Aerosol generation

Abstract

The present invention provides an aerosol-generating material comprising an amorphous solid. The amorphous solid comprises a gelling agent, an aerosol-forming material, a flavoring and / or active agent, and a filler. The filler extends only partially through the thickness of the amorphous solid. According to a further aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol delivery system. The consumable comprises an aerosol-generating material as defined herein.

Description

[Technical Field]

[0001] The present invention relates to an aerosol generating material comprising an amorphous solid, and a consumable used in a non-combustible aerosol supply system, the consumable comprising an aerosol generating material comprising an amorphous solid, and a non-combustible aerosol supply system. [Background technology]

[0002] Smoking consumables such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Alternatives to these types of consumables release inhalable aerosols or vapors by heating a substrate material without combustion, thereby releasing compounds from the substrate. These are sometimes referred to as non-combustion smoking consumables or aerosol-generating assemblies.

[0003] An example of such a product is a heating device that releases compounds by heating a solid aerosol-generating material without combustion. In some examples, this solid aerosol-generating material may include plant-based materials. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes called heat-not-burn devices, cigarette heating devices, or cigarette heating products. Various different configurations are known for volatilizing at least one component of the solid aerosol-generating material.

[0004] Another example is a hybrid device. These include a liquid source (which may or may not contain nicotine) that vaporizes upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-generating material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to form an inhalation medium. [Overview of the project]

[0005] According to a first aspect of the present invention, an aerosol-generating material comprising an amorphous solid is provided. This amorphous solid is Gelling agent and Aerosol-forming material and Flavorings and / or active substances, Filler and The filler is provided and extends over the thickness of a partially amorphous solid.

[0006] According to a further aspect of the present invention, there are consumables used in a non-combustible aerosol supply system. These consumables comprise an aerosol-generating material as defined herein.

[0007] A further aspect of the present invention provides a non-combustible aerosol supply system comprising a consumable as defined herein and a non-combustible aerosol supply device. The non-combustible aerosol supply device includes an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used together with the non-combustible aerosol supply device.

[0008] A further aspect of the present invention provides the use of an aerosol-generating material as defined herein in a consumable used in a non-combustible aerosol supply device. This non-combustible aerosol supply device comprises an aerosol-generating device arranged to generate an aerosol from the consumable when the consumable is used in conjunction with the non-combustible aerosol supply device.

[0009] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which are provided for illustrative purposes only with reference to the accompanying drawings. [Brief explanation of the drawing]

[0010] [Figure 1] This is a cross-sectional view of an example of a consumable item. [Figure 2] Figure 1 is a perspective view of the consumables. [Figure 3] This is a cross-sectional elevation view of an example of a consumable part. [Figure 4] Figure 3 is a perspective view of the consumables. [Figure 5] This is a perspective view of an example of a non-combustion type aerosol supply system. [Figure 6] This is a cross-sectional view of an example of a non-combustible aerosol supply system. [Figure 7] This is a perspective view of an example of a non-combustion type aerosol supply system. [Modes for carrying out the invention]

[0011] Preferably, the aerosol-generating material of the present invention is in the form of an aerosol-forming "amorphous solid." The aerosol-forming "amorphous solid" may also be called a "monolithic solid" (i.e., non-fibrous) or "dry gel." An amorphous solid is a solid material that can hold some fluid, such as a liquid, within it. The amorphous solid forms part of the aerosol-generating material, and the aerosol-generating material comprises 50% by weight, 60% by weight, or 70% by weight of amorphous solid to about 90% by weight, 95% by weight, or 100% by weight of amorphous solid. In some examples, the aerosol-generating material consists of an amorphous solid.

[0012] The amorphous solid aerosol-generating materials described throughout are formed from a dry gel. The inventors have found that using the component ratios described herein means that as the gel hardens, the fragrance compounds are stabilized within the gel matrix, allowing for higher fragrance additions than in non-gel compositions. The added fragrance (e.g., menthol) is stabilized at high concentrations, and the product has a good shelf life.

[0013] In some examples, the amorphous solid comprises 5 to 50 wt%, 10 to 40 wt%, or 15 to 30 wt% filler. In some such examples, the amorphous solid comprises at least 1 wt% filler, such as at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler. In an exemplary embodiment, the amorphous solid comprises 5 to 25 wt% filler.

[0014] In some embodiments, the amorphous solid comprises less than 60 wt% filler, such as 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt% filler.

[0015] In some embodiments, the amorphous solid comprises less than 60 wt% filler, such as 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt% filler.

[0016] In other embodiments, the amorphous solid comprises less than 20 wt%, preferably less than 10 wt% filler.

[0017] The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methyl cellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

[0018] In certain examples, the amorphous solid does not comprise an inorganic filler material, such as the amorphous solid does not comprise calcium carbonate such as chalk.

[0019] Preferably, the filler is fibrous, such as the filler is in the form of fibers. For example, the filler may be a fibrous organic filler material, such as wood pulp (such as wood fibers), hemp fibers, cellulose, or a cellulose derivative (such as methyl cellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

[0020] While not wishing to be bound by theory, it is believed that including a fibrous filler in an amorphous solid can increase the tensile strength of the material. Further, it has been found that including a fibrous filler improves the handling of the amorphous solid during manufacture.

[0021] The inventors of the present application have found that when the filler extends only partially across the thickness of the amorphous solid, in other words when the filler does not penetrate across the full thickness of the amorphous solid, the loss of flavorant during storage is reduced. While not wishing to be bound by theory, it is believed that using the filler in this way can reduce the wicking of the flavorant by the filler towards the surface of the amorphous solid where the flavorant may be lost by evaporation.

