Consumables for use with aerosol delivery devices

Abstract

A consumable (24) for use with an aerosol delivery device (2) is disclosed. The consumable (24) comprises a substrate (28), an aerosol-generating material (26), and one or more perforations (38). The perforations (38) are configured to allow the passage of heat or aerosol along the perforations (38).

Description

[Technical field]

[0001] The present disclosure relates to the field of non-combustion smoking articles, and in particular to consumables for use with aerosol delivery devices, and aerosol delivery systems including consumables and aerosol delivery devices. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, and the like, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by liberating compounds from a substrate material through heating without burning. These may be referred to as non-combustion smoking articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases compounds by heating, rather than burning, an aerosolizable material, sometimes called a solid aerosol-generating material. In some cases, the solid aerosol-generating material may contain tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be called non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of a solid aerosol-generating material.

[0004] As another example, there are hybrid devices that contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device additionally contains a solid aerosol-forming material (which may or may not contain tobacco material) whose components are entrained in the inhalable vapor or aerosol to produce an inhalable medium. Summary of the Invention

[0005] (overview) According to a first aspect of the present disclosure, there is provided a consumable for use with an aerosol delivery device, the consumable comprising a support, an aerosol generating material, and one or more perforations, the perforations configured to allow the passage of heat or aerosol along the perforations.

[0006] According to a second aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable according to the first aspect of the present disclosure.

[0007] According to a third aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable according to the first aspect of the present disclosure using an aerosol generating device having at least one heat source arranged to heat rather than burn the consumable in use, wherein the at least one heat source is a resistive heater element or a magnetic field generator suitable for inducing electrical eddy currents in a susceptor.

[0008] Further features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure, given by way of example only, and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0009] [Figure 1] 1A-1D show schematic diagrams of an embodiment of an aerosol delivery device and an embodiment of a consumable according to the present disclosure. [Diagram 2] 2 shows a first embodiment of the consumable of FIG. 1 along section line AA'. [Diagram 3] 2 shows a second embodiment of the consumable of FIG. 1 along section line AA'. [Figure 4] FIG. 4 shows a perspective view of a portion of the consumable of FIG. 2 or FIG. 3. [Diagram 5] 2 shows a third embodiment of the consumable of FIG. 1 along section line AA'. [Figure 6] 2 shows a fourth embodiment of the consumable of FIG. 1 along section line AA'. [Figure 7] FIG. 7 shows a perspective view of a portion of the consumable of FIG. 5 or FIG. 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] (Detailed Description) The consumables of this description may alternatively be referred to as articles.

[0011] In some embodiments, the consumable may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, an aerosol modifier, one or more active ingredients, one or more fragrances, one or more aerosol forming materials, and / or one or more other functional materials.

[0012] The device for heating the aerosol-forming material used with the consumable is part of a non-combustion aerosol delivery system that liberates compounds from the aerosol-forming material without combusting the aerosol-forming material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials.

[0013] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that is a component of the aerosol delivery system is not combusted or burned to facilitate delivery of at least one substance to a user.

[0014] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0015] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0016] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0017] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. The solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0018] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0019] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0020] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0021] In one embodiment of any of the above embodiments, the consumable comprises a support, an aerosol-generating material, and one or more perforations configured to allow passage of heat or aerosols along the perforations, and the perforations are not configured or positioned on or within the consumable to facilitate tearing of the consumable along the tear path.

[0022] In some embodiments of any of the above embodiments, the perforations are at least 0.01 mm 2 , at least 0.05 mm 2 , at least 0.1 mm 2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 Such a configuration is advantageous in that it allows the consumable to allow aerosol or heat generated at or adjacent one portion of the consumable to migrate along the perforations to another portion of the consumable, which movement may be blocked by the structure of the consumable in consumables other than those disclosed herein. For example, aerosol generated on one side of a planar support may migrate or be transferred to the other side of the support. This allows the aerosol generated by the consumable to mix thoroughly at the location of generation of the aerosol before the mixed vapor travels to the mouthpiece of the aerosol delivery device. In another example, the perforations may extend from a mouth blocked by the susceptor, through the support, and into the aerosol-generating material to transfer heat from the susceptor to the aerosol-generating material.

[0023] In some of the above embodiments, the support supports the aerosol-forming material on a surface of the support.

[0024] In some of the above embodiments, the support further supports an aerosol-forming material on a second surface of the support.

[0025] In some of the above embodiments, at least some of the aerosol-generating material supported on the first surface of the support is supported as one or more separate portions of aerosol-generating material, which may be distributed on the first surface of the support and spaced apart from one another.

[0026] In some of the above embodiments, at least some of the aerosol-generating material supported on the second surface of the support is supported as one or more separate portions of aerosol-generating material, which may be dispersed on the first surface of the support and spaced apart from one another.

