Aerosol-generating compositions, articles comprising same and systems

Abstract

The present invention relates to aerosol generating compositions, and in particular to compositions comprising from about 50 wt% to about 95 wt% of a first aerosol generating material comprising plant material and from about 5 wt% to about 50 wt% of a second aerosol generating material comprising a film. The present invention also relates to articles comprising such compositions, for example articles for use in aerosol provision systems. The present invention further relates to aerosol provision systems and methods for forming aerosol generating articles.

Description

Technical Field

[0001] This invention relates to aerosol-generating compositions and articles comprising such compositions, such as articles for use in aerosol supply systems. The invention also relates to aerosol supply systems and methods for forming aerosol-generating articles. Background Technology

[0002] Smoking products such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Alternatives to these types of combustible products release compounds from the substrate material through heating without combustion, thus releasing inhalable aerosols or vapors. These can be referred to as non-combustible smoking products or aerosol-generating products.

[0003] One example of such a product is a heating device that releases compounds by heating a solid aerosolizable material without burning it. This solid aerosolizable material may, in some cases, contain tobacco material. Heating causes at least one component of the material to volatilize, typically forming an inhalable aerosol. These products may be referred to as heated non-combustible devices, tobacco heating devices, or tobacco heating products. Various different arrangements for volatilizing at least one component of the solid aerosolizable material are known. Summary of the Invention

[0004] According to a first aspect of the present invention, an aerosol generating composition is provided, comprising about 50 wt% to about 95 wt% of a first aerosol generating material and about 5 wt% to about 50 wt% of a second aerosol generating material, wherein the first aerosol generating material comprises botanical material and the second aerosol generating material comprises a film.

[0005] In some embodiments, the film includes an adhesive, an aerosol forming agent material, and a botanical extract.

[0006] In some implementations, the film contains virtually no plant material.

[0007] In some embodiments, the film is substantially free of plant material particles with a diameter greater than about 2 µm.

[0008] In some embodiments, the film comprises plant extracts with a solids (non-aqueous) content of at least about 65%.

[0009] In some implementations, the plant material is tobacco.

[0010] In some implementations, the tobacco is in one or more of the following forms: cut rags, leaves, and reconstituted tobacco.

[0011] In some embodiments, the film contains tobacco extract.

[0012] In some embodiments, the nicotine content of the film is from about 1.5% to about 7% by weight of the film.

[0013] In some embodiments, the nicotine content of the film is about 2% to about 4% by weight of the film.

[0014] In some embodiments, the aerosol generating composition comprises about 70% to about 90% of a first aerosol generating material and about 10 wt% to about 30 wt% of a second aerosol generating material.

[0015] In some implementations, the film is cut or shredded.

[0016] In some embodiments, the film is in the form of a sheet. In some embodiments, the sheet is wound.

[0017] In some embodiments, the aerosol generating composition comprises about 10 wt% to about 25 wt% of aerosol forming agent material.

[0018] In some embodiments, the film contains about 10 wt% to about 40 wt% of aerosol forming agent material.

[0019] In some embodiments, the water content of the aerosol-generating composition is no more than about 12%.

[0020] In some embodiments, the water content of the film is no more than about 5%.

[0021] According to a second aspect of the invention, an aerosol generating article for use in an aerosol supply system is provided, comprising an aerosol generating section comprising an aerosol generating composition according to the first aspect.

[0022] In some embodiments, the second aerosol generating material is contained in the form of a sheet positioned around at least a portion of a plug or segment containing the first aerosol generating material.

[0023] In some embodiments, the second aerosol generating material is included in the form of a cut or shredded material blended with the first aerosol generating material.

[0024] In some embodiments, the article comprises: a first segment of a first aerosol generating material and a second segment of a wound sheet containing a second aerosol generating material.

[0025] In some embodiments, the article comprises a wrapping paper circumscribing an aerosol-generating composition, wherein the second aerosol-generating material is a sheet positioned between the first aerosol-generating material and the wrapping paper.

[0026] In some embodiments, the article includes a cooling section comprising a longitudinally extending air passage for cooling an airflow passing through it.

[0027] According to a third aspect of the invention, a system is provided for heating an aerosol-generating composition to volatilize at least one component of the aerosol-generating material, the system comprising: According to the second aspect of the product, and An aerosol delivery device for heating an aerosol generation section to volatilize at least one component of an aerosol generation composition.

[0028] In some embodiments, the heating device is configured as an externally heated aerosol generating section, and / or an induction heated aerosol generating section, and / or a resistance heated aerosol generating section.

[0029] According to a fourth aspect of the present invention, a method for forming an article according to the second aspect is provided, comprising the following steps: Provides an aerosol generating composition and packaging material according to the first aspect; The aerosol generating composition is wrapped with packaging material to form an aerosol generating segment; and any further segment is attached. Attached Figure Description

[0030] Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, wherein: Figure 1 This is a side cross-sectional view of an article used in an aerosol supply system according to one embodiment; Figure 2 This is a side cross-sectional view of an article according to another embodiment; Figure 3 This is a side cross-sectional view of the article according to an alternative embodiment; Figure 4 This is a side cross-sectional view of an article according to another embodiment; Figure 5 This is a side cross-sectional view of an article of manufacture according to another embodiment including a distal plug; and Figure 6 This is a perspective view of a non-flammable aerosol supply apparatus for generating aerosol from an article of manufacture, according to the present disclosure. Detailed Implementation

[0031] The present invention generally relates to an aerosol generating composition for use in an aerosol generating article, said aerosol generating article being configured to heat (but not burn) the composition to generate an aerosol for inhalation.

[0032] The aerosol generating composition comprises a first aerosol generating material including plant material and a second aerosol generating material including a thin film. Specifically, the first aerosol generating material including plant material is present in an amount of about 95 wt% to about 50 wt%, and the second aerosol generating material is present in an amount of about 5 wt% to about 50 wt%.

[0033] Both the first and second aerosol-generating materials are heated during use to generate one or more aerosols. The combination of these two materials provides a variety of beneficial properties to the aerosol-generating composition. For example, the plant material can provide a source of authentic, natural plant flavor and active substances. These flavors and / or active substances can be supplemented by flavors and / or active substances provided by the film material, which may, for example, contain plant extracts, providing a concentrated source of such substances. The film also provides volatile components, including the volatile components of the plant extracts, in a stable form.

[0034] Thin films can also represent a source of aerosol forming agent materials that are difficult to incorporate into plant materials in sufficient quantities to provide the required aerosol body and visible aerosols, while still retaining the properties that make the plant materials suitable for incorporation into aerosol-generated articles.

[0035] In embodiments of the invention, the film can provide flavor and / or active substances in a concentrated form. This means that the amount of such film contained in an aerosol-generating composition can be reduced compared to the amount of film contained in a conventional aerosol-generating composition. For example, the aerosol-generating composition can contain as little as 5 wt% of a second aerosol-generating material while still contributing to the generation of a flavorful and impactful aerosol.

[0036] The reduced amount of film present in the aerosol-generating composition provides additional flexibility in how the material is incorporated into the aerosol-generating composition and in designing articles incorporating the composition. This enables the design of articles that allow for controlled heating of the film and controlled generation of aerosols from the aerosol-generating composition.

[0037] Including a relatively small amount of film can also mean a reduction in the total mass of aerosol-generating compositions and aerosol-generating articles, thereby reducing costs and potentially energy requirements.

[0038] There is also an additional benefit: the sensory quality of the initial puff (such as the first 1 or 2 puffs) can be improved, resulting in a better user experience and increased user satisfaction.

[0039] A major challenge associated with aerosol supply systems is a phenomenon known as "hot puff." This refers to the vapor released when the aerosol generating material is initially heated. As the temperature rises, moisture evaporates, forming vapor that the user can inhale. The higher the water content of the aerosol generating material, the more vapor is generated upon heating, and the more severe the hot puff phenomenon. Aerosol generating materials with a high aerosol forming agent content often have a relatively high moisture content, which contributes to hot puff. Reducing the amount of this aerosol generating material or lowering its water content can significantly mitigate the hot puff problem experienced by the user.

[0040] film

[0041] As mentioned herein, a film is a sheet material that can be heated to form an aerosol. Films may also be alternatively referred to as "dry gels." A film is a solid material in which some fluid, such as a liquid, can be retained. In some embodiments, the film is optionally cast or extruded to form a sheet.