[0022] There are a number of means by which the wicking of flavorant can be reduced. However, the inventors have found that when a fibrous filler is used, the wicking can be reduced when the fibers extend only partially across the thickness of the amorphous solid; that is, when the fibers do not extend across the full thickness of the amorphous solid (such as in the case of short fibers). Thus, in some embodiments, the fibers are suitably added to the amorphous solid such that the fibers do not extend across the full thickness of the amorphous solid. While short fibers can be used, an alternative strategy for reducing flavorant loss due to wicking is to include a mat of fibers (i.e., a woven or non-woven sheet of fibers) that does not penetrate across the full thickness of the amorphous solid. This effect can also be achieved by including a porous layer within the amorphous solid, which provides a similar tensile strength to the fibers while reducing wicking.

[0023] As used herein, “a filler” and “the filler” may encompass both “all filler particles” and “each filler particle” contained in the amorphous solid. For example, if the filler includes fibers, “fibers” may encompass both “all fibers” and “each fiber” unless the context of the term requires that “fibers” be interpreted as “all fibers.” Thus, when it is stated that “the fibers extend over less than 90% of the thickness of the amorphous solid,” this may mean both that each fiber extends over less than 90% of the thickness of the amorphous solid, and that all of the fibers extend over less than 90% of the thickness of the amorphous solid.

[0024] In some embodiments, the amorphous solid is in the form of a sheet. In some of these embodiments, the sheet comprises a first layer comprising a first portion of amorphous solid comprising at least 0 to 25% by weight of the filler present in the amorphous solid; and a second layer comprising a second portion of amorphous solid comprising at least 75% by weight of the filler present in the amorphous solid. In some such embodiments, the first portion comprises a first flat surface, and the second portion comprises a second flat surface opposite to the first flat surface, and the filler is exposed on only one of the first and second flat surfaces of the amorphous solid. In such embodiments, flavor loss during storage is reduced because the flavor is likely to evaporate from only a single flat surface of the amorphous solid.

[0025] The amorphous solid extends over a first dimension, a second dimension, and a third dimension. In the example, the amorphous solid is provided as a sheet having length, width, and thickness. Typically, the length and width of the amorphous solid sheet are each significantly greater than its thickness (for example, extending significantly greater in the first and second dimensions than in the third dimension).

[0026] As used herein, “flat surface” typically refers to a surface that extends along first and second dimensions of an amorphous solid (e.g., along its length and thickness). In the example, the flat surface refers to the top or bottom surface of the sheet. Other surfaces of an amorphous solid may be flat (e.g., a surface that extends along the first dimension (thickness) connecting the top and bottom surfaces of the amorphous solid sheet), but these are not considered “flat surfaces” as used herein.

[0027] In some embodiments, the amorphous solid comprises two or more flat layers of amorphous solid, the first layer comprising 0 to 25% by weight of the filler present in the amorphous solid, and the second layer comprising at least 75% by weight of the filler present in the amorphous solid. In some embodiments, the amorphous solid comprises three layers, the first layer comprising 0 to 15% by weight of the filler present in the amorphous solid, the second layer comprising at least 70% by weight of the filler present in the amorphous solid, and the third layer comprising 0 to 15% by weight of the filler present in the amorphous solid, with the second layer positioned between the first and third layers. In some such embodiments, the first and third layers have flat outer surfaces (as in a sheet) that are opposite each other, and the second layer is located between the first and third layers. Using such an arrangement in the amorphous solid reduces the surface area of ​​the amorphous solid to which the filler is exposed to the atmosphere. This is thought to reduce the loss of flavorings due to evaporation from the surface of amorphous solids.

[0028] In some embodiments, if the filler comprises fibers, the fibers are not exposed to the atmosphere on any flat surface of the amorphous solid. In some embodiments, the amorphous solid is in sheet form and comprises fibers whose length is shorter than the thickness of the amorphous solid sheet. In some embodiments, at least about 10% by weight, 20% by weight, 30% by weight, 40% by weight, or 50% by weight (on a dry weight basis) of the fibers in the amorphous solid sheet have a length shorter than the thickness of the amorphous solid sheet. In some embodiments, 10 to 40% by weight, or 50 to 100% by weight (on a dry weight basis) of the fibers in the amorphous solid sheet have a length shorter than the thickness of the amorphous solid sheet. For example, in some embodiments, the fibers or each fiber extend over less than 90% of the thickness of the amorphous solid (e.g., the amorphous solid sheet). In some embodiments, all fibers are dispersed over the entire thickness of the amorphous solid.

[0029] In embodiments where the fibers are arranged as a woven or nonwoven sheet, preferably the woven or nonwoven sheet is exposed on only one flat surface of the amorphous solid (e.g., an amorphous solid sheet). However, in other embodiments, the woven or nonwoven sheet of fibers is not exposed on any flat surface of the amorphous solid (e.g., an amorphous solid sheet). In embodiments where the amorphous solid comprises two or more flat layers of amorphous solid, only one layer comprises the woven or nonwoven sheet of fibers. In embodiments where the amorphous solid comprises three layers, only one layer comprises the woven or nonwoven sheet of fibers. In some of these embodiments, the second layer (between the first and third layers) comprises the woven or nonwoven sheet of fibers. Such arrangement minimizes the surface area of ​​the amorphous solid to which the fibers are exposed. While we do not wish to be bound by theory, it is believed that using such an arrangement can reduce the wicking of flavorings onto the surface of amorphous solids compared to cases where fibers extend across the entire width of the amorphous solid, causing such fibers to wick the flavorings onto the surface of the amorphous solid, which can then be lost through evaporation. Therefore, using woven or nonwoven sheets of fibers in this manner provides stability and tensile strength to the amorphous solid, while reducing flavoring loss during storage.