[0027] In some of the above embodiments, the number of distinct portions of aerosol-generating material on the first surface corresponds to the number of distinct portions on the second surface, and the positions of the distinct portions on the first surface of the support substantially correspond to the positions of the distinct portions supported on the second surface of the support. This arrangement has the effect that for a substantially planar or flat support, at a position on the support, there is aerosol-generating material supported on both surfaces of the support, typically the two major surfaces (having the largest area). In some embodiments, the perforations may extend from a position in the aerosol-generating material supported on the first surface to a position in the aerosol-generating material supported on the second surface. In other embodiments, the perforations may pass from a free surface of the aerosol-generating material supported on the first surface (the surface in contact with the atmosphere and not other elements of the consumable) to a free surface of the aerosol-generating material supported on the second surface.

[0028] In some of the above embodiments, all of the aerosol-forming materials supported on the support are of substantially the same composition.

[0029] In some of the above embodiments, the aerosol-generating material supported on the support is composed of two or more separate portions, at least one of which has a different composition than at least one of the other separate portions, allowing the different separate portions to provide different experiences, e.g., fragrances, to the user when the different separate portions are aerosolized.

[0030] In some of the above embodiments, one or more of the perforations have at least one open end that opens through and is defined by a surface of the support, aerosol generating material, or any other element of the consumable. An open end of a perforation is an end that is open to the atmosphere surrounding the consumable and is not blocked or obstructed by an element of the consumable.

[0031] In some of the above embodiments, one or more of the perforations have at least one plugged end that is plugged by the support, the aerosol-generating material, or any other element of the consumable. A plugged end of a perforation is an end that is blocked or obstructed by an element of the consumable and does not communicate with the atmosphere surrounding the consumable other than perhaps through the perforation itself.

[0032] In some of the above embodiments, one or more of the perforations extend at least partially through the support or aerosol-forming material.

[0033] In some of the above embodiments, at least some of the aerosol-generating material is supported on the first surface of the support as one or more of the separate portions of the aerosol-generating material. Such an arrangement is advantageous because it allows the separate portions of the aerosol-generating material to be aerosolized at different times. A further advantage is that the composition of at least one different separate portion of the aerosol-generating material can be different from other different separate portions of the aerosol-generating material. The separation of these separate portions makes it easier to select a separate portion of a particular composition of the aerosol-generating material than if there were no gaps between the separate portions of the aerosol-generating material.

[0034] In some of any of the above embodiments, one or more of the open ends of the perforations in the first or second surface are overlapped, blocked or obstructed by an aerosol-generating material supported on that surface. Such a configuration allows aerosol generated from the aerosol-generating material that overlaps, blocks or obstructs the ends of the perforations to enter the perforations and flow to another surface of the support supporting the aerosol-generating material. Such a configuration may also provide improved adhesion of the aerosol-generating material to the support, as some of the aerosol-generating material may become locked into the perforations.

[0035] In some embodiments of any of the above embodiments, one or more of the open ends of the perforations in the first or second surface are not overlapped by, blocked or occluded by, the aerosol-generating material supported on that surface. Such a configuration is advantageous because the perforations readily permit passage of an aerosol from the surface of the support supporting the aerosol-generating material to the second surface.

[0036] In some embodiments of any of the above embodiments, the support supports aerosol-generating material on the other of the first and second surfaces of the support, i.e., the support supports aerosol-generating material on both the first and second surfaces of the support. Such an arrangement is advantageous because it increases the amount of aerosol-generating material that can be supported on the consumable of this embodiment relative to a consumable having aerosol-generating material supported on only one surface of the support.

[0037] In some embodiments of any of the above embodiments, at least some of the aerosol-generating material is supported on the other of the first and second surfaces of the support as one or more separate portions of aerosol-generating material.

[0038] In some embodiments of any of the above embodiments, one or more of the open ends of the perforations in the other of the first and second surfaces overlap with an aerosol-generating material supported on that surface.

[0039] In some embodiments of any of the above embodiments, the open ends of the second number of perforations in the other of the first and second surfaces are not overlapped by aerosol-generating material supported on that surface.

[0040] In some embodiments of any of the above embodiments, one or more locations of aerosol-generating material supported on a first surface of the support substantially correspond to one or more locations of aerosol-generating material supported on a second surface of the support.

[0041] In some embodiments of any of the above embodiments, the support includes an impermeable material, and optionally the impermeable material is a sheet material. The impermeable material is impermeable to at least the components of the aerosol-generating material. In such embodiments, the components of the aerosol-generating material cannot migrate or diffuse into the support.

[0042] In some embodiments of any of the above embodiments, the impermeable material is a ferrous or non-ferrous metal.

[0043] In some embodiments of any of the above embodiments, the impermeable material is a susceptor.

[0044] A susceptor is a material that can be heated by the penetration of a changing magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, where the penetration of the changing magnetic field results in inductive heating of the susceptor by resistive heating as a result of electrical eddy currents. The susceptor can be a magnetic material, where the penetration of the changing magnetic field results in magnetic hysteresis heating of the susceptor. The susceptor can be both conductive and magnetic, and therefore the susceptor is heatable by both heating mechanisms. A device configured to generate a changing magnetic field is called a magnetic field generator.