[0042] The film may contain binders (such as gelling agents) and aerosol forming agents. Optionally, a substance to be delivered and / or fillers may also be present. Optionally, a solvent (such as water) may also be present, and one or more other components of the film may be soluble in or insoluble in the solvent.

[0043] The thickness of the film can be from about 0.015 mm to about 1 mm. For example, the thickness can be in the range of about 0.05 mm, about 0.1 mm or about 0.15 mm to about 0.5 mm or about 0.3 mm.

[0044] Thin films may include more than one layer or film, and the thickness mentioned herein may refer to the aggregate thickness of those layers or films.

[0045] The film can be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, such as surrounding at least a portion of a stopper or section comprising the first aerosol-generating material. In some embodiments, the sheet may be wound, for example, to form a tube. The tube may be empty or filled with a material that may be or may include the first aerosol-generating material. In other embodiments, the film sheet may be gathered to form a gathered sheet. In still other embodiments, the film sheet may be cut or shredded to form shredded material. Shredded material may comprise one or more film strips or film tapes.

[0046] Aerosol-generating films can be formed by combining a binder (such as a gelling agent) with a solvent (such as water), an aerosol forming agent material, 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 evaporate at least some of the solvent, thereby forming the film.

[0047] The slurry may be heated to remove at least about 60 wt%, about 70 wt%, about 80 wt%, about 85 wt%, or about 90 wt% of the solvent.

[0048] The film can be a "monolithic solid". The film can be substantially non-fibrous. In some embodiments, the film can be a desiccant. The film is a solid material in which some fluid (such as a liquid) can be retained. In some embodiments, the second aerosol generating material may, for example, comprise about 50 wt%, about 60 wt%, or about 70 wt% to about 90 wt%, about 95 wt%, or about 100 wt% of the film.

[0049] In some embodiments, the film is substantially free of (solid) plant material. This means that the film is substantially free of plant material particles with a particle size greater than about 2 µm. This also means that the plant extracts included in the film are also substantially free of plant material particles with a particle size greater than about 2 µm.

[0050] The term "plant material" does not cover materials such as wood pulp or carboxymethyl cellulose. These are not plant material particles, but rather materials extracted from or derived from plant materials, such as those obtained through chemical processing. Such derived materials can be included as fillers in films, as discussed elsewhere in this document.

[0051] In particular, in some embodiments, the film is substantially free of tobacco. This can mean that the film does not contain any tobacco material particles with a diameter greater than about 2 µm, i.e., tobacco leaf or stem particles.

[0052] As used herein, the term “substantially free” means including less than about 1 wt%, less than about 0.5 wt%, or about 0 wt%.

[0053] In some embodiments, the film comprises a liquid plant extract.

[0054] The film may include multiple components, including a binder that binds the components together to form a cohesive whole. The binder may be a gelling agent.

[0055] In some embodiments, the film may include one or more adhesives (DWB) of about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 10 wt%, about 15 wt%, or about 20 wt% to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 25 wt%, about 20 wt%, about 15 wt%, or about 10 wt%. For example, the film may include adhesives (DWB) of about 1 wt% to about 40 wt%, about 2 wt% to about 20 wt%, or about 4 wt% to about 15 wt%.

[0056] Suitably, the film may comprise from about 1 wt% to about 60 wt% of a gelling agent, such as about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 10 wt%, about 15 wt%, or about 20 wt% to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 25 wt%, about 20 wt%, about 15 wt%, or about 10 wt% of a gelling agent (all based on dry weight). For example, the second aerosol generating material may comprise from about 1 wt% to about 30 wt%, about 2 wt% to about 20 wt%, or about 4 wt% to about 15 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid.

[0057] In some embodiments, the gelling agent includes (or is) one or more compounds selected from the following: polysaccharide gelling agents, such as alginate, pectin, starch or derivatives thereof, cellulose or derivatives thereof, pullulan, carrageenan, agar and agarose; gelatin; gums, such as xanthan gum, guar gum and gum arabic; silica or silicone compounds, such as PDMS and sodium silicate; clay, such as kaolin; and polyvinyl alcohol.

[0058] In some embodiments, the gelling agent includes (or is) one or more polysaccharide gelling agents.

[0059] In some embodiments, the polysaccharide gelling agent is selected from alginate, pectin, starch or derivatives thereof, or cellulose or derivatives thereof. In some embodiments, the polysaccharide gelling agent is selected from alginate and cellulose derivatives.

[0060] In some embodiments, the gelling agent is a polysaccharide gelling agent, optionally selected from alginate and cellulose derivatives.

[0061] In some embodiments, the alginate is sodium alginate.

[0062] In some embodiments, the polysaccharide gelling agent is a cellulose derivative. Not wanting to be bound by theory, the inventors believe that such gelling agents do not react with calcium ions to form crosslinks.

[0063] In some embodiments, the polysaccharide gelling agent is an alginate.

[0064] In some embodiments, the gelling agent is not cross-linked. The absence of cross-linking in the gelling agent facilitates faster delivery of plant components, derivatives, or extracts (as well as any optional additional active substances and / or flavorings) from the second aerosol-generating material.

[0065] Examples of cellulosic gelling agents (also referred to herein as cellulose derivatives) include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, cellulose or its derivatives are selected from hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose derivative is CMC.

[0066] For example, in some embodiments, the gelling agent includes (or is) one or more of the following: alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

[0067] In some embodiments, the gelling agent includes (or is) one or more of the following: hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, guar gum, gum arabic, alginate and / or pectin.

[0068] In some cases, the gelling agent includes (or is) alginate and / or pectin, and may be combined with a coagulant (such as a calcium source) during film formation. In some cases, the aerosol-generating material may include calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0069] In some embodiments, the gelling agent includes (or is) alginate, optionally wherein the alginate is present in the aerosol-generating material in an amount of about 1 wt% to about 10 wt%, for example about 3 wt% to about 6 wt% (based on dry weight).

[0070] In some implementations, alginate is the only gelling agent present in the film.

[0071] In other embodiments, the gelling agent includes alginate and at least one other gelling agent, such as pectin.

[0072] In certain embodiments, the gelling agent is carboxymethyl cellulose, optionally wherein the amount of carboxymethyl cellulose (CMC) present is from about 15 wt% to about 50 wt%, for example from about 20 wt% to about 40 wt% or about 30 wt%. In some embodiments, CMC is the only gelling agent present in the film.

[0073] In some embodiments, the weight ratio of the total amount of gelling agent to the total amount of plant extract is from about 1:1 to about 1:20, such as from about 1:5 to about 1:15 or from about 1:10 to about 1:12.

[0074] To enhance aerosol formation, the film may preferably include an aerosol forming agent material. The aerosol forming agent material may include one or more components capable of forming aerosols.

[0075] The film may comprise about 5 wt%, about 10 wt%, about 15%, about 20 wt%, about 25 wt%, about 27 wt%, or about 30 wt% to about 60 wt%, about 55 wt%, about 50 wt%, about 45 wt%, about 40 wt%, or about 35 wt% of aerosol forming agent material (DWB). For example, the film may comprise about 10 wt% to about 60 wt%, about 10 wt% to about 40 wt%, about 20 wt% to about 50 wt%, about 25 wt% to about 40 wt%, or about 30 wt% to about 35 wt% of aerosol forming agent material.

[0076] Suitably, the film may comprise about 0.1 wt%, about 0.5 wt%, about 1 wt%, about 3 wt%, about 5 wt%, about 7 wt%, or about 10 wt% to about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt%, or about 25 wt% of aerosol forming agent material (all based on dry weight). For example, the film may comprise about 0.5 wt% to about 40 wt%, about 3 wt% to about 35 wt%, or about 10 wt% to about 25 wt% of aerosol forming agent material.

[0077] In some embodiments, the aerosol forming agent material may include one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, triacetin, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0078] In some cases, the aerosol forming agent material includes one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In other cases, the aerosol forming agent material includes glycerol, is substantially composed of glycerol, or is composed of glycerol.

[0079] In some embodiments, the aerosol forming agent material comprises a mixture of glycerol and propylene glycol in a weight ratio of about 3:1 to about 1:3, about 2:1 to about 1:2, about 1.5:1 to about 1:1.5, about 55:45 to about 45:55, or about 45:55.