[0030] In some embodiments, the filler is provided as a porous layer, which is exposed on only one flat surface of the amorphous solid (e.g., an amorphous solid sheet). In other embodiments, the porous layer is exposed on any flat surface of the amorphous solid. In embodiments where the amorphous solid comprises two or more flat layers, only one layer comprises the porous layer. In embodiments where the amorphous solid comprises three layers, only one layer comprises the porous layer. In some of these embodiments, a second layer (between the first and third layers) comprises the porous layer. Such an arrangement minimizes the surface area of ​​the amorphous solid to which the filler is exposed. While we do not wish to be bound by theory, it is conceivable that using such a porous layer can reduce the wicking of flavoring onto the surface of the amorphous solid compared to a case where fibers extend across the entire width of the amorphous solid, causing such fibers to wick the flavoring onto the surface of the amorphous solid, which can then be lost by evaporation. Therefore, using such a porous layer provides stability and tensile strength to the amorphous solid, while reducing the loss of flavorings during storage.

[0031] In some embodiments, when the filler is provided as a porous layer, the porous layer comprises paper, polymer fibers, open-cell foam, ceramics and / or zeolites. The polymer fibers may be woven or braided in some examples. Suitable polymer fibers include, without limitation, polypropylene, low-density polyethylene, polyethylene terephthalate, polyurethane, polyvinyl acetate, polyvinyl alcohol, styrene, ethyl vinyl acetate, rayon, silk, cotton, polyester, cellulose materials, e.g., hydroxypropyl cellulose and combinations thereof. In some examples, the polymer fibers may include pigmented or dyed polymers. In some examples, reconstituted cellulose fibers (e.g., derived from tobacco plant tissue) may be used. In some examples, the porous layer is selected from the group consisting of open-cell foam, polymer fibers and paper.

[0032] In some embodiments, the filler added to the amorphous solid may comprise or consist of a material exhibiting reduced wicking characteristics compared to wood fibers or wood pulp. Such fibers may comprise or consist of nonporous materials. One class of nonporous materials that can be used is synthetic polymer fibers, e.g., plastics. Other fillers with reduced wicking characteristics that can be used instead of wood fibers include fine particle cork, extruded fibers, e.g., ceramic fibers, plastic / polymer fibers, HPMC (hydroxypropyl methylcellulose), cellulose nanofibers, crystalline cellulose, glass fibers, or fibers made from amorphous materials that can also be used instead of wood fibers to reduce flavor loss during storage. Wood fibers with a high lignin content can also be used to reduce flavor loss during storage.

[0033] The “thickness” of an amorphous solid refers to the shortest distance between a first surface and a second surface. In embodiments where the amorphous solid is in the form of a sheet, the thickness of the amorphous solid is the shortest distance between a first flat surface of the sheet and a second flat surface of the sheet opposite the first flat surface. In some examples, the aerosol-generating material may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The amorphous solid may comprise two or more layers, and the thickness described herein refers to the total thickness of these layers.

[0034] In some examples, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The amorphous solid may comprise two or more layers, and the thickness described herein refers to the total thickness of these layers.

[0035] The inventors have found that if the aerosol-generating material or amorphous solid is too thick, the heating efficiency is impaired. This negatively affects the power consumption during use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it becomes difficult to manufacture and handle. Very thin materials are more difficult to cast, are brittle, and may impair aerosol formation during use.

[0036] The inventors have found that the thickness of the aerosol-generating material as defined herein optimizes the material properties, taking these competing considerations into account.

[0037] The thicknesses specified herein are the average thickness of the material. In some examples, the thickness of the amorphous solid may vary by only 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0038] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the amorphous solid may have a tensile strength of 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material comprising the amorphous solid is formed as a sheet and incorporated into an aerosol-generating consumable.

[0039] Preferably, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent. In the exemplary embodiment, the amorphous solid contains about 20 wt%, 22 wt%, 24 wt%, or 25 to about 30 wt%, 32 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 20 to 35 wt%, or 25 to 30 wt% of a gelling agent.

[0040] In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginates and / or pectin, which may be combined with a curing agent (such as a calcium source) during the formation of an amorphous solid. In some examples, the amorphous solid may comprise calcium crosslinked alginates and / or calcium crosslinked pectin.

[0041] In some embodiments, the gelling agent comprises an alginate, which is present in the amorphous solid in an amount of 10-30%, 20-35% by weight, or 25-30% by weight (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one further gelling agent, such as pectin.

[0042] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0043] As a result of incorporating a gelling agent into the slurry to form an amorphous solid, an aerosol-generating material is formed from the dried gel. The inventors have found that by including a gel in the aerosol-generating material, flavoring compounds, such as menthol, are stabilized within the gel matrix, enabling controlled release of the flavor over the course of a smoking session. The flavoring (e.g., menthol) is stabilized at high concentrations, and the product has a good shelf life.

[0044] Preferably, the amorphous solid comprises about 0.1% by weight, 0.5% by weight, 1% by weight, 3% by weight, 5% by weight, 7% by weight, or 10% to about 50% by weight, 45% by weight, 40% by weight, 35% by weight, 30% by weight, or 25% by weight of an aerosol-forming material (all calculated on a dry weight basis). In exemplary embodiments, the amorphous solid comprises 10 to 25% by weight of an aerosol-forming material. The aerosol-forming material may act as a plasticizer. In some examples, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-forming material comprises glycerol, is essentially made of glycerol, or consists of glycerol. The inventors have found that if the plasticizer content is too high, the amorphous solid may absorb water, resulting in a material that does not produce a suitable consumption experience during use. The inventors have found that if the plasticizer content is too low, the amorphous solid can become brittle and easily break. The plasticizer content specified herein results in amorphous solid flexibility that allows the sheet to be wound onto a bobbin, which is useful in the manufacture of consumables.

[0045] Preferably, the amorphous solid comprises about 80% by weight, 70% by weight, 60% by weight, 55% by weight, 50% by weight, or up to 45% by weight of flavoring. In some examples, the amorphous solid may comprise at least about 0.1% by weight, 1% by weight, 10% by weight, 20% by weight, 30% by weight, 35% by weight, or 40% by weight of flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-80% by weight, 10-80% by weight, 20-70% by weight, 30-60% by weight, 35-55% by weight, or 30-45% by weight of flavoring. In the exemplary embodiment, the amorphous solid comprises 35-50% by weight of flavoring. In some examples, the flavoring contains menthol, is essentially made of menthol, or consists of menthol.