[0045] The susceptor may include a ferromagnetic metal such as iron or an iron alloy such as steel or an iron-nickel alloy. Some examples of ferromagnetic metals include 400 series stainless steel such as grade 410 stainless steel, grade 420 stainless steel, or grade 430 stainless steel, or similar grades of stainless steel. Alternatively, the susceptor may include a suitable non-magnetic, especially paramagnetic, conductive material such as aluminum. In paramagnetic conductive materials, induction heating occurs primarily by resistive heating due to eddy currents. Alternatively, the susceptor may include a non-conductive ferrimagnetic material such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated only by hysteresis losses. The susceptor may include a commercially available alloy such as Phytherm 230 (having a composition (in weight percent = wt%) of 50 wt% Ni, 10 wt% Cr, and balance Fe) or Phytherm 260 (having a composition of 50 wt% Ni, 9 wt% Cr, and balance Fe).

[0046] In some embodiments of any of the above embodiments, the impermeable material is aluminum foil.

[0047] In some embodiments of any of the above embodiments, the impermeable material is composed of two or more separate pieces.

[0048] In some of any of the above embodiments, the distinct portions of impermeable material correspond in number or location to one or more distinct portions of aerosol-forming material.

[0049] In some of any of the above embodiments, each separate portion of the aerosol-generating material is supported on a separate portion of the impermeable material. In such embodiments, each separate portion of the impermeable material may be a susceptor that can be individually heated. The use of separate portions of the susceptor is advantageous in embodiments of a consumable that includes two or more separate portions of aerosol-generating material, as the breaks in the susceptor reduce the amount of heat transferred from one separate portion of the aerosol-generating material that is heated to an adjacent portion of the aerosol-generating material that is not heated. In some of any of the above embodiments, one or more of the perforations extend through the aerosol-generating material supported on one or both of the first and second surfaces of the support. An advantage of such an arrangement is that the surface area of ​​the aerosol-generating material is increased by the perforations, thus increasing the efficiency of generation of aerosol from the aerosol-generating material compared to aerosol-generating materials of smaller surface area. A further advantage is that aerosols formed from the aerosol-generating material adjacent to the perforations may easily pass in either direction along the passageway formed by the perforations.

[0050] In some embodiments of any of the above embodiments, the location of one or more of the perforations through the support is determined by the location of the aerosol-generating material on one or both of the first and second surfaces of the support.

[0051] In some embodiments of any of the above embodiments, the aerosol-forming material is an amorphous solid.

[0052] In some embodiments of any of the above embodiments, the aerosol-forming material is an aerosolizable gel.

[0053] In some embodiments of any of the above embodiments, all of the aerosol-forming materials supported on the first and / or second surface of the support are of substantially the same composition.

[0054] In one embodiment of any of the above embodiments, the aerosol-generating material supported on the support is arranged such that there is a band of the support on both surfaces of the support that extends on the support a predetermined distance from the edge where there is no aerosol-generating material. The band may extend the same distance from the edge of the support for the entire length of the edge of the support. The band may aid in handling of the consumable during use and / or packaging. The band may be continuous along the entire length of the edge of the support or may be discontinuous. The band may extend different distances on the surface of the support at different locations around the edge of the support.

[0055] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0056] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or promote a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. An active substance may be naturally occurring or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, non-cannabinoid terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof.

[0057] The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other botanical substances.

[0058] The active substance may include a cannabis component, derivative or extract, such as one or more cannabinoids or terpenes.

[0059] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0060] The active material may include or be obtained from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material obtained from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, pods, husks, etc. Alternatively, the material may include active compounds naturally present in the botanical material, synthetically obtained active compounds. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderberry, vanilla, wintergreen, shiso, turmeric, turmeric, sandalwood, cilantro, bergamot, orange blossom, silver plum blossom, black currant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, carvi, 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 species: Mentha arventis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0061] In some embodiments, the active substance comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0062] In some embodiments, the active material comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0063] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0064] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0065] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to produce a desired taste, odor, or other somatic sensation in products intended for adult consumers.Fragrances and flavorings include naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropic, citrus, citrus fruit ... Calfruit, 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 quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, konnyaku jack, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, silver plum blossom, black currant, valerian, pimento, melon, thyme, thyme leaf, thyme, thyme flower, thyme ... The additives may include other additives such as sucralose, damiane, marjoram, olive, lemon balm, lemon basil, chives, caraway, 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, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The fragrances and flavorings may be imitation, synthetic or natural ingredients, or mixtures thereof. The fragrances and flavorings may be in any suitable form, for example liquids such as oils, solids such as powders, or gases.

[0066] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus fruit, and / or red berry flavor ingredients. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor ingredients extracted from tobacco. In some embodiments, the flavor comprises flavor ingredients extracted from cannabis.

[0067] In some embodiments, the flavoring may include sensates, which are intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and these may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0068] An aerosol-generating material is a material capable of generating an aerosol when, for example, heated, irradiated, or energized by any other method. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, which may or may not contain actives and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid." (i.e., non-fibrous). In some embodiments, the amorphous solid may be a gel or a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0069] Amorphous solids include aerosol generating agents.