[0080] Aerosol forming agent materials can be used as plasticizers. It has been determined that if the aerosol forming agent content is too high, the film may absorb moisture (because aerosol forming agent materials are hygroscopic), resulting in a material that fails to provide a suitable consumer experience during use. It has also been determined that if the aerosol forming agent content is too low, the film may become brittle and fragile (because aerosol forming agent materials can be used as plasticizers). The aerosol forming agent content specified herein provides the film with flexibility, allowing it to be wound onto a spool, which is useful in the manufacture of aerosol-generated articles.

[0081] The film may comprise about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt%, or about 45 wt% to about 60 wt%, about 55 wt%, or about 50 wt% of plant extracts (DWB). For example, the film may comprise about 20 wt% to about 60 wt%, about 40 wt% to about 55 wt%, or about 45 wt% to about 50 wt% of plant extracts (DWB).

[0082] In some embodiments, the plant extract is a liquid or solid separated from plant material. For example, the extract may be prepared by processing techniques such as pressing (e.g., juicing or pressing) or solvent extraction. Optionally, the extract may be concentrated and / or purified, for example by distillation. In some embodiments, the plant material is impregnated (typically without heating) prior to extraction to soften and degrade the material.

[0083] In some cases, plant extracts are aqueous extracts, obtained by extraction with water. Additionally or alternatively, other solvents, including supercritical fluids, may be used.

[0084] In some embodiments, the plant extracts included in the film are one or more extracts of any plant material discussed herein.

[0085] In some implementations, the plant extract includes or is composed of tobacco extract.

[0086] In some cases, tobacco extracts may be aqueous extracts, obtained by extraction with water. Tobacco extracts may be extracts from any suitable tobacco, such as single or blended grades, shredded or whole leaves, including Virginia and / or Burley and / or Oriental. They may also be extracts from tobacco particle “dust” or powder, expanded tobacco, stems, expanded stems, and other processed stem materials (such as shredded and rolled stems). The extracts may be obtained from ground tobacco or reconstituted tobacco material.

[0087] In some embodiments, the plant extract used to form the film has a high content of non-aqueous components. This will include soluble plant components as well as any non-aqueous solvents or co-solvents. This may also be referred to as high solid content of the extract, but for the avoidance of doubt, this does not mean the presence of solid plant material.

[0088] Conventional aqueous tobacco extracts have a solids content (non-aqueous) of at most about 50%. In contrast, in some embodiments of the present invention, the plant extracts used to form the film have a solids content (non-aqueous) of at least about 65%, at least about 70%, at least about 75%, or at least about 78%. This means that the extracts are more concentrated than conventional extracts and can provide the film with a rich and impactful flavor and active substance content when heated to form vapor or aerosol. In some embodiments, the high solids content in the plant extracts can be achieved by using an alcohol such as ethanol as a co-solvent shared with water.

[0089] In some embodiments, the film includes about 1 wt%, about 1.5 wt%, or about 2 wt% to about 6 wt%, about 5 wt%, about 4 wt%, or about 3 wt% nicotine (DWB). In some cases, the film may be nicotine-free except for nicotine derived from tobacco extracts.

[0090] In some embodiments, the film includes additional or added flavoring agents and / or active substances in addition to those present in the plant extract. Suitably, the film may include up to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 20 wt%, about 10 wt%, or about 5 wt% of such additional flavoring agents and / or active substances. In some cases, the film may include at least about 0.5 wt%, about 1 wt%, about 2 wt%, about 5 wt%, about 10 wt%, about 20 wt%, or about 30 wt% of additional flavoring agents and / or active substances (all based on dry weight). For example, the film may include about 10 wt% to about 60 wt%, about 20 wt% to about 50 wt%, or about 30 wt% to about 40 wt% of additional flavoring agents and / or active substances.

[0091] Suitably, the film may include up to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 20 wt%, about 10 wt%, or about 5 wt% of additional or added flavoring agents. In some cases, the film may include at least about 0.5 wt%, about 1 wt%, about 2 wt%, about 5 wt%, about 10 wt%, about 20 wt%, or about 30 wt% of additional flavoring agents (all based on dry weight). For example, the film may include about 10 wt% to about 60 wt%, about 20 wt% to about 50 wt%, or about 30 wt% to about 40 wt% of additional flavoring agents. In some cases, the additional flavoring agents (if present) include menthol, consist essentially of menthol, or consist of menthol.

[0092] In some cases, the film does not contain added flavorings and / or active substances. In some cases, the film does not contain additional flavorings. In some cases, the film does not contain additional active substances.

[0093] In some cases, the total content of plant extracts with additional flavoring agents and / or active substances may be no more than about 80 wt%, about 70 wt%, about 60 wt%, about 50 wt%, or about 40 wt% (all based on dry weight).

[0094] In some embodiments, the film includes nicotine. In some embodiments, the nicotine may be derived from plant extracts included in the film. In other embodiments, such as those where the plant extract is not a tobacco extract, nicotine is an additional active substance included in the film. In some embodiments, the nicotine content of the film is from about 1.5 wt% to about 7 wt% (DWB) based on the weight of the film.

[0095] In some cases, the film may include at least about 1.5 wt%, about 2 wt%, about 2.5 wt%, about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, or about 5 wt% of nicotine (DWB). The film may include no more than about 7 wt%, about 6.5 wt%, about 6 wt%, about 5.5 wt%, about 5 wt%, about 4.5 wt%, about 4 wt%, about 3.5 wt%, or about 3 wt% of nicotine (DWB) by weight of the film. For example, the film may include about 2 wt% to about 6 wt%, or about 4 wt% to about 5 wt% of nicotine (DWB) by weight of the film.

[0096] In some embodiments, the film includes fillers. The fillers may be present to modify the physical and / or chemical properties of the material. For example, in some embodiments, the fillers may increase the tensile strength of the film, making it more suitable for large-scale manufacturing of aerosol-generating articles. On the other hand, including fillers may increase the cost, weight, and density of the film. Increasing the mass of the film may increase the energy and time required to heat the film to generate the desired aerosol.

[0097] In some embodiments, the film includes no more than about 60 wt% of filler, such as about 1 wt% to about 60 wt%, or about 5 wt% to about 50 wt%, or about 5 wt% to about 30 wt%, or about 10 wt% to about 20 wt%.

[0098] In other embodiments, the film includes no more than about 20 wt%, suitably no more than about 10 wt%, or no more than about 5 wt% of filler. In some cases, the film includes no more than about 1 wt% of filler, and in some cases, no filler is included.

[0099] The filler (if present) may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may also include one or more organic filler materials, such as wood pulp; tobacco pulp; hemp fiber; starch and starch derivatives, such as maltodextrin; chitosan; and cellulose and cellulose derivatives, such as microcrystalline cellulose and nanocrystalline cellulose. In certain cases, the membrane may not contain calcium carbonate such as chalk.

[0100] In certain embodiments that include fillers, the fillers are fibrous. For example, the fillers may be fibrous organic filler materials, such as wood pulp, hemp fiber, cellulose, or cellulose derivatives. In some embodiments, the fibrous filler is wood pulp. It is not desirable to be bound by theory, but it is believed that including fibrous fillers in a film can improve the tensile strength of the material. This can be particularly advantageous in instances where the film is provided in sheet form, such as when the film sheet wraps around rods of an aerosolizable material.

[0101] In some embodiments, the film does not include tobacco fibers. In certain embodiments, the film does not include fibrous materials.

[0102] In some embodiments, the gelling agent is cellulose (such as CMC) and / or guar gum, and is used in conjunction with wood pulp as a filler.

[0103] In some cases, the membrane may include water. In some cases, the membrane is a hydrogel. In some embodiments, the membrane includes no more than about 20 wt%, about 15 wt%, about 12 wt%, about 10 wt%, about 9 wt%, or about 8 wt% water. In some cases, the membrane may include at least about 1 wt%, about 2 wt%, or about 5 wt% water. The membrane may include about 10 wt% water. In some cases, the membrane includes about 5 wt% to about 10 wt% water, or about 5 wt% to about 9 wt% water. Suitably, the water content of the membrane may be about 5 wt%.

[0104] In some cases, the film may consist essentially of or consist of one or more binders, aerosol-forming materials, plant extracts, water, and one or more fillers. In other cases, the film may consist essentially of or consist of glycerol, guar gum and / or cellulose, plant extracts, and fillers such as wood pulp.

[0105] In some embodiments, the thin film includes: 1-10 wt% guar gum; 10-30 wt% glycerol; 10-60 wt% plant extracts; 1-15 wt% wood pulp; and 20-40 wt% ground cellulose; These weights are calculated based on dry weight.

