Article for forming an aerosol

Abstract

An article (1) for forming an aerosol, the article (1) comprising a cover layer (2) having a peripheral mould surface (20) which circumscribes a moulded aerosol-forming substrate (3). The article (1) is insertable, in use, into a heating chamber of a device for generating an aerosol. A method of manufacture of the article (1) is also provided.

1 . A method of manufacturing an article for forming an aerosol, the method comprising the steps of:
 a) providing a cover layer which comprises, defines or provides a mould surface for defining the periphery of an article for forming an aerosol;   b) depositing a substance which is at least partially fluid and comprises aerosol-forming substrate into the mould surface; and   c) causing or allowing the substance to at least partially solidify thereby to provide an article for forming an aerosol having a periphery formed from the cover layer, wherein the mould surface circumscribes the moulded aerosol-forming substrate.   
     
     
         2 . The method according to  claim 1 , comprising a step d) of foaming the substance. 
     
     
         3 . The method according to  claim 2 , wherein step d) occurs subsequent to step b). 
     
     
         4 . The method according to  claim 2 , comprising a step e) of reticulating the foam. 
     
     
         5 . The method according to  claim 4 , wherein step e) occurs subsequent to step b). 
     
     
         6 . The method according to  claim 1 , comprising a step f) of adding to the mould surface and/or the substance one or more of a volatile flavour-generating component, an aerosol former and nicotine. 
     
     
         7 . The method according to  claim 6 , wherein step f) comprises adding the or each of the one or more of the volatile flavour-generating component, aerosol former and nicotine to the mould surface prior to step b). 
     
     
         8 . The method according to  claim 1 , comprising a step g) of forming a line of weakness in the substance and/or mould surface to thereby at least partially define first and second portions of the substance. 
     
     
         9 . The method according to  claim 1 , comprising a step h) of separating a or the first portion of the substance from a or the second portion of the substance, for example with a separator. 
     
     
         10 . An article for forming an aerosol, the article comprising a cover layer which comprises, provides or defines a peripheral mould surface circumscribing a moulded aerosol-forming substrate, the article being insertable, in use, into a heating chamber of a device for generating an aerosol. 
     
     
         11 . The article according to  claim 10 , wherein the aerosol-forming substrate comprises first and second portions at least partially defined by a frangible portion of the aerosol-forming substrate and/or of the peripheral surface. 
     
     
         12 . An article for forming an aerosol, the article comprising a peripheral surface circumscribing an aerosol-forming substrate, the article being insertable, in use, into a heating chamber of a device for generating an aerosol, wherein the aerosol-forming substrate comprises first and second portions at least partially defined by a frangible portion of the aerosol-forming substrate and/or of the peripheral surface. 
     
     
         13 . The article according to  claim 11 , wherein the frangible portion comprises a separator and/or by a line of weakness in the aerosol-forming substrate between the first and second portions. 
     
     
         14 . The article according to  claim 11 , wherein the article comprises a separator at least partially defining the first and second portions, and the peripheral surface comprises the separator. 
     
     
         15 . The article according to  claim 11 , wherein the first and second portions have substantially similar shapes and/or volumes. 
     
     
         16 . The article according to  claim 10 , wherein the aerosol-forming substrate comprises a foam, for example a reticulated foam, say formed from reconstituted tobacco. 
     
     
         17 . The article according to  claim 12 , wherein the frangible portion comprises a separator and/or by a line of weakness in the aerosol-forming substrate between the first and second portions. 
     
     
         18 . The article according to  claim 12 , wherein the article comprises a separator at least partially defining the first and second portions, and the peripheral surface comprises the separator. 
     
     
         19 . The article according to  claim 12 , wherein the first and second portions have substantially similar shapes and/or volumes. 
     
     
         20 . The article according to  claim 12 , wherein the aerosol-forming substrate comprises a foam, for example a reticulated foam, say formed from reconstituted tobacco.