[0046] In some examples, the amorphous solid may further contain an emulsifier, which emulsifies the flavoring during manufacturing. For example, the amorphous solid may contain about 5% to about 15% by weight, preferably about 10% by weight, of an emulsifier (calculated on a dry weight basis). The emulsifier may include acacia gum.

[0047] In some embodiments, the amorphous solid is a hydrogel comprising less than about 20% by weight of water on a wet weight basis. In some examples, the hydrogel may comprise less than 15% by weight, 12% by weight, or 10% by weight of water on a wet weight basis. In some examples, the hydrogel may comprise at least about 1% by weight, 2% by weight, or at least about 5% by weight of water (WWB).

[0048] In some embodiments, the amorphous solid further comprises an active substance. For example, in some examples, the amorphous solid further comprises tobacco material and / or nicotine. In some examples, the amorphous solid may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some examples, the amorphous solid may comprise about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% by weight to about 70% by weight, 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight (calculated on a dry weight basis) of the active substance. In some examples, the amorphous solid may contain approximately 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to approximately 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid may contain 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco material. In some examples, the amorphous solid may contain approximately 1 wt%, 2 wt%, 3 wt%, or 4 to approximately 20 wt%, 18 wt%, 15 wt%, or 12 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0049] In some examples, the amorphous solid comprises an active substance such as tobacco extract. In some examples, the amorphous solid may comprise 5–60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the amorphous solid may comprise tobacco extract in amounts of approximately 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% to approximately 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight (calculated on a dry weight basis). For example, the amorphous solid may comprise 10–50% by weight, 15–40% by weight, or 20–35% by weight of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises 1% by weight, 1.5% by weight, 2% by weight, or 2.5% to approximately 6% by weight, 5% by weight, 4.5% by weight, or 4% by weight (calculated on a dry weight basis) of nicotine. In some cases, nicotine other than that derived from tobacco extract may not be present in the amorphous solid.

[0050] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such examples, the amorphous solid may contain about 1% by weight, 2% by weight, 3% by weight, or 4% by weight to about 20% by weight, 18% by weight, 15% by weight, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20% by weight, 2 to 18% by weight, or 3 to 12% by weight of nicotine.

[0051] In some examples, the total content of flavorings may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight. In some examples, the total content of active substances and / or flavorings may be less than about 90% by weight, 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight (all calculated on a dry weight basis). In some embodiments, the flavoring is menthol.

[0052] The amorphous solid may be prepared from a gel, which may further contain a solvent in an amount of 0.1 to 50% by weight. However, the inventors have found that the inclusion of a solvent to which flavorings can dissolve reduces gel stability, and the flavorings may leave the gel and crystallize. Therefore, in some examples, the gel does not contain a solvent to which flavorings can dissolve.

[0053] In the exemplary embodiment, the amorphous solid comprises 20-35% by weight of a gelling agent, 10-25% by weight of an aerosol-forming material, 5-25% by weight of a fiber-containing filler, and 35-50% by weight of a flavoring agent and / or an active substance.

[0054] In some examples, the amorphous solid consists essentially of, or may consist of, a gelling agent, water, an aerosol-forming material, a fragrance, and optionally, an active substance.

[0055] In some examples, the amorphous solid is essentially composed of, or may be composed of, a gelling agent, water, an aerosol-forming material, a flavoring, and optionally, tobacco material and / or a nicotine source.

[0056] The inventors have found that if the amorphous solid is too thick, heating efficiency is impaired. This negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. Very thin materials are more difficult to cast, are brittle, and may impair aerosol formation during use. The inventors have found that the amorphous solid thickness specified herein optimizes the material properties considering these competing considerations.

[0057] The thicknesses specified herein are average values ​​for the thickness in question. In some examples, the thickness may vary by only 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0058] Aerosol-generating materials comprising amorphous solids can have any suitable surface density, for example, 30 g / m². 2~120 g / m 2 may have. In some examples, the sheet is 80 - 120 g / m 2 , or about 70 - 110 g / m 2 , or particularly about 90 - 110 g / m 2 , or preferably about 100 g / m 2 per unit area mass (therefore, the sheet has a density similar to cut - lag tobacco and mixtures of these substances do not separate easily). Such areal density can be particularly suitable when the aerosol - forming material is included as a shredded sheet in the consumable / assembly (further described below). In some examples, the sheet may have a mass per unit area of about 30 - 70 g / m 2 , 40 - 60 g / m 2 , or 25 - 60 g / m 2 per unit area mass.

[0059] In some embodiments, the consumable comprises the aerosol - forming material described herein, and the aerosol - forming material is in the form of fragments. In such embodiments, the aerosol - forming material may be formed from a shredded sheet of an amorphous solid. In an exemplary consumable, the aerosol - forming material comprising the shredded amorphous solid is mixed with a tobacco material. In some examples where the tobacco material is fine - cut and the amorphous solid is a shredded sheet, the cut width of the amorphous solid is about 90 - 110% of the cut width of the tobacco material. That is, the amorphous solid and the tobacco material have a similar cut width, or shredded width. The inventors have determined that by configuring the amorphous solid and the tobacco material to have a similar cut width, a better blend of the amorphous solid and the tobacco material is possible. For example, a shredded amorphous solid sheet having a similar cut width and cut - lag tobacco can be blended to provide a more homogeneous aerosol - forming composition (e.g., a better distribution of each component throughout the aerosol - forming composition).

