A consumable for use with an aerosol provision device

Abstract

A method of manufacture of a product for use in the manufacture of an article for use in a non-combustible aerosol provision system is provided. The product includes aerosol generating material and a carrier. The carrier includes a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer. The method includes the following steps: (a) the carrier is provided; (b) an aerosol generating material is applied to a support surface of the carrier layer of the carrier; and (c) the carrier and aerosol generating material is configured for storage.

1 . A method of manufacture of a product for use in the manufacture of an article for use in a non-combustible aerosol provision system, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer,
 and the method comprises the following steps   (a) the carrier is provided,   (b) an aerosol generating material is applied to a support surface of the carrier layer of the carrier, and   (c) the carrier and aerosol generating material is configured for storage.   
     
     
         2 . A method according to  claim 1  in which the application of the aerosol generating material in step (b) is application of an aerosol generating material slurry. 
     
     
         3 . A method according to  claim 1  in which the application of the aerosol generating material in step (b) is application of one or more discrete portions of aerosol generating material. 
     
     
         4 . A method according to  claim 3  in which there are at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other. 
     
     
         5 . A method according to  claim 3  in which there are three or more distinct portions of aerosol generating material and the discrete portions are applied to the support surface of the carrier layer in a grid pattern. 
     
     
         6 . A method according to  claim 3  in which one or more of the discrete portions of the aerosol generating material applied in step (b) are, in the plane of the support surface of the carrier layer, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate. 
     
     
         7 . A method according to  claim 3  in which at least one discrete portion of the aerosol generating material applied in step (b) is of a shape and/or color that is indicative of the composition of the aerosol generating material forming the discrete portion. 
     
     
         8 . A method according to  claim 1  in which the carrier layer comprises a sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material. 
     
     
         9 . A method according to  claim 1  in which the method includes a further step of
 (d) introducing at least one line of separation into at least part of the carrier, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear. 
 
     
     
         10 . A method according to  claim 9  in which at least one line of separation is a predetermined line along which the carrier layer will separate or tear. 
     
     
         11 . A method according to  claim 9  in which at least one line of separation of step (d) comprises a line of perforations. 
     
     
         12 . A method according to  claim 9  in which at least one line of separation of step (d) comprises a cut line. 
     
     
         13 . A method according to  claim 12  in which the cut line is formed using a kiss cutting technique. 
     
     
         14 . A method according to  claim 9  when dependent on  claim 3  or any claim dependent on  claim 3  in which at least one line of separation extends between at least two discrete portions of aerosol generating material or between at least two locations at which discrete portions of aerosol generating material will be applied in step (b). 
     
     
         15 . A method according to  claim 9  in which at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer, or a location at which aerosol generating material will be applied in step (b). 
     
     
         16 . A method according to  claim 1  in which the carrier is a sheet of material, and the configuration of step (c) comprises stacking two or more sheets of the carrier into pile. 
     
     
         17 . A method according to  claim 1  in which the carrier is a longitudinally extending sheet of material, and the configuration of step (c) comprises forming at least one fold line in the carrier, and subsequently folding the carrier about at least one of those fold lines. 
     
     
         18 . A method according to  claim 17  in which the method includes a further step of
 (d) introducing at least one line of separation into at least part of the carrier, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear in which a fold line corresponds to a line of separation. 
 
     
     
         19 . A method according to  claim 17  in which the carrier is folded into a concertina. 
     
     
         20 . A method according to  claim 1  in which the configuration of step (c) comprises forming the carrier into a roll. 
     
     
         21 . A method according to  claim 20  in which the carrier is wound around a core. 
     
     
         22 . A method according to  claim 1  in which the method further comprises a step of
 (e) placing a sheet of barrier material over the support surface of the carrier layer and aerosol generating material, in which step (e) is performed before step (c). 
 
     
     
         23 . A product for use in the manufacture of a consumable for use with an article for use in a non-combustible aerosol provision system, in which the product comprises aerosol generating material and a carrier, in which
 the carrier comprises a base layer and a carrier layer,   the carrier layer is releasably attached to the base layer, and   at least one discrete portion of aerosol generating material is supported on a support surface of the carrier layer.   
     
     
         24 . A product according to  claim 23  in which the aerosol generating material is an aerosol generating film. 
     
     
         25 . A product according to  claim 23  in which there are at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other. 
     
     
         26 . A product according to  claim 23  in which there are three or more distinct portions of aerosol generating material and the discrete portions are applied to the support surface of the carrier layer in a grid pattern. 
     
     
         27 . A product according to  claim 23  in which one or more of the discrete portions of the aerosol generating material are, in the plane of the support surface of the carrier layer, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate. 
     
     
         28 . A product according to  claim 23  in which at least one discrete portion of the aerosol generating material is of a shape and/or color that is indicative of the composition of the aerosol generating material forming the discrete portion. 
     
     
         29 . A product according to  claim 23  in which the carrier layer comprises an adhesive backed sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material. 
     
     
         30 . A product according to  claim 23  in which the carrier comprises at least one line of separation, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear. 
     
     
         31 . A product according to  claim 30  in which at least one line of separation is a predetermined line along which the carrier layer will separate or tear. 
     
     
         32 . A product according to  claim 30  in which at least one line of separation comprises a line of perforations. 
     
     
         33 . A product according to  claim 30  in which at least one line of separation comprises a cut line. 
     
     
         34 . A product according to  claim 32  in which at least one cut line is the result of kiss cutting. 
     
     
         35 . A product according to  claim 29  in which at least one line of separation extends between at least two discrete portions of aerosol generating material. 
     
     
         36 . A product according to  claim 29  in which at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer. 
     
     
         37 . A product according to  claim 23  in which the carrier is a sheet material. 
     
     
         38 . A product according to  claim 23  in which the carrier is a longitudinally extending sheet of material, the carrier comprises at least one fold line, and the carrier is folded about at least one of those fold lines. 
     
     
         39 . A product according to  claim 38  in which a fold line corresponds to a separation line. 
     
     
         40 . A product according to  claim 38  in which the carrier is folded into a concertina. 
     
     
         41 . A product according to  claim 23  in which the carrier is rolled into a roll. 
     
     
         42 . A product according to  claim 41  in which the roll of carrier is wound around a core. 
     
     
         43 . A product according to  claim 23  in which the product further comprises a sheet of barrier material placed over the carrier layer and aerosol generating material. 
     
     
         44 . A method of making a consumable for use with an apparatus for heating an aerosol generating material, in which the method comprises
 (i) providing at least one product according to  claim 23 , and   (ii) releasing at least one portion of the carrier layer from the base layer of at least one product.   
     
     
         45 . An aerosol provision device for use with a consumable made according to the method of  claim 44  in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. 
     
     
         46 . An aerosol provision device in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable and in which the aerosol generator comprises a heatable plate adapted to support a consumable made according to the method of  claim 44 . 
     
     
         47 . An aerosol provision system comprising an aerosol provision device and a consumable made according to the method of  claim 44  in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. 
     
     
         48 . A method of generating aerosol from a consumable made according to the method of  claim 44  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.