[0106] Thin films with these compositions have been found to be efficiently heated to generate inhalable aerosols.

[0107] In some cases, the second aerosol generating material may additionally include a carrier on which a film is disposed. The carrier may be easy to manufacture and / or process, for example by: (a) providing a surface on which a slurry can be cast (and the slurry subsequently does not need to be separated from it), (b) providing a non-sticky surface for the aerosol generating material, and (c) providing a certain degree of rigidity for the aerosol generating material.

[0108] In some cases, the carrier may be formed from materials selected from: metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes (such as graphite and graphene), plastics, cardboard, wood, or combinations thereof. In some cases, the carrier may comprise or be composed of plant materials, such as reconstituted tobacco sheets. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood, or combinations thereof. In some cases, the carrier itself may be a laminated structure comprising layers of materials selected from the foregoing list. In some cases, the carrier may also be used as a flavoring carrier. For example, the carrier may be impregnated with flavoring agents or plant extracts.

[0109] In some cases, the carrier may be substantially or completely impermeable to gases and / or aerosols. This prevents aerosols or gases in use from passing through the carrier, thereby controlling flow and ensuring delivery to the user. It can also be used to prevent condensation or other deposition of gases / aerosols in use on heater surfaces, such as those in aerosol generation components. Therefore, in some cases, this can improve consumption efficiency and hygiene.

[0110] In some cases, the carrier in an aerosol-generating article may include, or consist of, a porous layer adjacent to or composed of such a porous layer. For example, the porous layer may be a paper layer. In certain specific cases, the film is positioned in direct contact with the porous layer; the porous layer is adjacent to the film and forms a strong bond. The film is formed by drying a slurry or gel, and is not theoretically limited to the belief that the slurry or gel partially impregnates the porous layer (e.g., paper) such that when the slurry or gel solidifies and forms crosslinks, the porous layer is partially incorporated into the film. This provides a strong bond between the film and the porous layer.

[0111] Additionally, surface roughness can contribute to the bonding strength between the film and the carrier. The paper roughness (of the surface adjacent to the carrier) is suitably in the range of about 50 to about 1000 Bekk seconds, preferably about 50 to about 150 Bekk seconds, preferably about 100 Bekk seconds (measured at an air pressure range of 50.66–48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the surface smoothness of paper, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample; the time (in seconds) required for a fixed volume of air to permeate between these two surfaces is called the "Bekk smoothness".)

[0112] Conversely, the surface of the carrier facing away from the film can be arranged to contact the heater, and a smoother surface can provide more efficient heat transfer. Therefore, in some cases, the carrier is configured such that the rougher side is adjacent to the film, while the smoother side faces away from the film.

[0113] In one specific case, the carrier can be a paper-backed foil; the paper layer is adjacent to the film layer and provides the properties discussed in the preceding paragraphs through this adjacency. The foil backing is substantially impermeable, providing control over the aerosol flow path. Metal foil backings can also be used for heat conduction to the film.

[0114] In another case, the foil layer of the paper-backing foil is adjacent to the film. The foil is substantially impermeable, thus preventing water supplied in the film from being absorbed into the paper, which would otherwise compromise its structural integrity.

[0115] In some cases, the carrier is formed of or comprises a metal foil (such as aluminum foil). A metal carrier allows for better heat conduction to the thin film. Additionally or alternatively, the metal foil can be used as a sensor in an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the thickness of the metal foil layer may be no greater than about 20 µm, such as about 1 µm to about 10 µm, suitably about 5 µm.

[0116] In some cases, the carrier can be magnetic. This feature can be used to secure the carrier to an assembly during use, or to generate specific film shapes. In some cases, the aerosol-generating material may include one or more magnets, which can be used to secure the material to an induction heater during use.

[0117] In some cases, aerosol-generating materials may include heating devices embedded in a thin film, such as resistance or induction heating elements.

[0118] In some cases, the thickness of the film can be from about 0.015 mm to about 1.0 mm. Suitably, the thickness can be in the range of about 0.05 mm, about 0.1 mm, or about 0.15 mm to about 0.5 mm or about 0.3 mm. A material with a thickness of about 0.2 mm may be particularly suitable. The film may comprise more than one layer, and the thickness described herein refers to the total thickness of those layers.

[0119] If the film is too thick, heating efficiency may be compromised. This negatively impacts power consumption during use. Conversely, if the film is too thin, it becomes difficult to manufacture and handle; very thin materials are more difficult to cast and may be brittle, thus impairing aerosol formation during use.

[0120] The film thicknesses specified herein optimize material properties in view of these competing considerations. The thicknesses specified herein are the average thicknesses of the materials. In some cases, the film thicknesses may vary by no more than about 25%, about 20%, about 15%, about 10%, about 5%, or about 1%.

[0121] The second aerosol-generating material, including the thin film, can have any suitable areal density, such as about 30 g / m³. 2 Approximately 120 g / m 2 In some embodiments, the second aerosol-generating material may have a concentration of approximately 30 g / m³. 2 Approximately 70 g / m 2 or approximately 40g / m 2 Approximately 60 g / m 2 The areal density. In some embodiments, the film may have an areal density of about 80 g / m³. 2 Approximately 120 g / m 2 or approximately 70 g / m2 Approximately 110 g / m 2 or especially about 90 g / m 2 Approximately 110 g / m 2 The areal density. This areal density is particularly suitable when the second aerosol-generating material is included in aerosol-generating articles / assemblies in sheet or shredded form (as further described below).

[0122] The film can be formed into a sheet. It can be incorporated into the article in sheet form. In some cases, the second aerosol generating material can be included as a planar sheet, as a bundled or aggregated sheet, as an embossed sheet, or as a wound sheet (i.e., in the form of a tube or a wound plug).

[0123] In some embodiments, the film may be included as a sheet in the aerosol-generating article / assembly, such as a sheet surrounding a rod of the first aerosol-generating material. In some other cases, the second aerosol-generating material may be formed as a sheet, then shredded and incorporated into the article. In some cases, the shredded material may be mixed with the first aerosol-generating material and incorporated into the article. In such cases, the area mass of the second aerosol-generating material may be selected to be comparable to the density of the first aerosol-generating material, such that the components of the mixture do not separate. For example, the area mass of the second aerosol-generating material may be about 80 g / m³. 2 Approximately 120 g / m 2 This is done to make its density comparable to that of shredded tobacco.

[0124] In some instances, the film in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some instances, such as when the film does not include fillers, the film may have a tensile strength of about 200 N / m to about 400 N / m, or about 200 N / m to about 300 N / m, or about 250 N / m. Such tensile strength is particularly suitable for embodiments in which the aerosol generating material is formed as a sheet, then shredded and incorporated into the aerosol generating article. In some instances, such as when the film includes fillers, the film may have a tensile strength of about 600 N / m to about 900 N / m, or about 700 N / m to about 900 N / m, or about 800 N / m. Such tensile strength is particularly suitable for embodiments in which the aerosol generating material is included in the aerosol generating article / assembly as packaging paper or as a wound sheet (suitably in tubular form).

[0125] plant materials

[0126] The first aerosol-generating materials include plant materials.

[0127] As used herein, the term "plant material" includes any material derived from plants, including but not limited to leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, pods, etc. In some embodiments, the term "plant material" refers to solid plant matter (i.e., a part of a plant) and does not cover "plant extracts".

[0128] Examples of plants include: tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin. Nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, holly, perilla, turmeric, turmeric root, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, allspice, nutmeg skin, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint can be selected from the following varieties: wild mint (Mentha arvensis), cultivated mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), cultivated lemon peppermint (Mentha piperita citrata cv), cultivated peppermint (Mentha piperita cv), spearmint (Mentha spicata crispa), heart-leaf mint (Mentha cordifolia), long-leaf mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), lip mint (Mentha pulegium), cultivated spearmint (Mentha spicata cv), and round-leaf mint (Mentha suaveolens).

[0129] In some implementations, the plant is selected from eucalyptus, star anise, and cocoa.

[0130] In some implementations, the plant is selected from rooibos and fennel.

[0131] In some implementations, the plant material includes leaf material.

[0132] In some implementations, the plant material is tobacco.

[0133] As used herein, the term "tobacco material" means any material that includes tobacco or its derivatives. The term "tobacco material" may include one or more of the following: tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of the following: ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extracts.