[0070] In some embodiments, the aerosol generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of 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, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol generating agent includes glycerol. In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols, such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0071] In some embodiments, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol generating agent.

[0072] In some embodiments, the amorphous solid can comprise from about 5 wt%, 10 wt%, 20 wt%, 25 wt%, 27 wt%, or 30 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the aerosol generating agent (DWB (dry weight basis)). For example, the amorphous solid can comprise 10-60 wt%, 20-50 wt%, 25-40 wt%, or 30-35 wt% of the aerosol generating agent.

[0073] In some embodiments, the amorphous solid can comprise up to about 80 wt% of the aerosol generating agent (DWB), such as about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0074] The amorphous solid may also include a gelling agent.

[0075] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginic acid, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginic acid, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginic acid and / or pectin, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may comprise calcium cross-linked alginic acid and / or calcium cross-linked pectin.

[0076] In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0077] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0078] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0079] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginic acid or agar.

[0080] In some embodiments, the gelling agent comprises alginic acid, and the alginic acid is present in the amorphous solid in an amount of 10-30 wt% of the amorphous solid (calculated on a dry weight basis). In some embodiments, the alginic acid is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginic acid and at least one additional gelling agent, such as pectin. In some embodiments, the amorphous solid comprises from 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 the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% of the gelling agent.

[0081] In some embodiments, the amorphous solid comprises from about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 20-35 wt%, or 25-30 wt% of the gelling agent.

[0082] In some cases, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the amorphous solid may comprise 10-40 wt%, 15-30 wt%, or 20-25 wt% of the gelling agent (DWB).

[0083] In embodiments, the amorphous solid comprises gelling agent and filler in a combined amount of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the amorphous solid. In embodiments, the amorphous solid comprises gelling agent and filler in a combined amount of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the amorphous solid.

[0084] In embodiments, the amorphous solid comprises gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the amorphous solid (i.e., not considering the amount of filler). In embodiments, the amorphous solid comprises gelling agent in an amount of about 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the amorphous solid (i.e., not considering the amount of filler).

[0085] In some embodiments, the gelling agent comprises alginic acid in an amount of about 5-40 wt% or 15-40 wt% of the amorphous solid, i.e., the amorphous solid comprises alginic acid in an amount of about 5-40 wt% or 15-40 wt% of the amorphous solid by dry weight, In some embodiments, the amorphous solid comprises alginic acid in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the amorphous solid.

[0086] In some embodiments, the gelling agent comprises pectin in an amount of about 3-15% by weight of the amorphous solid, i.e., the amorphous solid comprises pectin in an amount of about 3-15% by weight of the amorphous solid, by dry weight, in some embodiments, the amorphous solid comprises pectin in an amount of about 5-10% by weight of the amorphous solid.

[0087] In some embodiments, the gelling agent comprises guar gum in an amount of about 3-40 wt% of the amorphous solids. That is, the amorphous solids comprise guar gum in an amount of about 3-40 wt% of the amorphous solids by dry weight. In some embodiments, the amorphous solids comprise guar gum in an amount of about 5-10 wt% of the amorphous solids. In some embodiments, the amorphous solids comprise guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the amorphous solids. In some embodiments, the alginic acid is present in an amount of at least about 50 wt% of the gelling agent. In some embodiments, the amorphous solids comprise alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically greater than 1:1, that is, there is an amount of alginic acid greater than the amount of pectin. In embodiments, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

[0088] The amorphous solid may be formed by (a) forming a slurry including components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form the amorphous solid. (b) forming the layer of the slurry typically includes spraying, casting, or extruding the slurry. In an embodiment, the slurry layer is formed by electrospraying the slurry. In an embodiment, the slurry layer is formed by casting the slurry.

[0089] In some embodiments, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrospraying). In some embodiments, (b), (c) and (d) are performed sequentially.

[0090] In some embodiments, the slurry is applied to a substrate and a layer may be formed on the substrate. In an embodiment, the slurry includes a gelling agent, an aerosol forming material, and an active agent. The slurry may include these components in any of the ratios given herein for compositions of amorphous solids. For example, the slurry may include (on a dry weight basis): a gelling agent and optionally a filler, the amount of the gelling agent and the filler together being about 10-60 wt% of the slurry; an aerosol-forming material in an amount of about 40-80 wt% of the slurry; Optionally, an active material in an amount of up to about 20 wt% of the slurry; may include.

[0091] (c) Hardening the gel may include providing a hardening agent to the slurry. For example, the slurry may include sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a hardening agent including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel. In embodiments, the hardening agent includes or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some embodiments, the hardening agent includes or consists of calcium formate and / or calcium lactate. In certain embodiments, the hardening agent includes or consists of calcium formate. The inventors have found that using calcium formate as a hardening agent typically results in an amorphous solid having greater tensile strength and greater resistance to elongation.