[0060] Consumables and Non - Combustion Aerosol Delivery Systems As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user, Combustion-type aerosol supply systems, for example, cigarettes, cigarillos, cigar tobacco, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, puffed tobacco, recombined tobacco, tobacco substitutes or other smoking materials), A non-combustion aerosol supply system that releases compounds from aerosol-generating materials without burning the materials, for example, a hybrid system that generates aerosols using a combination of e-cigarettes, tobacco heating products, and aerosol-generating materials. Consumables comprising aerosol generating material and configured for use within one of these non-combustible aerosol supply systems, as well as Aerosol-free delivery systems that deliver one or more substances (with or without nicotine) to a user orally, nasally, transdermally, or by other means without forming an aerosol (including, but not limited to, consumables comprising lozenges, gums, patches, inhalation powders, and oral products such as oral tobacco, which include snus or wet snuff). Includes.

[0061] According to this disclosure, a "combustible" aerosol supply system is one in which the aerosol-generating material (or its components) of the aerosol supply system is combusted or burned during use to facilitate delivery to the user.

[0062] According to this disclosure, a “non-combustible” aerosol supply system is one in which the aerosol-generating material (or its components) of the aerosol supply system is not combusted or burned during use in order to facilitate delivery to the user.

[0063] In some embodiments, the delivery system is a combustion-type aerosol delivery system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0064] In some embodiments, the disclosure relates to components used in combustion-type aerosol supply systems, such as additive-releasing components including filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or to papers such as plug wraps, tip paper, or cigarette paper.

[0065] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powdered non-combustible aerosol supply system.

[0066] In some embodiments, the non-combustion aerosol supply system is an e-cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0067] In some embodiments, the non-combustion aerosol supply system is a tobacco heating system also known as a non-combustion heating system.

[0068] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, consist of tobacco or non-tobacco products.

[0069] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables used in conjunction with the non-combustible aerosol supply device. However, it is conceivable that a consumable having means for supplying power to an aerosol generating component itself may constitute a non-combustible aerosol supply system.

[0070] In some embodiments, the non-combustible aerosol supply device may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source comprises a carbon substrate that may be energized to distribute power in the form of heat to the aerosol-generating material, or a heat transfer material adjacent to the heat source. In some embodiments, the power source, such as the heat source, is provided in a consumable to form a non-combustible aerosol supply.

[0071] In some embodiments, consumables used with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating component, an aerosol generating area, a mouthpiece, and / or an area for receiving the aerosol generating material.

[0072] In some embodiments, the aerosol-generating component is a heater capable of interacting with an aerosol-generating material to cause the material to release one or more volatile substances and form an aerosol. In some embodiments, the aerosol-generating component is capable of generating an aerosol from an aerosol-generating material without heating. For example, the aerosol-generating component may be capable of generating an aerosol from an aerosol-generating material without applying heat, for example, via one or more means such as vibration, mechanical, pressurized, or electrostatic means.

[0073] This consumable may also be referred to as a cartridge in this specification. This consumable may be adapted for use in a THP, hybrid device, or other aerosol generating device. In some examples, the consumable may further comprise a filter and / or cooling element as already described. In some examples, the consumable may be enclosed in packaging material such as paper.

[0074] The consumables may further include vents. These may be provided on the side walls of the consumables. In some examples, the vents may be provided on the filter and / or cooling element. These vents allow cold air to be drawn into the consumables during use, and this cold air can mix with the heated volatile components, thereby cooling the aerosol.

[0075] Ventilation facilitates the generation of visible thermal volatile components from consumables when they are heated during use. These thermal volatile components are made visible by a process of cooling them to the point where supersaturation occurs. The thermal volatile components then undergo droplet formation (also known as nucleation), and ultimately, the size of the thermal volatile component aerosol particles increases due to further condensation of the thermal volatile components and the aggregation of newly formed droplets from the thermal volatile components.

[0076] In some cases, the ratio of cold air to the total amount of heated volatile components (known as the permeability ratio) is at least 15%. A permeability ratio of 15% makes it possible to visualize the heated volatile components in the manner described above. The visibility of heated volatile components allows the user to identify that volatile components have been generated, enhancing the perceptual experience of the smoking experience.

[0077] In another example, the permeability ratio is 50% to 85% to further cool the heated volatile components. In some examples, the permeability ratio may be at least 60% or 65%.

[0078] Referring to Figures 1 and 2, a partial cross-sectional view and a perspective view of an example of an aerosol generating consumable 101 are shown. The consumable 101 is adapted for use with a device having a power supply and a heater. The consumable 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 5 to 7, which are described below. When in use, the consumable 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 5.

[0079] One example of a consumable 101 is in the form of a substantially cylindrical rod, comprising an aerosol-generating material body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in the form of a sheet. In some embodiments, it may be included in the form of a shredded sheet. In some embodiments, the aerosol-generating material described herein may be incorporated in both sheet and shredded forms. In some embodiments, the aerosol-generating material provided in the consumable may comprise a blend of shredded amorphous solid and tobacco.

[0080] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouth-end segment 111. The consumable 101 has a first end 113, also known as the mouth-end or proximal end, and a second end 115, also known as the distal end. The aerosol-generating material 103 is located on the distal end 115 side of the consumable 101. In one example, the cooling segment 107 is positioned adjacent to the aerosol-generating material 103 between the aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in contact with the aerosol-generating material 103 and the filter segment 109. In other examples, there may be separations between the aerosol-generating material 103 and the cooling segment 107, and between the aerosol-generating material 103 and the filter segment 109. The filter segment 109 is positioned between the cooling segment 107 and the mouth-end segment 111. The mouth end segment 111 is positioned on the proximal end 113 side of the consumable 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in contact with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is 37 mm to 45 mm, and more preferably, the total length of the filter assembly 105 is 41 mm.

[0081] In one example, the rod of the aerosol generating material 103 has a length of 34 mm to 50 mm, preferably 38 mm to 46 mm, and preferably 42 mm.

[0082] In one example, the total length of the consumable 101 is 25mm to 95mm, preferably 79mm to 87mm, and preferably 83mm. In another example, the total length of the consumable is 25mm to 40mm, preferably 25mm to 35mm.

[0083] One axial end of the aerosol-generating material 103 is visible at the distal end 115 of the consumable 101. However, in other embodiments, the distal end 115 of the consumable 101 may include an end member (not shown) that covers one axial end of the aerosol-generating material 103.