[0134] The tobacco used to produce tobacco material can be any suitable tobacco, such as single or blended grades, shredded or whole leaves, including Virginia tobacco and / or Burley and / or Oriental tobacco. It can also be tobacco particle "dust" or powder, expanded tobacco, stems, expanded stems, and other processed stem materials, such as shredded and rolled stems. The tobacco material can be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may include tobacco fibers and can be formed by casting, by a papermaking process using a fourdrinier-based paper machine with the addition of tobacco extracts, or by extrusion.

[0135] In some cases, the plant material may include water. In some cases, the plant material is dried plant material, i.e., the plant material has been treated to remove naturally occurring water from the plant. In some embodiments, the plant material includes no more than about 20 wt%, about 15 wt%, about 12 wt%, or about 10 wt% water. In some cases, the plant material may include at least about 1 wt%, about 2 wt%, or about 5 wt% water. The plant material may include about 10 wt% to about 20 wt% water, or about 10 wt% to about 15 wt% water. Suitably, the water content of the membrane may be about 12 wt%.

[0136] In some embodiments, the first aerosol-generating material includes an aerosol-forming agent material. For example, the aerosol-forming agent material may be added to or incorporated into the plant material.

[0137] In some embodiments, the first aerosol generating material comprises at least about 10 wt%, about 12 wt%, about 15 wt%, about 18 wt%, about 20 wt%, or about 22 wt% of an aerosol forming agent. Additionally or alternatively, the first aerosol generating material comprises no more than about 25 wt%, about 22 wt%, about 20 wt%, about 18 wt%, about 15 wt%, or about 12 wt% of an aerosol forming agent. In some embodiments, the amount of aerosol forming agent in the first aerosol generating material is about 15 wt% to about 25 wt%, or about 20 wt% to about 25 wt% (DWB).

[0138] Aerosol generating composition

[0139] The aerosol generating composition is a combination of two or more different aerosol generating materials, wherein the first aerosol generating material includes plant material and the second aerosol generating material includes a thin film.

[0140] The aerosol generating composition comprises about 50 wt% to about 95 wt% of a first aerosol generating material containing plant material and about 5 wt% to about 50 wt% of a second aerosol generating material containing a film.

[0141] In some embodiments, the aerosol generating composition comprises about 70% to about 90% of a first aerosol generating material and about 10 wt% to about 30 wt% of a second aerosol generating material.

[0142] Two aerosol-generating materials are included in the aerosol-generating composition. The aerosol-generating materials may differ in one or more other respects. For example, in some embodiments, the first and second aerosol-generating materials comprise different active substances.

[0143] Aerosol-generating materials can have different thicknesses and / or can be provided in other different sizes, such as being cut into different sizes or average particle sizes.

[0144] The density of materials that generate aerosols can vary.

[0145] In some embodiments, the aerosol-generating material comprises different components or includes the same components in different amounts.

[0146] Two or more aerosol generating materials may be included in the aerosol generating materials in different amounts.

[0147] In some embodiments, different aerosol-generating materials may be mixed to form a generally homogeneous blend. In other embodiments, the distribution of the different aerosol-generating materials is controlled to provide a desired distribution within the materials, optionally wherein the materials are unmixed or substantially unmixed. When the aerosol-generating composition comprises a blend of two or more different aerosol-generating materials, this allows for control of the release of the active agent. For example, the blend can provide a consistent release throughout the use of the consumable and can be configured / formulated to provide rapid or slow release.

[0148] Aerosol-generating materials may be arranged within the composition to allow them to be heated together or separately. Separate heating may mean in terms of time (e.g., sequentially) and / or in terms of heating to different temperatures.

[0149] As discussed above, the film of the first aerosol generating material may include an aerosol forming agent material. Additionally, the aerosol forming agent material may optionally be included in the second aerosol generating material. In some embodiments, the aerosol generating composition (total) includes about 10 wt% to about 25 wt% of aerosol forming agent material (DWB).

[0150] In some embodiments, the aerosol generating composition comprises at least about 10 wt%, about 12 wt%, about 15 wt%, about 18 wt%, about 20 wt%, or about 22 wt% of one or more aerosol forming agent materials. Additionally or alternatively, the aerosol generating composition comprises no more than about 40 wt%, about 35 wt%, about 30 wt%, about 25 wt%, about 22 wt%, about 20 wt%, about 18 wt%, about 15 wt%, or no more than about 12 wt% of aerosol forming agent materials. In some embodiments, the amount of aerosol forming agent material in the aerosol generating composition is about 10 wt% to about 40 wt%, about 15 wt% to about 25 wt%, or about 20 wt% to about 25 wt% (DWB).

[0151] The aerosol-generating composition may include water. In some embodiments, the aerosol-generating composition includes no more than about 20 wt%, about 15 wt%, about 12 wt%, or about 10 wt% water. In some cases, the aerosol-generating composition may include at least about 1 wt%, about 2 wt%, or about 5 wt% water. In some cases, the aerosol-generating composition includes about 5 wt% to about 15 wt% water, or about 10 wt% to about 12 wt% water.

[0152] Products

[0153] Articles for use in aerosol supply systems include an aerosol generating portion, said aerosol generating portion including the aerosol generating composition described herein.

[0154] In some implementations, the aerosol-generating article may be wrapped in packaging materials such as paper.

[0155] In some cases, the article may additionally include filters and / or cooling elements. In some embodiments, the filters and / or cooling elements are joined to the aerosol-generating portion by tipping paper that wraps around at least a portion of two of these portions of the article.

[0156] Cooling elements (if present) may serve to cool gaseous or aerosol components. In some cases, they may cool gaseous components to cause them to condense and form aerosols. They may also serve to isolate extremely hot parts of the device from the user. In some embodiments, the cooling section includes a longitudinally extending air passage for cooling the airflow passing through it.

[0157] The filter (if present) may include any suitable filter known in the art, such as a cellulose acetate stopper or a paper stopper, and optionally include a capsule.

[0158] In some embodiments, the article includes a hollow tubular nozzle. One or more segments selected from the tubular nozzle, a filter plug, and a cooling element may be combined with packaging material to form the nozzle of the article. The nozzle may be attached to the aerosol-generating portion, for example, via a tipping paper.

[0159] In some embodiments, the aerosol generating article and / or its aerosol generating portion includes a second aerosol generating material in the form of a sheet positioned around at least a portion of a plug or segment including the first aerosol generating material.

[0160] In some embodiments, the second aerosol generating material is included in the form of a cut or shredded material blended with the first aerosol generating material.

[0161] In some embodiments, the aerosol-generating portion of the article includes a first section containing a first aerosol-generating material and a second section containing a second aerosol-generating material. In some embodiments, the section includes a wound sheet of the second aerosol-generating material.

[0162] In some embodiments, the article comprises packaging paper surrounding the aerosol-generating composition, wherein a second aerosol-generating material is positioned between the first aerosol-generating material and the packaging paper. In some embodiments, the second aerosol-generating material is a sheet positioned between the packaging paper and the first aerosol-generating material. In some embodiments, a film is disposed on the inner surface of the packaging paper surrounding the second aerosol-generating material.

[0163] In some embodiments, the article also includes a component or plug at the end of the article opposite the mouthpiece. This is also referred to herein as the upstream or distal end of the article. The component comprises a body of material having a generally cylindrical shape. In some embodiments, the body of material is formed from an embossed and gathered sheet of material (such as paper).

[0164] Placing such components upstream of the article offers several advantages. For example, article stability can be improved by preventing aerosol-generating material from falling off the upstream end of the article. When the component comprises a material body with a suction resistance between approximately 1% and 30% of the article's suction resistance, its presence also makes the suction resistance more uniform across articles, as the contribution of the aerosol-generating material rods to the overall suction resistance of the article is relatively small. Advantageously, the relatively high suction resistance of the component makes the overall suction resistance of the article less sensitive to variations in the suction resistance of the aerosol-generating material rods. The presence of the component also helps manage the intensity of the aerosol generated by the article by managing ventilation dilution.

[0165] In some embodiments, the length of the component is in the range of about 3 mm to about 15 mm, and preferably about 4 mm to about 6 mm.

[0166] The outer perimeter of the components is roughly the same as that of the aerosol generation section, resulting in a smooth transition between these components.

[0167] Figure 1 This is a side cross-sectional view of article 1 used in an aerosol supply system. In this example, the article includes consumables for use in a non-flammable aerosol supply system.

[0168] The article includes an aerosol generating section (in this example, a cylindrical aerosol generating section 2) and a nozzle 3 located downstream of and connected to the aerosol generating section 2.