[0092] The total amount of hardening agent, such as calcium source, may be 0.5-5 wt% (calculated on a dry weight basis). Preferably, the total amount may be from about 1 wt%, 2.5 wt%, or 4 wt% to about 4.8 wt%, or 4.5 wt%. The inventors have found that adding too little hardening agent may result in an amorphous solid in which the amorphous solid components are not stabilized and there is shedding of these components from the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

[0093] When the amorphous solid does not contain tobacco, a larger amount of hardener may need to be applied. Thus, in some cases, the total amount of hardener may be 0.5-12 wt%, such as 5-10 wt%, calculated on a dry weight basis. Preferably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt%, or 10 wt%. In this case, the amorphous solid generally does not contain any tobacco.

[0094] In an embodiment, providing the hardening agent to the slurry includes spraying the hardening agent onto the slurry, such as onto a top surface of the slurry.

[0095] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginic acid crosslinks to form a gel. Alginates with high G monomer content have been found to form gels more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include alginates in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-guluronic acid (G) units.

[0096] In embodiments, (d) drying removes about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% of the water in the slurry (WWB).

[0097] In embodiments, (d) drying reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast to a thickness of 2 mm and the resulting dried amorphous solid material has a thickness of 0.2 mm.

[0098] In some embodiments, the slurry solvent consists essentially of or consists of water, hi some embodiments, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB).

[0099] In embodiments where the solvent comprises water, the dry weight content of the slurry can match the dry weight content of the amorphous solids, and thus any discussion herein of solids composition is expressly incorporated herein in its entirety with respect to the slurry aspects of the invention.

[0100] The amorphous solid may include a flavoring. The amorphous solid may preferably include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the amorphous solid may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0101] The amorphous solid may include a filler.

[0102] In some embodiments, the amorphous solid comprises less than 60 wt% filler, such as between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0103] In other embodiments, the amorphous solid comprises less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% of a filler. In some cases, the amorphous solid comprises less than 1 wt% of a filler, and in some cases, no filler.

[0104] In some such cases, the amorphous solid comprises at least 1 wt% filler, e.g., 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, hi some embodiments, the amorphous solid comprises 5-25 wt% filler.

[0105] 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 include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0106] In certain embodiments that include a filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0107] Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers in the amorphous solid may increase the tensile strength of the material, which may be particularly advantageous in embodiments where the amorphous solid is provided as a sheet, such as when the amorphous solid sheet surrounds a rod of aerosolizable material.

[0108] In some embodiments, the amorphous solid does not include tobacco fiber. In certain embodiments, the amorphous solid does not include fibrous material. In some embodiments, the aerosol-forming material does not include tobacco fiber. In certain embodiments, the aerosol-forming material does not include fibrous material.

[0109] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0110] In some embodiments, the amorphous solid additionally comprises an active agent. For example, in some cases, the amorphous solid additionally comprises tobacco material and / or nicotine. In some embodiments, the amorphous solid comprises powdered tobacco and / or nicotine and / or tobacco extract.

[0111] In some cases, the amorphous solids may comprise 5-60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). In some cases, the amorphous solids may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% active material (calculated on a dry weight basis). In some cases, the amorphous solids may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco material (calculated on a dry weight basis). For example, the amorphous solid may comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the amorphous solid may comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0112] In some cases, the amorphous solid comprises an active agent such as tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the amorphous solid may comprise about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solids contain from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, no nicotine other than that provided by the tobacco extract may be present in the amorphous solids.

[0113] In some embodiments, the amorphous solid does not include tobacco material, but does include nicotine. In some such cases, the amorphous solid may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0114] In some cases, the total content of actives and / or flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0115] The aerosol-generating composition may include one or more active agents. In embodiments, the amorphous solid includes one or more active agents, for example, up to about 20 wt% of the amorphous solid. In embodiments, the amorphous solid includes active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the amorphous solid.

[0116] The active agents may include physiologically and / or olfactory active agents that are included in the aerosol forming composition to achieve a physiological and / or olfactory response.

[0117] The tobacco material may be present in the aerosol forming composition in an amount of about 50-95 wt%, or about 60-90 wt%, or about 70-90 wt%, or about 75-85 wt%.

[0118] The tobacco material can be present in any format, but is typically shredded (e.g., cut into thin strips). The shredded tobacco material can be advantageously mixed with the amorphous solids to provide an aerosol-forming composition having an even distribution of the tobacco material and the amorphous solids throughout the aerosol-forming composition.

[0119] In embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have found that a relatively large amount of lamina tobacco can be used in the aerosol generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. Lamina tobacco typically provides superior sensory characteristics. In embodiments, the tobacco material comprises lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain embodiments, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0120] The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0121] In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0122] In some cases, the amorphous solids may additionally comprise an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solids may comprise about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum acacia.

[0123] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0124] The amorphous solid can have any suitable water content, such as 1 wt% to 15 wt%. The water content of the amorphous solid is preferably from about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), and most preferably about 10 wt%. The water content of the amorphous solid can be determined, for example, by Karl Fischer titration or gas chromatography with thermal conductivity detection (GC-TCD).

