A method of manufacturing an article for use in an aerosol provision system and an article for use in an aerosol provision system

Abstract

The present disclosure relates to a method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a first sheet material: providing a substrate comprising a first aerosol generating material, wherein the substrate is attached to the first sheet material; and, arranging the first sheet material with the substrate attached thereto such that the first sheet material surrounds the substrate. The present disclosure also relates to an article for an aerosol provision device. The present disclosure also relates to an assembly for use in manufacturing an aerosol provision device, a kit of parts comprising an article and an aerosol provision device, and to a package of articles.

1 . A method of manufacturing an article for use in an aerosol provision system, the method comprising:
 providing a first sheet material;   providing a substrate comprising a first aerosol generating material, wherein the substrate is attached to the first sheet material; and,   arranging the first sheet material with the substrate attached thereto such that the first sheet material surrounds the substrate.   
     
     
         2 . A method according to  claim 1 , wherein the first sheet material comprises paper or card. 
     
     
         3 . A method according to  claim 1 or claim 2 , wherein the first sheet material comprises a metal. 
     
     
         4 . A method according to  any one of the preceding claims , wherein the first sheet material comprises a co-laminated material comprising a paper layer and an aluminium layer. 
     
     
         5 . A method according to  claim 4 , wherein attaching the substrate to the first sheet material comprises attaching the substrate to the aluminium layer. 
     
     
         6 . A method according to  any preceding claim  further comprising cutting ventilation apertures into the substrate and/or first sheet of material. 
     
     
         7 . A method according to any one of  claims 1 to 6 , wherein the substrate comprises a second sheet material and, preferably, providing the substrate comprises attaching the second sheet material to the first sheet material. 
     
     
         8 . A method according to  claim 7 , wherein the second sheet material is a cast sheet. 
     
     
         9 . A method according to  claim 7 or claim 8 , wherein the second sheet material comprises the first aerosol generating material. 
     
     
         10 . A method according to  claim 9 , wherein the second sheet material is formed from a slurry that comprises the first aerosol generating material and, preferably, wherein the slurry is cast to form the second sheet material. 
     
     
         11 . A method according to  claim 7 , wherein the first aerosol generating material is attached to a surface of the second sheet material and, preferably, is adhered to the surface of the second sheet material. 
     
     
         12 . A method according to  claim 11 , wherein the first aerosol generating material is attached to the surface of the second sheet material before or after attaching the second sheet material to the first sheet material. 
     
     
         13 . A method according to any one of  claims 7 to 12 , wherein the second sheet material comprises one or more of: paper, card and/or aerosol generating material. 
     
     
         14 . A method according to  any one of the preceding claims , wherein providing the first sheet material comprises providing a web of first sheet material. 
     
     
         15 . A method according to  claim 14 , wherein providing the substrate comprises applying the substrate to the web of first sheet material. 
     
     
         16 . A method according to  claim 15 , when dependent on any one of  claims 2 to 8 , wherein applying the substrate to the web of first sheet material comprising applying a web of the second sheet material to the web of first sheet material. 
     
     
         17 . A method according to  claim 15 , when dependent on any one of  claims 2 to 8 , wherein applying the substrate to the web of first sheet material comprising applying a plurality of portions of second sheet material to the web of first sheet material. 
     
     
         18 . A method according to  claim 17 , wherein the plurality of portions of second sheet material are spaced from each other on the web of first sheet material. 
     
     
         19 . A method according to  any one of the preceding claims , wherein an edge of the substrate is spaced from an edge of the first sheet material such that a region of the first sheet material is not covered by the substrate and, preferably, the method comprises applying adhesive to said region. 
     
     
         20 . A method according to  any one of the preceding claims , wherein the first sheet material has a permeability of at most 100 Coresta Units. 
     
     
         21 . A method according to  any one of the preceding claims , wherein the first sheet material forms an exterior surface of the article. 
     
     
         22 . A method according to  any one of the preceding claims , wherein the first aerosol generating material comprises aerosol generating material dust and/or aerosol generating material fibres. 
     
     
         23 . A method according to  any one of the preceding claims , wherein the first aerosol generating material comprises extruded and/or compressed aerosol generating material. 
     
     
         24 . A method according to  any one of the preceding claims , wherein the first aerosol generating material comprises beads. 
     
     
         25 . A method according to  any one of the preceding claims , wherein the first aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         26 . A method according to  any one of the preceding claims , wherein the article further comprises a second aerosol generating material. 
     
     
         27 . A method according to  claim 26 , wherein the second aerosol generating material has a higher or lower density than the first aerosol generating material. 
     
     
         28 . A method according to  claim 26 or claim 27 , wherein the second aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         29 . A method according to any one of  claims 26 to 28 , wherein the substrate comprises the second aerosol generating material. 
     
     
         30 . A method according to  any one of the preceding claims , wherein arranging the first sheet material with the substrate attached thereto comprises providing the first sheet material and substrate around at least a portion of a body of material and, preferably, comprises wrapping the first sheet material with substrate about the body of material. 
     
     
         31 . A method according to  claim 30 , wherein the body of material comprises a third sheet material that is gathered to form the body of material. 
     
     
         32 . A method according to  claim 31 , wherein the third sheet material is crimped and/or cut into strips. 
     
     
         33 . A method according to any one of  claims 30 to 32 , when dependent on any one of  claims 21 to 24 , wherein the body of material comprises the second aerosol generating material. 
     