[0169] The aerosol generating portion 2 includes a rod or segment of the aerosol generating composition 20 packaged in a rod wrapping paper 10.

[0170] exist Figure 1 In this embodiment, the rod of the aerosol generating composition 20 comprises a blend of a first aerosol generating material containing plant material and a second aerosol generating material containing a thin film. In this embodiment, the two materials are cut or shredded, and the two different shredded materials are blended to form rod segments. In this embodiment, the two aerosol generating materials are distributed fairly uniformly within the rod and along its length.

[0171] The article 1 also includes a nozzle 3, which has a nozzle end 3b and a distal end 3a adjacent to the aerosol generating portion 2.

[0172] Figure 1The nozzle 3 shown is located at the nozzle end of the article 1 and includes three elements: a nozzle body 14 located downstream of the cooling section 13, and a hollow tubular element 15 located downstream of the nozzle body 14. In other embodiments, one or two of these different nozzle elements may be omitted or repeated, and / or these elements may be provided in a different order. For example, the hollow tubular element 15 may be omitted, and the nozzle body 14 may form the nozzle end of the article. In some instances where the hollow tubular element 15 is omitted, the length of the nozzle body 14 may be increased, or an additional material body may be provided at the nozzle end.

[0173] In an alternative arrangement not shown, the mouthpiece includes a mouthpiece body located at the mouthpiece end, optionally including a plug of cellulose acetate filaments or paper, and optionally including a capsule. Adjacent to the mouthpiece body is a first tube (optionally formed of paper), the first tube being adjacent at its other end to another tubular segment (optionally including cellulose acetate).

[0174] exist Figure 1 In the nozzle shown, the cooling section 13, the nozzle body 14, and the hollow tubular element 15 are connected by a combined packaging material 11.

[0175] like Figure 1 As shown, the tipping paper 9 surrounds the entire length of the nozzle 3 and covers a portion of the aerosol generating portion 2. The tipping paper 9 has an adhesive on its inner surface (not shown) to connect the nozzle 3 and the rod 2. In the illustrated embodiment, the tipping paper 9 extends 5 mm over the rod 2 of the aerosol generating material, but it can alternatively extend approximately 3 mm to approximately 15 mm, or approximately 4 mm to approximately 6 mm, over said rod 2 to provide a strong attachment between the nozzle 3 and the rod 2.

[0176] In the illustrated embodiment, the article 1 has first and second parallel rows of perforations 12 passing through the receiving material 9, the combined packaging material 11, and the cooling section 13, providing ventilation to the nozzle 3 at the cooling section 13. The perforations 12 shown are laser-perforated and are located approximately 18 mm and approximately 19 mm from the downstream nozzle end 3b of the nozzle 3, respectively. In other embodiments, ventilation may be provided to the nozzle 3 at other locations.

[0177] Figure 2 Product 1 is shown, which is related to Figure 1 The articles shown and described above have a similar overall construction. Specifically, the spout and the wrapping paper are identical.

[0178] exist Figure 2 In the case of rods containing aerosol-generating compositions, the difference is... Figure 1As shown. In this embodiment, the aerosol generating section includes a rod or segment containing a first aerosol generating material 21. This could be a rod of chopped plant material. The entire length of the rod or segment is surrounded by a sheet 22 of a second aerosol generating material comprising a film. In this embodiment, the two aerosol generating materials are provided together, but they are not blended, and they exist in different and dissimilar or separate forms in the aerosol generating section. Figure 2 In the embodiment shown, both aerosol generating materials are present along the entire length of the aerosol generating portion 2.

[0179] Figure 3 Product 1 is shown, which is related to Figure 2 The articles shown and described above have a similar overall construction. Specifically, the spout and the wrapping paper are identical.

[0180] exist Figure 3 In the middle, aerosol generation part 2 and Figure 2 The difference shown is that only a portion of the length of the rod or segment comprising the first aerosol-generating material 21 is surrounded by a sheet 22 of the second aerosol-generating material containing a thin film. Similarly, the first aerosol-generating material 21 can be shredded plant material. Therefore, in Figure 3 In the illustrated embodiment, only the first aerosol-generating material 21 exists along the entire length of the aerosol-generating portion 2. The second aerosol-generating material 22 exists only along a portion of the length of the aerosol-generating portion 2. This arrangement means that the second aerosol-generating material 22 can be heated and generate an aerosol at specific times throughout the entire use of the article.

[0181] Figure 4 Article 1 with a different aerosol generating section 2 is shown. Similarly, the nozzle and packaging paper are the same as those shown in the foregoing figures, and as described above.

[0182] exist Figure 4 In this embodiment, the aerosol generating section 2 comprises two separate segments. The first segment is a rod or stopper comprising a first aerosol generating material 21. This segment is adjacent to the distal end 3a of the nozzle 3. The second segment of the aerosol generating section 2 is a rod or stopper comprising a second aerosol generating material 22 containing a thin film. This second segment is formed from a roll of a sheet of the second aerosol generating material. In an alternative embodiment, the rod or stopper may comprise a folded or gathered sheet of the second aerosol generating material 22, an aligned strip of the second aerosol generating sheet material, or a stopper of cut or shredded second aerosol generating sheet material.

[0183] exist Figure 4 In the illustrated embodiment, the first aerosol generating material 21 and the second aerosol generating material 22 are located at different positions along the length of the aerosol generating portion 2. This allows them to be heated separately or independently if desired.

[0184] exist Figure 4 In this embodiment, the two segments of the aerosol generating portion 2 are respectively wrapped by packaging papers 10 and 6. The two segments are held together by a splice paper 7, which wraps around the entire length of the segment including the second aerosol generating material 22 and covers a portion of the segment including the first aerosol generating material 21. The splice paper 7 has an adhesive on its inner surface (not shown) to connect the segments of the aerosol generating portion 2. In the illustrated embodiment, the splice paper 7 extends 5 mm over the segment including the first aerosol generating material 21, but it can alternatively extend over the entire length of the aerosol generating portion 2, or even the entire length of the article 1.

[0185] exist Figure 5 The image shows aerosol-generating article 1, which is related to... Figure 2 The illustrated article is similar, but includes an upstream component or plug 16. The aerosol generating section 2 includes a rod or plug of a first aerosol generating material 21. The entire length of this section 2 is surrounded by a sheet 22 of a second aerosol generating material comprising a thin film.

[0186] Located upstream or distal to article 1 is component 16. Component 16 comprises a material body 17 and is surrounded by wrapping paper 18 (such as paper plug wrapping paper). In some instances, component wrapping paper 18 is non-flammable. In some instances, component wrapping paper 18 may be formed of paper that has been treated, coated, or laminated with another material to make it non-flammable, such as foil backing paper.

[0187] The aerosol generating section 2 and the upstream component 16 are held together by a splice paper 19, which wraps around the entire length of the aerosol generating section 2 and around the upstream component 16. The splice paper 19 has an adhesive on its inner surface (not shown) to connect these separate portions of the article. In the illustrated embodiment, the splice paper 19 extends over the entire length of both the aerosol generating section 2 and the upstream component 16 of the article 1. In other embodiments, the splice paper may extend over the length of the upstream component 16 and only over a portion (e.g., about 5 mm) of the upstream end of the aerosol generating section 2.

[0188] Components

[0189] The present invention also relates to an aerosol generating assembly comprising the aerosol generating article described herein and a heater configured to heat but not burn the aerosol generating composition (also referred to herein as an aerosolizable material).

[0190] In some cases, the heater may be a thin-film resistance heater. In other cases, the heater may include an induction heater or the like. In other embodiments, the heater may be an infrared or radiant heater. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol generating assembly may include multiple heaters. The heater may be battery powered.

[0191] In some cases, the heater can heat the aerosolizable material without combustion to temperatures of approximately 120°C to approximately 350°C during use. In some cases, the heater can heat the aerosolizable material without combustion to temperatures of approximately 140°C to approximately 250°C during use. In some cases, during use, substantially all of the second aerosol-generating composition is no more than about 4 mm, about 3 mm, about 2 mm, or about 1 mm from the heater. In some cases, the second aerosol-generating composition is set to be about 0.01 mm to about 2 mm from the heater, suitably about 0.02 mm to about 1.0 mm, suitably about 0.1 mm to about 0.5 mm. These minimum distances may, in some cases, reflect the thickness of the carrier supporting the film. In some cases, the surface of the film and / or the second aerosol-generating composition may be in direct contact with the heater.

