation is one or more of infrared, microwaves or a radio frequency. - 46 -

15 A method according to claim 13 or 14 in which the indirect heating is heating of the surface.

16 A method according to any of claims 1 to 14 in which application of aerosol generating material slurry to the surface comprises application of one or more discrete portions of aerosol generating material slurry to the surface.

17 A method according to claim 16 in which each discrete portion of aerosol generating material slurry has a predetermined shape and dimensions.

18 A method according to any of claims 1 to 16 in which the method further comprises cutting the at least partially set aerosol generating material into one or more aerosol generating material portions, each aerosol generating material portion having a predetermined shape and dimensions.

19 A method according to claim 18 in which cutting the at least partially set aerosol generating material into one or more aerosol generating material portions is performed before the at least partially set aerosol generating material is separated from the surface.

20 A method according to claim 18 or 19 in which cutting the at least partially set aerosol generating material into one or more aerosol generating material portions is performed using a kiss cutting technique.

21 A method according to any of claims 1 to 20 in which the surface is caused to have a waved, grooved or dimpled surface, the application of the aerosol generating material slurry is application of a sufficiently deep layer of aerosol generating material slurry that the surface is completely covered, the thickness of the aerosol generating material slurry is sufficient that the at least partial setting of the aerosol generating material slurry does not cause such shrinkage that any of the surface ceases to be covered by the aerosol generating material, and the separated aerosol generating material has areas of greater and areas of lesser thickness relative to the average thickness of the aerosol generating material. 22 A method according to claim 21 in which the surface is caused to have a waved, grooved or dimpled surface with a predetermined pattern of waves, groves or dimples, and the separated aerosol generating material has the predetermined pattern of waves, groves or dimples.

23 A method according to any of claims 1 to 20 in which the surface is caused to have a waved, grooved or dimpled surface, the application of the aerosol generating material slurry is application of a sufficiently deep layer of aerosol generating material slurry that the surface is completely covered, the thickness of the aerosol generating material slurry is sufficiently small that the at least partial setting of the aerosol generating material slurry causes such shrinkage of the aerosol generating material that portions of the surface cease to be covered by the aerosol generating material, and the separated aerosol generating material has the form of a plurality of separate portions which correspond to the areas on the surface that had the form of depressions which were located between the portions of the surface that ceased to have a covering of aerosol generating material.

24 A method according to any of claims 1 to 23 in which the surface is a surface of one of a plastics film, a plastics sheet, a metallic film, a metallic foil, or an aluminium foil.

25 A method according to any of claims 1 to 24 in which the method further comprises placing a metallic foil on the free surface of the aerosol generating material slurry, in which the placing of the metallic foil is performed whilst the aerosol generating material is a slurry or whilst the aerosol generating material is partially set.

26 A method according to any of claims 1 to 25 in which the aerosol generating material slurry is non-fibrous.

27 A method according to any of claims 1 to 26 in which the aerosol generating material slurry is free from or substantially free from tobacco. 28 A method according to any of claims 1 to 27 in which the aerosol generating material slurry is free from or substantially free from any substance obtained from tobacco.

29 A method of manufacture of a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision device, in which the product comprises a cover material and an aerosol generating material, in which the method comprises providing a cover material, providing an aerosol generating material and applying the aerosol generating material to the cover material.

30 A method according to claim 29 in which the aerosol generating material is made using the method according to any of claims 1 to 28.

31 A method according to claim 29 or 30 in which providing the aerosol generating material comprises making the aerosol generating material using the method according to any of claims 1 to 28.

32 A method according to any of claims 29 to 31 , in which the application of the aerosol generating to the cover material comprises application of an adhesive to one or both of the cover material and the aerosol generating material film.

33 A method according to claim 32 in which the adhesive comprises aerosol generating material slurry.

34 A method according to any of claims 29 to 33 in which the method further comprises providing a second cover material, and applying the second cover material to the surface of the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material.

35 A method according to claim 34 in which the application of the aerosol generating material to the cover material, and the application of the second cover - 49 - material to the surface of the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material occurs sequentially or at approximately the same time.

36 A method according to claim 34 or 35 in which the application of the second cover material to the surface of the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material comprises application of an adhesive to one or more of the cover material, the aerosol generating material, and the second cover material.

37 A method according to claim 36 in which the adhesive comprises aerosol generating material slurry.

38 A method according to any of claims 29 to 37 in which the aerosol generating material is sufficiently set to be handleable.

39 A method according to any of claims 29 to 38 in which one or both of the cover material and the second cover material is a material which undergoes a dimensional change if an aerosol generating material slurry is applied to the cover material and I or second cover material.

40 A method according to any of claims 29 to 38 in which one or both of the cover material and the second cover material comprises a first material, and a physical property of the first material changes if an aerosol generating material slurry is applied to the first material.

41 A method according to any of claims 29 to 40 in which one or both of the cover material and the second cover material comprises a susceptor.

42 A product for use with a non-combustible aerosol provision device, in which the product comprises a cover material and an aerosol generating material, and the aerosol generating material is applied to the cover material. - 50 -

43 A product according to claim 42 in which the aerosol generating material is the product of the method according to any of claims 1 to 28.

44 A product according to claim 42 or 43 in which the aerosol generating is fixed to the cover material using an adhesive.

45 A product according to claim 43 in which the adhesive comprises aerosol generating material slurry.

46 A product according to any of claims 42 to 45 in which the product further comprises a second cover material, and the second cover material is applied to the surface of the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material.

47 A product according to claim 46 in which the application of the second cover material to the surface of the cover material to which the aerosol generating material has been applied and the surface of the aerosol generating material not in contact with the cover material comprises use of an adhesive.

48 A product according to claim 47 in which the adhesive comprises aerosol generating material slurry.

49 A product according to any of claims 42 to 48 in which one or both of the cover material and the second cover material comprises a material which undergoes a dimensional change if an aerosol generating material slurry is applied to the material.

50 A product according to any of claims 42 to 49 in which one or both of the cover material and the second cover material comprises a first material, and a physical property of the first material changes if an aerosol generating material slurry is applied to the first material.

51 A product according to any of claims 42 to 50 in which one or both of the cover material and the second cover material comprises a susceptor. - 51 -

52 A consumable for use with a non-combustible aerosol provision system, in which the consumable is a portion of a product according to any of claims 42 to 51 which has been shaped and dimensioned to a desired configuration.

53 A consumable for use with a non-combustible aerosol provision system, in which the consumable is a portion of a product according to any of claims 46 or 47 or any of claims 48 to 51 when dependent on claim 46 or 47 which has been shaped and dimensioned to a desired configuration, and at least one edge of the portion of the product has been sealed.

54 A consumable according to claim 53 in which the at least one edge of the portion of the product has been sealed using an adhesive.

56 An aerosol provision device for use with a consumable according to any of claims 52 to 54 in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the support.

57 An aerosol provision system comprising an aerosol provision device and a consumable according to any of claims 52 to 54.

58 A method of generating aerosol from a consumable according to any of claims 52 to 54 using an aerosol-generating device comprising at least one aerosol generator disposed to heat the aerosol-generating material in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.