[0125] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol generating agent, a flavoring agent, and optionally an active agent.

[0126] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol forming agent, flavorings, and optionally tobacco material and / or a nicotine source.

[0127] In embodiments, the amorphous solid consists essentially of, or consists of, a gelling agent, an aerosol generating agent, an active agent, and water.In embodiments, the amorphous solid consists essentially of, or consists of, a gelling agent, an aerosol generating agent, and water.

[0128] In some embodiments, the amorphous solid does not include a flavoring, and in certain embodiments, the amorphous solid does not include an active agent. In some embodiments, the aerosol-forming material comprises an amorphous solid, and the amorphous solid is 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 0.1~80wt% fragrance and and these weights are calculated on a dry weight basis. In some embodiments, the amorphous solid comprises 1-80 wt% flavoring (on a dry weight basis).

[0129] In some embodiments, the amorphous solid is 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% fragrance and These weights are calculated on a dry weight basis.

[0130] In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10-60wt% tobacco extract These weights are calculated on a dry weight basis.

[0131] In some embodiments, the amorphous solid is 1 to 60 wt % of a gelling agent; 20 to 60 wt % of an aerosol generating agent; 10-60wt% tobacco extract These weights are calculated on a dry weight basis.

[0132] In some embodiments, the amorphous solid comprises 20-35 wt.% gelling agent, 10-25 wt.% aerosol forming material, 5-25 wt.% filler including fibers, and 35-50 wt.% flavoring and / or active agent.

[0133] In some cases, the amorphous solids may consist essentially of or consist of a gelling agent, an aerosol generating agent, a tobacco extract, water, and optionally flavorings. In some cases, the amorphous solids may consist essentially of or consist of glycerol, alginic acid and / or pectin, a tobacco extract, and water.

[0134] In some embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably including alginic acid) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to about 30 wt%, or about 15 wt% to about 25 wt%, tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to about 55 wt%, or about 45 wt% to about 50 wt%, and aerosol generating agent (preferably including glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB). In one embodiment, the amorphous solid comprises about 20 wt% alginic acid gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (DWB).

[0135] The "thickness" of an amorphous solid refers to the shortest distance between a first surface and a second surface. In embodiments in which the amorphous solid is in the form of a sheet, the thickness of the amorphous solid is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet opposite the first planar surface of the sheet.

[0136] In some cases, the aerosol-forming amorphous solid layer has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm, or 0.05 mm to about 1.0 mm. Preferably, the thickness can range from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm.

[0137] In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0138] Particularly preferred is a material having a thickness of 0.2 mm. Amorphous solids may have more than one layer, and the thicknesses expressed herein refer to the combined thickness of these layers.

[0139] If the aerosol-generating material or amorphous solid is too thick, heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it becomes difficult to manufacture and handle, and very thin materials are more difficult to mold and can be fragile, compromising aerosol formation during use.

[0140] The thicknesses presented herein are average thicknesses for the material. In some cases, the thickness of the amorphous solid may vary slightly by 25%, 20%, 15%, 10%, 5%, or 1%.

[0141] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200N / m to about 900N / m. In some examples, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200N / m to 400N / m, or 200N / m to 300N / m, or about 250N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet and then chopped and incorporated into the aerosol product article. In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of about 600N / m to 900N / m, or 700N / m to 900N / m, or 800N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol product article / assembly as a rolled sheet, preferably in the form of a tube.

[0142] In some examples, the amorphous solid in sheet form may have a tensile strength of around 200 N / m to around 2600 N / m. In some examples, the amorphous solid may have a tensile strength of around 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or around 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol generating material including the amorphous solid is formed as a sheet and incorporated into an aerosol generating consumable.

[0143] Aerosol-forming materials containing amorphous solids have a density of 30 g / m 2 ~120g / m 2 In some cases, the sheet may have a density of 80 to 120 g / m (to have a density similar to that of cut rag tobacco, so that mixtures of these materials do not easily separate). 2 , or about 70 to 110 g / m 2 , or in particular, about 90 to 110 g / m 2 , or preferably about 100 g / m 2 In some cases, the sheet may have a weight per unit area of ​​about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be used to encase aerosolizable material such as tobacco.

[0144] All weight percentages (indicated as wt%) described herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis refer to the totality of the extract or slurry or material other than water, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages quoted on a wet weight basis refer to all ingredients, including water.

[0145] The amorphous solid may include a colorant. The addition of a colorant may change the visual appearance of the amorphous solid. The presence of a colorant in the amorphous solid may enhance the visual appearance of the amorphous solid and the aerosol-forming material. By adding a colorant to the amorphous solid, the amorphous solid may be color-matched to other components of the aerosol-forming material or other components of an article that includes the amorphous solid.

[0146] A variety of colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components in the aerosol-forming material that includes the amorphous solid, such as tobacco materials. In some embodiments, the addition of a colorant to the amorphous solid renders the amorphous solid visually indistinguishable from other components in the aerosol-forming material.