[0192] In some cases, the heater may be embedded in the aerosol-generating composition or inserted into the aerosol-generating article during use. Such heaters may be referred to as internal heaters. In some such cases, the heater may be a resistance heater (having exposed contacts for connection to a circuit). In other such cases, the heater may be a sensor embedded in the aerosol-generating composition, which is heated by induction. Alternatively, the heater may be a radiant or infrared heater.

[0193] Internal heaters may be in the form of sheets, foils, or needles. They may be part of the aerosol-generating article or part of the device into which the article is inserted for use.

[0194] In some cases, the aerosol generating assembly may be a heat-not-burn device. That is, it may contain a solid aerosol generating composition but not a liquid aerosolizable material. In some cases, the aerosol generating composition may include tobacco material. A heat-not-burn device is disclosed in WO 2015 / 062983 A2, the entire contents of which are incorporated herein by reference.

[0195] In some cases, the aerosol generating component may be an electronic cigarette mixing device. That is, it may contain a solid aerosol generating composition and a liquid aerosolizable material. In some cases, the solid aerosol generating composition may include nicotine. In some cases, the solid aerosol generating composition may include tobacco material. In some cases, the solid aerosol generating composition may include tobacco material and a separate nicotine source. Each aerosolizable material may be heated by a separate heater, the same heater, or in one case, the downstream solid aerosol generating composition may be heated by hot aerosol generated from the upstream aerosolizable material. An electronic mixing device is disclosed in WO 2016 / 135331 A1, the entire contents of which are incorporated herein by reference.

[0196] Aerosol-generating articles or components may additionally include vents. These vents may be located in the side walls of the article. In some cases, the vents may be located in filters and / or cooling elements. These vents allow cooled ambient air to be drawn into the article during use, which can mix with the heated volatile components, thereby cooling the aerosol.

[0197] Ventilation enhances the formation of visible heat-sensitive volatile components when the product is heated during use. These components become visible through a process of cooling them to supersaturation. Subsequently, droplet formation (also known as nucleation) occurs, and ultimately, the size of the aerosol particles of the heat-sensitive volatile components increases through further condensation and the coalescence of newly formed droplets.

[0198] Ventilation rate represents the ratio of ambient air drawn into a ventilated area and combined with vapors and / or aerosols from the ventilated aerosol-generating composition. Therefore, a 65% ventilation rate means that the aerosols leaving the aerosol-generating composition comprise 65% by volume of ambient air and 35% by volume of vapors and / or aerosols generated by the heated aerosol-generating composition. Ventilation rate is measured using ISO 9512:2019.

[0199] In some cases, the ratio of cool air or ambient air to the sum of heated volatile components and cool air (called the ventilation rate) is at least about 15%. A ventilation rate of about 15% makes the heated volatile components visible through the methods described above. The visibility of the heated volatile components allows users to recognize that volatile components have been generated and enhances the sensory experience of smoking.

[0200] In another example, the ventilation rate is from about 50% to about 85% to provide additional cooling to the heated volatile components. In some cases, the ventilation rate may be at least about 60% or about 65%.

[0201] The components may include an integrated aerosol-generating article and a heater, or may include a heater device inserted into the article during use. In either case, the heater is configured to heat but not burn the aerosol-generating composition.

[0202] Figure 6 An example of a non-flammable aerosol supply device 100 is shown, which is used to generate an aerosol from an aerosol generating composition of an article or consumable 110 as described herein. For example, article 110 may be... Figures 1 to 4 Any one of the products 1 shown.

[0203] In summary, device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating composition as described herein, such as articles as described in other parts of this document, to generate an aerosol or other inhalable medium to be inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0204] The device 100 includes a housing 102 (in the form of an outer casing) surrounding and housing various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by a heating assembly. In use, the article 110 can be fully or partially inserted into the heating assembly, where it can be heated by one or more components of the heater assembly. The article 110 shown has a rod shape, and... Figures 1 to 4 The product shown is similar to product 1.

[0205] The apparatus 100 in this example includes a first end member 106, which includes a cover 108 movable relative to the first end member 106 to close the opening 104 when no article 110 is in place. Figure 6 In the diagram, cover 108 is shown in an open configuration; however, cover 108 can be moved to a closed configuration. For example, a user can slide cover 108 in the direction of arrow "B".

[0206] The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user can turn on the device 100 by operating the switch 112. The switch may also actuate a means for opening a container inserted into the device, preparing it for use.

[0207] Device 100 may also include electrical components, such as a receptacle / interface 114, which can receive a cable to charge the battery of device 100. For example, receptacle 114 may be a charging interface, such as a USB charging interface.

[0208] Manufacturing method

[0209] The present invention also provides a method for manufacturing aerosol-generating articles as described herein.

[0210] Specifically, the method includes the following steps: Provided are aerosol generating compositions as described herein, comprising a first aerosol generating material and a second aerosol generating material, and packaging material; and The aerosol-generating composition is wrapped with packaging material to form an aerosol-generating section. Any additional sections or portions of the article may be attached to the aerosol-generating section.

[0211] The method may include manufacturing an aerosol-generating composition as described herein and incorporating it into an aerosol-generating article.

[0212] The method may include: (a) forming a slurry comprising a component or a precursor of a film, (b) forming a slurry layer, (c) optionally coagulating the slurry to form a gel, and (d) drying to form a film.

[0213] Step (b) of forming the slurry layer may include, for example, spraying, casting, or extruding the slurry. In some cases, the layer is formed by electrostatically spraying the slurry. In some cases, the layer is formed by casting the slurry.

[0214] In some cases, the slurry is applied to the carrier.

[0215] In some cases, steps (b) and / or (c) and / or (d) may occur at least partially simultaneously (e.g., during electrostatic spraying). In other cases, these steps may occur sequentially.

[0216] In some instances, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, such as about 14 to about 16 Pa·s at 46.5°C. In some instances, the slurry may have an elastic modulus (also known as storage modulus) of about 5 to about 1200 Pa; in some cases, the slurry may have a viscous modulus (also known as loss modulus) of about 5 to about 600 Pa.

[0217] Step (c) of gelling may include adding a coagulant to the slurry. For example, the slurry may include sodium alginate, potassium alginate, or ammonium alginate as a gelling agent, and a coagulant including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0218] The total amount of coagulant (such as a calcium source) can be from about 0.5 wt% to about 5 wt% (based on dry weight). Adding too little coagulant may result in an unstable film composition, causing these components to detach from the film. Adding too much coagulant may result in a very sticky / / or brittle film, thus poor workability.

[0219] However, in some cases, a coagulant is not needed because the plant extract contains enough calcium to achieve gelation. This may be the case with tobacco extract, for example.

[0220] Algates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of polysaccharides formed by β-D-mannuronic acid (M) units and α-L-guluronic acid (G) units (blocks) linked together by (1,4)-glycosidic bonds. Upon the addition of calcium cations, alginate crosslinks to form a gel. The inventors have determined that alginate with a high G monomer content is more likely to form a gel upon the addition of a calcium source. Therefore, in some cases, the gel precursor may include alginate wherein at least about 40%, about 45%, about 50%, about 55%, about 60%, or about 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0221] In some cases, the slurry solvent may consist essentially of water or be composed of water. In some cases, the slurry may include about 50 wt%, about 60 wt%, about 70 wt%, about 80 wt%, or about 90 wt% of a solvent (WWB).

[0222] When the solvent is water, the dry weight content of the slurry will be consistent with the dry weight content of the film. Therefore, the discussion of the solid composition herein is explicitly disclosed in conjunction with the slurry aspect of the present invention.

[0223] Example

[0224] In one example, a tobacco extract was obtained by extraction with ethanol and deionized water. The extract contained 3.12 wt% nicotine and had a solids content (including nicotine) of 62.92 wt% (WWB).

[0225] The extract is then used to form a binder, aerosol forming agent material, filler, and a mixture of deionized and purified water to form a slurry having the following composition.

[0226]

[0227] The slurry was prepared in a Silverson L5M-A laboratory mixer placed in a 10-liter glass or metal beaker. A premix of glycerol and guar gum was formed and stored for later use.

[0228] Step 1: Add wood pulp and water (97% moisture) to a beaker and run the mixer at 1200 rpm for 2 minutes.

[0229] Step 2: Slowly add the ground cellulose (ARBOCEL B 600) to the wood pulp mixture over a period of 2 minutes. Increase the speed to 2000 rpm and mix for another 2 minutes.