[0084] The aerosol-generating material 103 is bonded to the filter assembly 105 by annular tip paper (not shown), which is positioned substantially around the filter assembly 105 so as to surround it and partially extends along the length of the aerosol-generating material 103. In one example, the tip paper is made from 58GSM standard tip base paper. In one example, the tip paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0085] In one example, the cooling segment 107 is an annular tube positioned around a void within the cooling segment, defining the void. This void provides a chamber through which heated volatile components generated from the aerosol-generating material 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the consumable 101 is being used during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

[0086] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient between the two ends of the cooling segment 107 in the longitudinal direction. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In another example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference between the two ends of the cooling element 107 in the longitudinal direction protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol-generating material 103 when the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the aerosol-generating material 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and may not effectively perform its required function.

[0087] In one example, the length of the cooling segment 107 is at least 15 mm. In another example, the length of the cooling segment 107 is 20 mm to 30 mm, more specifically 23 mm to 27 mm, more specifically 25 mm to 27 mm, preferably 25 mm.

[0088] The cooling segment 107 is made of paper, meaning that the cooling segment 107 is composed of a material that does not generate compounds of concern (e.g., toxic compounds) when it is adjacent to the heater of the device 51 during use. In one example, the cooling segment 107 is manufactured from a spiral-wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spiral-wound paper tube can meet the stringent dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and straightness of the tube.

[0089] In another example, the cooling segment 107 is a recess made from rigid plug wrap or tip paper. The rigid plug wrap or tip paper is manufactured to be rigid enough to withstand the axial compressive forces and bending moments that may occur during manufacturing and while the consumable 101 is being used during insertion into the device 51.

[0090] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heat-volatile components of the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material such as cellulose acetate. The filter segment 109 provides cooling and irritation reduction of the heat-volatile components without depleting the amount of heat-volatile components to an unsatisfactory level for the user.

[0091] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. This capsule may be positioned substantially at the center of the filter segment 109 in both the radial and longitudinal directions. In other examples, the capsule may be offset from the center in one or more dimensions. In some examples, if a capsule is present, it may contain volatile components such as flavorings or aerosol-generating agents.

[0092] The density of the cellulose acetate tow material in the filter segment 109 controls the pressure drop between the ends of the filter segment 109, and consequently controls the suction resistance of the consumable 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the suction resistance of the consumable 101. Furthermore, the filter segment performs a filtration function in the consumable 101.

[0093] In one example, filter segment 109 is made of 8Y15 grade filter tow material. This filter tow material provides a filtering effect against heated volatile materials while reducing the size of condensed aerosol droplets generated from the heated volatile materials.

[0094] The presence of the filter segment 109 provides an insulating effect by further cooling the heated volatile components that exit the cooling segment 107. This further cooling effect lowers the contact temperature of the user's lips with the surface of the filter segment 109.

[0095] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0096] The mouth end segment 111 is an annular tube positioned around a void within the mouth end segment 111, defining the void. This void provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the consumables during manufacturing and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is 6 mm to 10 mm, preferably 8 mm.

[0097] The mouth end segment 111 may be manufactured from a helical paper tube that provides a hollow internal chamber while maintaining important mechanical rigidity. The helical paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0098] The mouth end segment 111 provides a function to prevent liquid condensation accumulating at the outlet of the filter segment 109 from coming into direct contact with the user.

[0099] In one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, and the filter segment 109 may be placed inside that tube to separate the mouth end segment 111 and the cooling segment 107.

[0100] Referring to Figures 3 and 4, a partial fractured section view and perspective view of an example of consumable part 301 are shown. The reference numerals shown in Figures 3 and 4 correspond to the reference numerals shown in Figures 1 and 2, but the numbers are increased by 200.

[0101] In the example of the consumable 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the consumable 301 to allow air to flow from the outside of the consumable 301 into the inside of the consumable 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the consumable 301. These ventilation holes may be located in a cooling segment 307 to help cool the consumable 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes arranged along the outer circumference of the consumable 301 in a cross section substantially perpendicular to the longitudinal axis of the consumable 301.

[0102] In one example, the consumable 301 has 1 to 4 rows of vents to provide ventilation. Each row of vents may have 12 to 36 vents 317. The diameter of the vents 317 can be, for example, 100 to 500 μm. In one example, the axial spacing between rows of vents 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0103] In one example, the vents 317 have a uniform size. In another example, the vents 317 have varying sizes. The vents can be fabricated using one or more of any suitable techniques, such as laser technology, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before it is formed in the consumable 301. The vents 317 are positioned to effectively cool the consumable 301.

[0104] In one example, the row of vents 317 is located at least 11 mm from the proximal end 313 of the consumable, preferably 17 mm to 20 mm from the proximal end 313 of the consumable 301. The position of the vents 317 is determined so that the user does not block the vents 317 when using the consumable 301.

[0105] By providing a row of vents 17mm to 20mm from the proximal end 313 of the consumable 301, the vents 317 can be positioned outside the device 51 when the consumable 301 is fully inserted into the device 51, as shown in Figures 6 and 7. Positioning the vents outside the device allows unheated air to enter the consumable 301 from outside the device 51 through the vents, helping to cool the consumable 301.

[0106] The length of the cooling segment 307 is such that when the consumable 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 has two functions: firstly, it provides a physical gap between the heating device and the heat-sensitive filter device 309 of the device 51, and secondly, it allows the vents 317 to be located within the cooling segment while also being located outside the device 51 when the consumable 301 is fully inserted into the device 51. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located inside the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vents 317 are located in this portion of the cooling element 307 that extends outside the device 51.

[0107] Referring more closely to Figures 5 to 7, an example of a device 51 is shown which is configured to heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby typically forming an inhalable aerosol. Device 51 is a heating device that releases compounds by heating the aerosol-generating material but not burning it.