[0147] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry containing the material that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0148] In some embodiments of any of the above embodiments, talc powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one distinct portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0149] In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0150] In the following discussion of the accompanying drawings, when identical elements are present in one or more embodiments, the same reference numerals are used throughout for those elements, and when similar elements are present, similar reference numerals (the same numerals increased by a multiple of 100) are used.

[0151] 1, an aerosol delivery device 2 includes a casing 4 within which is disposed a heater assembly 6. The heater assembly 6 is comprised of a heating chamber 8 and a heater 10. The heater 10 may be an electrical resistance heater or a magnetic field generator for use with a susceptor.

[0152] The heating chamber 8 defines a mouth 12 at a first end of the heating chamber 8. At the opposite end of the heating chamber 8 is an opening 14. The opening 14 is in fluid communication with a mouthpiece 16 through a conduit 18.

[0153] Also disposed within the casing 4 is a controller 20 which is in electronic communication with and controls the functioning of the heater 10. The controller 20 may include a memory (not shown) in which one or more tables relating to the operation of the heater 10 may be stored. The heater 10 and the controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments, the power source may be another suitable source of electrical power.

[0154] The aerosol delivery device 2 is suitable for use with a consumable 24. The consumable 24 is comprised of one or more separate portions of aerosol-generating material 26 supported on a first surface 30 of a support 28. The separate portions of aerosol-generating material 26 are supported on the support 28 in a square grid pattern. Other non-illustrated embodiments of the consumable 24 may include more or fewer separate portions of aerosol-generating material 26 than are illustrated in FIG. 1, including a single portion of aerosol-generating material 26, and these portions may be distributed on the surface of the support 28 in any pattern. In FIG. 1, the separate portions of aerosol-generating material 26 are illustrated as having an approximately square shape, but in other embodiments they may be of other shapes.

[0155] 2 and 4, the support 28 is composed of a laminate of a support substrate 34 and a susceptor substrate 26. Separate portions of the aerosol-generating material 26 are supported on both the first and second surfaces 30, 32 of the support 28. The separate portions of the aerosol-generating material 26 supported on the first surface 30 of the support and the separate portions of the aerosol-generating material 26 supported on the second surface 32 of the support are disposed to correspond to each other. That is, when viewed from a position perpendicular to one of the first and second surfaces 30, 32, the separate portions of the aerosol-generating material 26 closer to the first and second surfaces overlap the separate portions of the aerosol-generating material 26 farther from the first and second surfaces.

[0156] Through the support 28, and where the support supports separate portions of the aerosol-generating material 26, are one or more perforations 38. For ease of visual clarity, not all of the perforations 38 are labeled in FIGS. 2 and 4. The perforations 38 are of a size sufficient to permit the flow of aerosol along the perforations between one side of the consumable 24 and the other. In some embodiments, the cross-section of the perforations 38 is at least 0.01 mm. 2 , at least 0.05 mm 2 , at least 0.1 mm2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 has a cross-sectional area of

[0157] 4, the perforations are disposed around and through the illustrated distinct portions of aerosol-generating material 26. There is an identical arrangement of perforations associated with each of the distinct portions of aerosol-generating material 26.

[0158] 2 and 4, the support substrate 34 is a layer of card. In other non-illustrated embodiments, the support substrate may be other materials, such as polyetheretherketone (PEEK). The susceptor substrate 36 is formed from aluminum foil. In other non-illustrated examples, the susceptor 36 may be an alternative metal foil or a thin layer of material that is inductively heated when exposed to a changing magnetic field.

[0159] 3 and 4, the support 28 is comprised of a laminate of a support substrate 34 and a susceptor substrate 26. A discrete portion of the aerosol-forming material 26 is supported on a first surface 30 of the support 28.

[0160] Through the support 28, and where the support supports separate portions of the aerosol-generating material 26, the aerosol-generating material 26 are perforated 38. For visual clarity, not all of the perforations 38 are labeled in FIGS. 3 and 4. The perforations 38 are of a size sufficient to permit the flow of aerosol along the perforations between one side of the consumable 24 and the other. In some embodiments, the cross section of the perforations 38 is greater than 1 mm. 2 Larger than 2mm 2 Greater than or equal to 3 mm 2 Greater than.

[0161] 4, the perforations are disposed around and through the illustrated distinct portions of aerosol-generating material 26. There is an identical arrangement of perforations associated with each of the distinct portions of aerosol-generating material 26.

[0162] 3 and 4, the support substrate 34 is a layer of card. In other non-illustrated embodiments, the support substrate may be other materials, such as polyetheretherketone (PEEK). The susceptor substrate 36 is formed from aluminum foil. In other non-illustrated examples, the susceptor 36 may be an alternative metal foil or a thin layer of material that is inductively heated when exposed to a changing magnetic field.

[0163] 5 and 7, the support 228 is comprised of a susceptor 226. Separate portions of the aerosol-generating material 26 are supported on both first and second surfaces 30, 32 of the susceptor 226.