[0230] Step 3: Slowly add the tobacco extract to the slurry mixture over 2 minutes, keeping the mixer speed at 2000 rpm, and mix for another 3 minutes.

[0231] Step 4: Slowly add the premix of glycerin and guar gum to the slurry at 3000 rpm for 2 minutes, and then mix for another 5 minutes.

[0232] Step 5: Adjust the casting cutter to between 0.10 and 0.13 cm and cast the slurry onto the metal plate to form a sheet. Dry the sheet in an oven at a temperature between 70°C and 120°C for 3 hours.

[0233] In an alternative casting process, the slurry is mixed to ensure it is a homogeneous mixture, then cast onto a metal plate to a thickness of about 2 mm and allowed to solidify to form a gel.

[0234] After the gel solidifies, it is dried in an oven at 65°C for about 2 hours. The drying process results in a shrinkage rate of about 90%, and the resulting film has about 10 wt% water and a thickness of 0.2 mm.

[0235] The objective is to provide a film with a tensile strength of at least about 7 N / mm. The film should also be 70 to 200 GSM. The dried cast sheets meet these criteria and contain about 17 wt% glycerol and about 2.5 wt% nicotine.

[0236] The film is in sheet form and is used to package a stopper containing a first aerosol material comprising shredded tobacco. The stopper, surrounded by the film material, is then wrapped with outer wrapping paper. The outer wrapping paper provides the article with an aesthetically pleasing and neat appearance and sufficient rigidity. The wrapping paper also helps retain glycerin within the aerosol-generating composition.

[0237] definition

[0238] As used in this article, the terms “upstream” and “downstream” are relative terms defined relative to the direction of the mainstream aerosol that has been pumped from the product or device in use.

[0239] As used herein, active substances may be physiologically active materials, which are materials designed to achieve or enhance physiological responses. Active substances may be selected from, for example, nutritional supplements, nootropics, or psychoactive drugs. Active substances may be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, or C), melatonin, or components, derivatives, or combinations thereof. Active substances may also include one or more components, derivatives, or extracts of another plant (other than tobacco).

[0240] In some implementations, the active substance includes nicotine.

[0241] In some implementations, the active substance includes caffeine, melatonin, or vitamin B12.

[0242] As used herein, the terms “flavoring agent” and “fragrance agent” refer to materials that, where permitted by local regulations, may be used to produce a desired taste, aroma, or other sensory experience in products intended for adult consumers. These may include naturally occurring flavoring materials, plants, plant extracts, synthetic materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberry, peach, apple). Oranges, mangoes, Clementines, lemons, limes, tropical fruits, papayas, rhubarb, grapes, durians, dragon fruit, cucumbers, blueberries, mulberries, citrus fruits, Tolingo, bourbon whiskey, Scotch whiskey, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, bitter bean husk, nutmeg, sandalwood, bergamot, geranium, khat, naswar, areca leaves, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, neroli. Cherry blossoms, cinnamon bark, caraway seeds, cognac, jasmine, ylang-ylang, sage, fennel, mustard, allspice, ginger, coriander, coffee, peppermint oil from any species of the peppermint genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, yerba mate, orange peel, rose, tea (such as green or black tea), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian Allspice, nutmeg, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitations, synthetic or natural ingredients or blends thereof. They may be in any suitable form, such as liquids (e.g., oils), solids (e.g., powders), or gases.

[0243] Flavoring agents may suitably include one or more peppermint flavors, preferably peppermint oil from any species of the genus *Mentha*. Flavoring agents may suitably include menthol, consist essentially of menthol, or consist of menthol.

[0244] In some implementations, the flavoring agents include menthol, spearmint, and / or peppermint.

[0245] In some embodiments, the flavoring agent includes flavor components of cucumber, blueberry, citrus fruits and / or red berries.

[0246] In some implementations, the flavoring agent includes eugenol.

[0247] In some implementations, the flavoring agent includes flavor components extracted from tobacco.

[0248] In some embodiments, the flavoring agent may include a sensory agent designed to achieve a somatosensory sensation, typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve), as a complement or substitute for aroma or taste nerves, and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heat-effecting agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol and WS-3.

[0249] All weight percentages (wt%) mentioned herein are based on dry weight unless otherwise explicitly stated. All weight ratios are also based on dry weight. Weights referenced on a dry weight basis refer to the whole of the extract, slurry, or material excluding water, and may include components that are liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages referenced on a wet weight basis refer to all components, including water.

[0250] For the avoidance of doubt, wherever the term "comprising" is used in this specification to define the invention or its features, it is also disclosed that embodiments in which the invention or its features may be defined using the terms "substantially constitutes" or "consisting of" instead of "comprising". References to materials "comprising" certain features mean that these features are included in, contained in, or retained within the material.

[0251] The above embodiments should be understood as illustrative examples of the present invention. It should be understood that any feature described in connection with any embodiment may be used alone or in combination with other described features, and may also be used in combination with one or more features of any other embodiment, or any combination of any other embodiment. Furthermore, equivalents and modifications not described above may be employed without departing from the scope of the invention as defined by the appended claims.

Claims

1. An aerosol generating composition comprising about 50 wt% to about 95 wt% of a first aerosol generating material and about 5 wt% to about 50 wt% of a second aerosol generating material, wherein the first aerosol generating material comprises plant material and the second aerosol generating material comprises a film.

2. The aerosol-generating composition according to claim 1, wherein, The film contains an adhesive, an aerosol forming agent, and plant extracts.

3. The aerosol-generating composition according to claim 1 or claim 2, wherein, The film is substantially free of plant material particles having a size greater than about 2 µm, and / or the film contains plant extracts having a solid content (non-aqueous) of at least about 65%.

4. The aerosol-generating composition according to any one of claims 1 to 3, wherein, The film contains tobacco extract.

5. The aerosol-generating composition according to any one of claims 1 to 4, wherein, The film has a nicotine content of about 1.5% to about 7% by weight of the film, optionally wherein the film has a nicotine content of about 2% to about 4% by weight of the film.

6. The aerosol generating composition according to any one of claims 1 to 5, comprising about 70% to about 90% of the first aerosol generating material and about 10 wt% to about 30 wt% of the second aerosol generating material.

7. The aerosol-generating composition according to any one of claims 1 to 6, wherein, The film is cut or shredded.

8. The aerosol-generating composition according to any one of claims 1 to 6, wherein, The film is in the form of a sheet, optionally in the form of a wound sheet.

9. The aerosol generating composition according to any one of claims 1 to 8, comprising about 10 wt% to about 25 wt% of an aerosol forming agent material, and / or wherein, The film contains about 10 wt% to about 60 wt% of aerosol forming agent material.

10. The aerosol-generating composition according to any one of claims 1 to 89, having a water content of not more than about 12%, and / or wherein, The film has a water content of no more than about 5%.

11. An aerosol generating article for use in an aerosol supply system, comprising an aerosol generating section, said aerosol generating section comprising the aerosol generating composition according to any one of claims 1 to 10, optionally wherein, The second aerosol generating material is contained in the form of a sheet, which is positioned to surround at least a portion of a plug or segment containing the first aerosol generating material.

12. The aerosol-generating article according to claim 11, wherein, The second aerosol generating material is contained in the form of a cut or shredded material blended with the first aerosol generating material, and / or the aerosol generating article comprises: a first segment of the first aerosol generating material and a second segment of a wound sheet containing the second aerosol generating material.

13. The aerosol-generating article according to claim 11 or claim 12, comprising packaging paper surrounding the aerosol-generating composition, wherein, The second aerosol generating material is a sheet positioned between the first aerosol generating material and the packaging paper, and / or the aerosol generating article includes a cooling section, the cooling section including a longitudinally extending air channel for cooling the airflow passing through it.

14. A system for heating an aerosol-generating composition to volatilize at least one component of the aerosol-generating composition, the system comprising: The aerosol-generating article according to any one of claims 11 to 13, and An aerosol delivery device for heating the aerosol generation section to volatilize at least one component of the aerosol generation composition. Optionally, the heating device is configured to externally heat the aerosol generating section, and / or inductively heat the aerosol generating section, and / or resistively heat the aerosol generating section.

15. A method for forming an aerosol-generating article according to any one of claims 11 to 13, comprising the following steps: Provided the aerosol generating composition and packaging material according to any one of claims 1 to 10; The aerosol generating composition is wrapped with the packaging material to form an aerosol generating section; And any other segments can be attached.

Images