[0108] The first end 53 may be referred to herein as the oral end or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on / off button 57 that allows the user to start / stop the entire device 51 as desired.

[0109] The device 51 includes a housing 59 for arranging and protecting various internal components of the device 51. In the illustrated example, the housing 59 comprises a single sleeve 11 surrounding the outer edge of the device 51, which is covered by a top panel 17 that generally forms the “upper” part of the device 51 and a bottom panel 19 that generally forms the “bottom” part of the device 51. In another example, the housing comprises a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and the bottom panel 19.

[0110] The top panel 17 and / or bottom panel 19 may be detachably fixed to the single-piece sleeve 11 to allow easy access to the interior of the device 51, or they may be "permanently" fixed to the single-piece sleeve 11 to prevent, for example, a user from accessing the interior of the device 51. In one example, the panels 17 and 19 are made of plastic material (including glass-filled nylon formed by injection molding, etc.) and the single-piece sleeve 11 is made of aluminum, but other materials and other manufacturing processes may be used.

[0111] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, so that during use, the user can insert consumables 101, 301 containing aerosol generating material into and out of the device 51 through this opening 20.

[0112] The housing 59 houses or secures the heating device 23, the control circuit 25, and the power supply 27. In this example, the heating device 23, the control circuit 25, and the power supply 27 are located close together laterally (i.e., close together when viewed from one end), and the control circuit 25 is generally located between the heating device 23 and the power supply 27, although other arrangements are possible.

[0113] The control circuit 25 may include a controller, such as a microprocessor, configured and positioned to control the heating of the aerosol-generating material in the consumables 101 and 301, as will be discussed further below.

[0114] The power source 27 may be, for example, a battery, which may be rechargeable or non-rechargeable. Suitable battery examples include lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery 27 is electrically coupled to the heating device 23 and supplies power under the control of the control circuit 25 when needed to heat the aerosol-generating material in the consumables (volatilizing the aerosol-generating material without burning it, as described above).

[0115] The advantage of positioning the power supply 27 laterally close to the heating device 23 is that a physically larger power supply 25 can be used without making the entire device 51 excessively long. Naturally, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.) and therefore can extend the battery life of the device 51.

[0116] In one example, the heating device 23 generally takes the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which consumables 101, 301 containing aerosol-generating material are inserted for heating during use. Various configurations are possible for the heating device 23. For example, the heating device 23 may have a single heating element, or it may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The heating element or each heating element may be annular or tubular, or at least partially annular or at least partially tubular along its outer circumference. In one example, the heating element or each heating element may be a thin-film heater. In another example, the heating element or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramics, aluminum nitride ceramics, and silicon nitride ceramics, which may be laminated and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by emitting infrared rays), and resistance heating elements formed by resistive electric windings.

[0117] In one particular example, the heating device 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heating device 23 is sized such that when the consumables 101, 301 are inserted into the device 51, substantially the entire body of the consumables 101, 301, consisting of the aerosol-generating material 103, 303, is inserted into the heating device 23.

[0118] The heating elements, or each heating element, may be arranged to independently heat multiple selected zones (areas) of the aerosol-generating material, for example, sequentially (over time as described above) or together (simultaneously), as desired.

[0119] In this example, the heating device 23 is surrounded by an insulating material 31 along at least a portion of its length. The insulating material 31 helps reduce the heat that passes from the heating device 23 to the outside of the device 51. This generally reduces heat loss and thus helps keep the power requirements of the heating device 23 low. The insulating material 31 also helps keep the outside of the device 51 cool while the heating device 23 is operating. In one example, the insulating material 31 may be a double-walled sleeve that provides a low-pressure region between the two walls of the sleeve. That is, the insulating material 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially vacuum-evacuated to minimize heat transfer by conduction and / or convection. Other configurations of the insulating material 31 are also possible, including the use of insulating material (including, for example, a suitable foam type material) in addition to, or instead of, a double-walled sleeve.

[0120] The housing 59, like the heating device 23, may further comprise various internal support structures 37 for supporting all internal components.

[0121] The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the housing 59, and a substantially tubular chamber 35 positioned between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a number of spaced-apart cooling fins 35f along the outer surface of the chamber 35, each cooling fin arranged to surround the outer surface of the chamber 35. When the consumables 101, 301 are inserted into the device 51 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the consumables 101, 301. The gap 36 surrounds the entire outer circumference of the consumables 101, 301 over at least a portion of the cooling segment 307.

[0122] The collar 33 is provided with a plurality of protrusions 60 arranged to surround the outer periphery of the opening 20, and these protrusions project into the opening 20. The protrusions 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the protrusions 60 is smaller than the opening distance of the opening 20 at the location without the protrusions 60. The protrusions 60 are configured to engage with the consumables 101, 301 inserted into the device and help to secure them within the device 51. The open space (not shown) defined by adjacent pairs of protrusions 60 and the consumables 101, 301 forms a ventilation path around the outer surface of the consumables 101, 301. These ventilation paths allow hot vapor escaping from the consumables 101, 301 to exit the device 51, and also allow cooling air to flow into the device 51 around the consumables 101, 301 within the void 36.

[0123] During operation, consumables 101 and 301 are removably inserted into the insertion points 20 of the device 51, as shown in Figures 5-7. Referring particularly to Figure 6, in one example, the aerosol-generating material bodies 103 and 303 (located on the distal ends 115 and 315 of consumables 101 and 301) are fully housed within the heating element 23 of the device 51. The proximal ends 113 and 313 of consumables 101 and 301 extend from the device 51 and function as a mouthpiece assembly for the user.

[0124] During operation, the heating device 23 heats the consumables 101 and 301 to volatilize at least one component of the aerosol-generating material from the aerosol-generating material bodies 103 and 303.