[0164] Extending through the support 228 are perforations 238. For ease of visual clarity, not all of the perforations 238 are labeled in FIGS. 5 and 7. The perforations are of sufficient size to permit aerosol flow along the perforations between one side of the consumable 224 and the other. In some embodiments, the cross section of the perforations 238 is greater than 1 mm. 2 Larger than 2mm 2 Greater than or equal to 3 mm 2 Greater than.

[0165] 7, the perforations 238 are disposed around and beneath the illustrated distinct portions of aerosol-generating material 26. There is an identical arrangement of perforations associated with each of the distinct portions of aerosol-generating material 26.

[0166] 5 and 7, the susceptor 236 is formed from aluminum foil. In other non-illustrated embodiments, the susceptor 236 may be an alternative metal foil or a thin layer of material that is inductively heated when exposed to a changing magnetic field.

[0167] 6 and 7, the support 228 is comprised of a susceptor 226. Discrete portions of the aerosol-generating material 26 are supported on a first surface 30 of the susceptor 226.

[0168] Extending through the support 228 are perforations 238. For ease of visual clarity, not all of the perforations 238 are labeled in FIGS. 6 and 7. The perforations are of a size sufficient to permit aerosol flow along the perforations between one side of the consumable 224 and the other. In some embodiments, the cross section of the perforations 238 is at least 0.01 mm. 2 , at least 0.05 mm 2 , at least 0.1 mm 2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 has a cross-sectional area of

[0169] 7, the perforations 238 are disposed around and beneath the illustrated distinct portions of aerosol-generating material 26. There is an identical arrangement of perforations associated with each of the distinct portions of aerosol-generating material 26.

[0170] 5 and 7, the susceptor 236 is formed from aluminum foil. In other non-illustrated embodiments, the susceptor 236 may be an alternative metal foil or a thin layer of material that is inductively heated when exposed to a changing magnetic field.

[0171] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations on the scope of the invention as defined by the claims, or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may preferably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A consumable for use with an aerosol delivery device, the consumable comprising a support, an aerosol generating material, and one or more perforations, the perforations configured to allow the passage of heat or aerosol along the perforations.

2. The consumable product of claim 1 , wherein the support supports the aerosol-forming material on a first surface of the support.

3. The consumable of claim 2 , wherein the support further supports an aerosol-forming material on a second surface of the support.

4. 4. The consumable product of claim 2 or 3, wherein at least some of the aerosol-generating material supported on the first surface of the support is supported as one or more separate portions of aerosol-generating material.

5. The consumable product of claim 3 , wherein at least some of the aerosol-generating material supported on the second surface of the support is supported as one or more separate portions of aerosol-generating material.

6. The method of claim 1, wherein at least some of the aerosol-generating material supported on the first surface of the support is supported as one or more separate portions of aerosol-generating material; 6. The consumable of claim 5, wherein the number of distinct portions of aerosol-generating material on the first surface corresponds to the number of distinct portions on the second surface, and the positions of the distinct portions on the first surface of the support substantially correspond to the positions of the distinct portions supported on the second surface of the support.

7. The consumable product according to any one of claims 1 to 3, 5 and 6, wherein all of the aerosol-forming materials supported on the support are of substantially the same composition.

8. 7. The consumable product of claim 1, wherein the aerosol-generating material supported on the support is comprised of two or more separate portions, at least one separate portion having a different composition than at least one of the other separate portions.

9. A consumable product according to any one of claims 1 to 3, 5 and 6, wherein one or more of the perforations have at least one open end that opens through and is defined by a surface of the support, aerosol generating material, or any other element of the consumable product.

10. A consumable product according to any one of claims 1 to 3, 5 and 6, wherein one or more of the perforations have at least one blocked end blocked by the support, the aerosol-generating material, or any other element of the consumable product.

11. A consumable product according to any one of claims 1 to 3, 5 and 6, wherein one or more of the perforations extend at least partially through the support.

12. The consumable product of any one of claims 1 to 3, 5 and 6, wherein one or more of the perforations extend at least partially through the aerosol-forming material.

13. The consumable product according to any one of claims 1 to 3, 5 and 6, wherein the support comprises an impermeable material.

14. The consumable of claim 13 , wherein the impermeable material is a susceptor.

15. The consumable of claim 13 , wherein the impermeable material is comprised of two or more separate pieces.

16. The consumable of claim 15 , wherein the distinct portions of impermeable material correspond in number or location to one or more distinct portions of aerosol-forming material.

17. 17. The consumable product of claim 16, wherein each separate portion of aerosol-forming material is supported on a surface of a separate portion of impermeable material.

18. The consumable of claim 13 , wherein one or more of the perforations have an open end that opens through a surface of the impermeable material.

19. The consumable of claim 13 , wherein one or more of the perforations have at least one blocked end blocked by the impermeable material.

20. The consumable of claim 14 , wherein one or more of the perforations extend at least partially through the susceptor.

21. The consumable of claim 1 , wherein the location of one or more of the perforations is determined by the location of the aerosol-generating material supported on one or both of the first and second surfaces of the support.

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