     
         34 . An assembly for use in a method of manufacturing an article for use in an aerosol provision system, the assembly comprising:
 a first sheet material; and,   a patch comprising a first aerosol generating material, wherein the patch is attached to the first sheet material.   
     
     
         35 . An article for use in an aerosol provision system, the article comprising:
 a first sheet material; and,   a patch comprising a first aerosol generating material, wherein the patch is attached to the first sheet material,   wherein the sheet material and patch are arranged such that the sheet material surrounds the patch.   
     
     
         36 . An article according to  claim 35 , wherein the first sheet material comprises paper or card. 
     
     
         37 . An article according to  claim 35 or claim 36 , wherein the first sheet material comprises a metal. 
     
     
         38 . An article according to any one of  claims 35 to 37 , wherein the first sheet material comprises a co-laminated material comprising a paper layer and an aluminium layer. 
     
     
         39 . An article according to  claim 38 , wherein the patch is attached the aluminium layer. 
     
     
         40 . An article according to any one of  claims 35 to 39 , wherein the first sheet material forms an exterior surface of the article. 
     
     
         41 . An article according to  claim 35 or claim 40 , wherein the article further comprises a second aerosol generating material. 
     
     
         42 . An article according to  claim 41 , wherein the second aerosol generating material has a higher or lower density than the first aerosol generating material. 
     
     
         43 . An article according to  claim 41 or claim 42 , wherein the second aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         44 . An article according to any one of  claims 35 to 43 , further comprising a body of material, wherein the first sheet material and patch are disposed around at least a portion of the body of material. 
     
     
         45 . An article according to  claim 44 , wherein the body of material comprises a third sheet material that is gathered to form the body of material. 
     
     
         46 . An article according to  claim 45 , wherein the third sheet material is crimped and/or cut into strips. 
     
     
         47 . An article according to any one of  claims 44 to 46 , when dependent on any one of  claims 32 to 34 , wherein the body of material comprises the second aerosol generating material. 
     
     
         48 . An arrangement according to  claim 34  or an article according to any one of  claims 35 to 47 , wherein the patch comprises a second sheet material and, preferably, the second sheet material is a cast sheet. 
     
     
         49 . An arrangement according to  claim 48  or an article according to  claim 48 ,
 wherein the second sheet material comprises the first aerosol generating material. 
 
     
     
         50 . An arrangement according to  claim 48 or claim 49  or an article according to  claim 48 or claim 49 , wherein the second sheet material is formed from a slurry that comprises the first aerosol generating material and, preferably, the slurry is cast to form the second sheet material. 
     
     
         51 . An arrangement according to  claim 48 or claim 49  or an article according to  claim 48 or claim 49 , wherein the first aerosol generating material is attached to a surface of the second sheet material and, preferably, is adhered to the surface of the second sheet material. 
     
     
         52 . An arrangement according to any one of  claims 48 to 51  or an article according to any one of  claims 48 to 51 , wherein the second sheet material comprises one or more of: paper, card and/or aerosol generating material. 
     
     
         53 . An arrangement according to  claim 34  or any one of  claims 48 to 52  or an article according to any one of  claims 35 to 52 , wherein the patch comprises a first end that is spaced from a first end of the first sheet material. 
     
     
         54 . An arrangement according to  claim 53  or an article according to  claim 53 , wherein the patch comprises a second end, opposite to the first end, wherein the second end is spaced from a second end of the first sheet material. 
     
     
         55 . An arrangement according to  claim 34  or any one of  claims 48 to 54  or an article according to any one of  claims 35 to 54 , wherein an edge of the substrate is spaced from an edge of the first sheet material such that a region of the first sheet material is not covered by the substrate and, preferably, wherein said edges are longitudinal edges of the substrate and first sheet material. 
     
     
         56 . An arrangement according to  claim 34  or any one of  claims 48 to 55  or an article according to any one of  claims 35 to 55 , wherein the first sheet material has a permeability of at most 100 Coresta Units. 
     
     
         57 . An arrangement according to  claim 34  or any one of  claims 48 to 56  or an article according to any one of  claims 35 to 56 , wherein the first aerosol generating material comprises aerosol generating material dust and/or aerosol generating material fibres. 
     
     
         58 . An arrangement according to  claim 34  or any one of  claims 48 to 57  or an article according to any one of  claims 35 to 57 , wherein the first aerosol generating material comprises extruded and/or compressed aerosol generating material. 
     
     
         59 . An arrangement according to  claim 34  or any one of  claims 48 to 57  or an article according to any one of  claims 35 to 58 , wherein the first aerosol generating material comprises beads. 
     
     
         60 . An arrangement according to  claim 34  or any one of  claims 48 to 59  or an article according to any one of  claims 35 to 59 , wherein the first aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         61 . An arrangement according to  claim 34 or claims 48 to 60  or an article according to any one of  claims 35 to 60 , wherein the patch comprises the second aerosol generating material. 
     
     
         62 . An article manufactured according to the method of any one of  claims 1 to 33 . 
     
     
         63 . A package comprising a plurality of articles according to any one of  claims 35 to 62  and, preferably, wherein the package is hermetically sealed. 
     
     
         64 . A kit of parts comprising the article of any one of  claims 35 to 62  and an aerosol provision device. 
     
     
         65 . A kit of parts according to  claim 64 , wherein the aerosol provision device comprises a heating chamber for receiving the article to heat the first and second aerosol generating materials.