[0125] The primary channel for heated volatile components from the aerosol-generating materials 103, 303 passes axially through consumables 101, 301, through the inner chambers of the cooling segments 107, 307, through filter segments 109, 309, and through mouth-end segments 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating materials is 60°C to 250°C, which may exceed the user's acceptable inhalation temperature. As the heated volatile components move through the cooling segments 107, 307, they are cooled, and some of the volatile components condense on the inner surfaces of the cooling segments 107, 307.

[0126] In the example of the consumable 301 shown in Figures 3 and 4, cold air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cold air mixes with the heated volatile components to further cool them.

[0127] definition active substance In some embodiments, the delivered substance comprises an active substance.

[0128] The active substances used herein are physiologically active materials, i.e., materials for achieving or enhancing physiological reactions. Active substances may be selected from, for example, functional foods, nootropics, and psychoactive substances. Active substances may be naturally occurring or obtained by synthesis. Active substances may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, and C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. Active substances may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

[0129] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0130] plant matter As described herein, the active substance may comprise or be derived from one or more plant materials or components, derivatives, or extracts thereof. As used herein, the term “plant material” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the material may comprise an active compound that is naturally present in the plant material or obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, shards, sheets, etc. Examples of plant-based ingredients include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0131] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substance being tobacco.

[0132] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0133] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from rooibos and fennel.

[0134] fragrance In some embodiments, the delivered substance comprises a fragrance.

[0135] As used herein, the terms “flavoring” and “flavoring” refer to materials that can be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where local regulations permit. These include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango). Clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, citrus Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any variety of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, laurel, mate, orange peel, rose, tea (green tea, black tea, etc.), Thai (Lumin, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators, or stimulants, sugars and / or sugar substitutes (e.g., sucralose,It may contain acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives, such as charcoal, chlorophyll, minerals, plant materials, or breath fresheners. These may be imitation ingredients, synthetic ingredients, natural ingredients, or blends thereof. They may be in any suitable form, such as liquid (e.g., oil), solid (e.g., powder), or gas.

[0136] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0137] In some embodiments, the fragrance may comprise sensory agents intended to achieve somatosensory effects that are normally chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0138] Aerosol generating materials Aerosol-generating materials are materials capable of generating aerosols when energy is supplied, for example, by heating, radiation, or any other method. Aerosol-generating materials may be in the form of, for example, a solid, a liquid, or a gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may also be called a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid to about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0139] The aerosol-generating material may comprise one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0140] Aerosol-forming materials The aerosol-forming material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0141] consumables Consumables are articles comprising or consisting of aerosol-generating material, some or all of which is intended to be consumed during use by the user. Consumables may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a rolled paper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater that generates heat to cause aerosol generation from the aerosol-generating material during use. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0142] aerosol generator An aerosol generator is a device configured to induce the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy, thereby causing one or more volatile substances to be released from the aerosol-generating material and forming an aerosol. In some embodiments, the aerosol generator is configured to induce the generation of an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of the following: vibration, high pressure, or electrostatic energy.

[0143] All weight percentages (indicated as wt%) used herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights expressed on a dry weight basis refer to the entirety of the extract, slurry, or material other than water, and may include components that are liquid by themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages expressed on a wet weight basis refer to all components, including water.

[0144] To avoid misunderstanding, while the term “equipped with” is used herein to define the invention or its features, embodiments are also disclosed in which the terms “essentially comprised of” or “consisting of” may be used instead of “equipped with.” References to materials “equipped with” certain features mean that those features are contained in, incorporated into, or retained within the material.

[0145] The embodiments described above should be understood as illustrative examples of the present invention. Further embodiments of the present invention are conceivable. Any feature described in relation to any one embodiment may be used alone or in combination with other features described, or in combination with one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may also be used without departing from the scope of the present invention as defined in the appended claims.

Claims

1. 1. An aerosol-forming material comprising an amorphous solid, The amorphous solid is A gelling agent; an aerosol-forming material; Flavorings and / or active substances; Filler and Equipped with the filler extends only partially through the thickness of the amorphous solid; the filler comprises fibers dispersed throughout but not traversing the entire thickness of the amorphous solid; the filler comprises fibers that are not exposed to the atmosphere on any flat surface of the amorphous solid; or An aerosol-forming material, wherein the filler is provided as a porous layer that is not exposed on any flat surface of the amorphous solid.

2. 10. The aerosol-forming material of claim 1, wherein the amorphous solid is in the form of a sheet.

3. the amorphous solid comprises a first portion and a second portion; the first portion comprising 0 to 25 weight percent of a filler present in the amorphous solid; 10. The aerosol-forming material of claim 1, wherein the second portion comprises at least 75% by weight of the filler present in the amorphous solid, these weights being calculated on a dry weight basis.

4. 4. The aerosol-generating material of claim 3, wherein the first portion has a first planar surface, the second portion has a second planar surface opposite the first planar surface, the filler is exposed at only one of the first planar surface and the second planar surface of the amorphous solid, and the filler comprises a fiber or a porous layer.

5. 5. The aerosol-generating material of claim 4, wherein the or each fiber extends through less than 90% of the thickness of the amorphous solid.

6. 6. The aerosol-forming material of claim 4, wherein 25 to 100% by weight of the fibers in the amorphous solid have a length that is less than the thickness of the amorphous solid, the weight of the fibers being calculated on a dry weight basis.

7. 6. The aerosol-forming material of claim 4 or 5, wherein the fibers are arranged as a woven sheet.

8. 6. The aerosol-forming material of claim 4 or 5, wherein the fibers are arranged as a nonwoven sheet.

9. 6. The aerosol-forming material of claim 4 or 5, wherein the fibers comprise wood fibers.

10. 6. The aerosol-generating material of claim 4 or 5, wherein the fibers comprise low-porosity polymer fibers.

11. 10. A consumable for use in a non-combustion aerosol delivery system, the consumable comprising the aerosol-forming material of claim 1.

12. 12. A non-combustion aerosol delivery system comprising the consumable of claim 11 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

13. 10. Use of the aerosol-generating material of claim 1 in a consumable for use in a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol-generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

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