A consumable for use with an aerosol provision device

Abstract

A method of manufacture of an article is provided, in which the article comprises a support and aerosol generating material. The method includes the steps of: (a) providing a mold body; (b) forming one or more mold recesses extending into a first surface) of the mold body; (c) applying at least one discrete portion of aerosol generating material to the first surface of the mold body, in which each mold recess extends into the first surface of the mold body, at least one discrete portion of aerosol generating material at least partially overlies a mold recess, or at least one discrete portion of aerosol generating material at least partially overlies the position where a mold meld recess will be formed in step (b).

1 . A method of manufacture of an article, in which the article comprises a support and aerosol generating material, in which the method comprises the steps of
 (a) providing a mold body,   (b) forming one or more mold recesses extending into a first surface of the mold body,   (c) applying at least one discrete portion of aerosol generating material to the first surface of the mold body, in which   each mold recess extends into the first surface of the mold body,   at least one discrete portion of aerosol generating material at least partially overlies a mold recess, or at least one discrete portion of aerosol generating material at least partially overlies the position where a mold recess will be formed in step (b).   
     
     
         2 . A method according to  claim 1  in which the article is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system. 
     
     
         3 . A method according to  claim 1  in which the method further comprises a step of
 (d) separating the article into two or more consumable portions, 
 in which each consumable portion is shaped and dimensioned for use as a consumable for use with an apparatus for heating an aerosol generating material to volatilize at least one component of the aerosol generating material. 
 
     
     
         4 . A method according to  claim 1  in which the aerosol generating material applied to the first surface of the mold body in step (c) is an aerosol generating material slurry. 
     
     
         5 . A method according to  claim 4  in which the method comprises a further method step of
 (e) allowing or causing the aerosol generating material slurry to set, 
 in which the aerosol generating slurry sets to form an aerosol generating material, and step (e) occurs after step (c). 
 
     
     
         6 . A method according to  claim 1  in which the aerosol generating material is an aerosol generating film. 
     
     
         7 . A method according to  claim 1  in which the aerosol generating material comprises a binder and an aerosol former. 
     
     
         8 . A method according to  claim 7  in which the aerosol generating material comprises an active. 
     
     
         9 . A method according to  claim 7  in which the binder is a gelling agent. 
     
     
         10 . A method according to  claim 1  in which steps (a) and (b) are performed before step (c). 
     
     
         11 . A method according to  claim 10  in which steps (a) and (b) are performed as a separate process to step (c), and the product of steps (a) and (b) is stored and/or transported between different locations before step (c) is performed. 
     
     
         12 . A method according to  claim 1  in which step (c) is performed after step (a) and before step (b). 
     
     
         13 . A method according to  claim 1  in which the method comprises a further step of
 (f) passing a scraper across at least part of the first surface of the mold body after step (c) has been performed and before or after step (e) has been performed. 
 
     
     
         14 . A method according to  claim 1  in which step (c) comprises applying aerosol generating material to at least the portions of the first surface of the mold body that comprise a mold recess. 
     
     
         15 . A method according to  claim 1  in which step (c) comprises applying aerosol generating material to substantially all of the first surface of the mold body. 
     
     
         16 . A method according to  claim 1  in which the method comprises a further step of
 (g) overlaying the first surface of the mold body with a layer of material. 
 
     
     
         17 . A method according to  claim 16  in which step (g) is performed after step (c) and after step (f) if step (f) is to be performed. 
     
     
         18 . A method according to  claim 16  in which the method comprises a further step of
 (h) causing the aerosol generating material to bond to the layer of material, 
 in which step (h) is performed after step (g). 
 
     
     
         19 . A method according to  claim 18  in which the method comprises the further steps of
 (i) applying a release agent to the first surface of the mold body, and 
 (j) removing the layer of material with the aerosol generating material bonded thereto from the mold body, 
 in which step (i) is performed before step (c), and step (j) is performed after step (h). 
 
     
     
         20 . A method according to  claim 19  in which the layer of material is attached to the support after step (i). 
     
     
         21 . A method according to  claim 20  in which the layer of material is attached to the support with the surface of the layer of material to which the aerosol generating material is bonded facing away from the support. 
     
     
         22 . A method according to  claim 16  in which the layer of material comprises a susceptor. 
     
     
         23 . A method according to  claim 16  in which the support comprises the layer of material. 
     
     
         24 . A method according to  claim 1  in which the support comprises the mold body. 
     
     
         25 . A method according to  claim 23  in which the support comprises a susceptor. 
     
     
         26 . A method according to  claim 1  in which the method comprises a further step of
 (k) applying a layer of a susceptor to the first surface of the mold body, 
 in which step (k) is performed after step (a) and before step (c). 
 
     
     
         27 . A method according to  claim 22 , in which the susceptor is a metallic foil or a metallic film. 
     
     
         28 . A method according to  claim 1  in which the method comprises a further step of
 (m) perforating one or more of the mold body (when present), the aerosol generating material, the support (when present), the susceptor (when present), and the layer of material (when present). 
 
     
     
         29 . A method according to  claim 1  in which at least one mold recess intersects with the first surface of the mold body with a shape that is one of longitudinally extending, rectangular, round or oval. 
     
     
         30 . A method according to  claim 1  in which step (c) comprises applying at least two discrete portions of aerosol generating material to the first surface of the mold body, in which those discrete portions of aerosol generating material have different compositions from each other. 
     
     
         31 . A consumable for use with an apparatus for heating an aerosol generating material comprising a support and aerosol generating material, in which the consumable is manufactured according to the method of  claim 1 . 
     
     
         32 . An aerosol provision device for use with a consumable according to  claim 31 , in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. 
     
     
         33 . An aerosol provision system comprising an aerosol provision device and a consumable according to  claim 31  in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. 
     
     
         34 . A method of generating aerosol from a consumable according to  claim 31  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.