Consumables for use with aerosol delivery devices

Abstract

A consumable (40) for use with an aerosol delivery device (2) is provided. The consumable (40) includes a support (48) and an aerosol-forming material (42). The aerosol-forming material (42) includes one or more discrete portions (44, 46) of the aerosol-forming material (42), the discrete portions (44, 46) being supported on the support (48). At least one of the discrete portions (44, 46) has a detectable characteristic, the detectable characteristic being indicative of at least one product characteristic of the discrete portions (44, 46).

Description

[Technical field]

[0001] The present disclosure relates to the field of non-flammable aerosol delivery systems, and in particular to consumables for use with aerosol delivery devices, methods of manufacturing consumables for use with aerosol delivery devices, and aerosol delivery systems including consumables and aerosol delivery devices.

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release compounds from a substrate material through heating without combustion, thereby emitting an inhalable aerosol or vapor. These are sometimes referred to as non-combustible 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, without combustion, an aerosolizable material, sometimes referred to as a solid aerosol-generating material, which may optionally include tobacco material. Upon heating, at least one component of the material is volatilized, typically forming an inhalable aerosol. These products may also be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known that volatilize at least one component of a solid aerosol-generating material.

[0004] Another example is a hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device also includes 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 the inhalation medium. Overview

[0005] 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 and an aerosol-generating material, the aerosol-forming material comprises two or more discrete portions of aerosol-forming material; The discrete portion is supported by the support portion; At least one of the discrete portions has a detectable characteristic; A consumable product is provided, wherein the detectable characteristic is indicative of at least one product characteristic of the discrete portion. According to a second aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable product according to any one of claims 1 to 21, comprising: an aerosol generator configured to heat at least one discrete portion of an aerosol-generating material supported by the consumable; a detector configured to detect a detectable characteristic of at least one discrete portion on the consumable; a memory including a table relating detectable characteristics of the discrete portions to product characteristics of the discrete portions; a controller configured to receive the detected detectable characteristic of the discrete portions, look up a table in a memory, and control operation of the aerosol delivery device based on the at least one product characteristic of the discrete portions; An aerosol delivery device is provided comprising:

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

[0007] According to a fourth aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable using an aerosol generation device according to the second aspect of the present disclosure comprising at least one aerosol generator arranged to heat, in use, the consumable according to the first aspect of the present disclosure without burning it, wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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

[0009] [Figure 1] FIG. 1 is a schematic diagram of one embodiment of an aerosol delivery device of the present disclosure. [Diagram 2] FIG. 1 illustrates an embodiment of a consumable of the present disclosure. Detailed Description

[0010] Consumables herein may alternatively be referred to as articles.

[0011] In some embodiments, the consumable includes an aerosol-generating material, which may include an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0012] The device for heating the aerosol-generating material with which the consumable is used is part of a non-combustion aerosol delivery system. Non-combustion aerosol delivery systems (such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols through a combination of aerosol-generating materials) release compounds from the aerosol-generating material without combustion.

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

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

[0015] In some embodiments, the non-combustible aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although 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-combustible aerosol delivery system is a hybrid system that generates aerosol by a combination of aerosol-generating materials, one or more of which may be adapted to 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 a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

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

[0019] In some embodiments, a non-flammable aerosol delivery system (e.g., a non-flammable 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 provide 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-flammable 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. 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 and an aerosol-generating material, the aerosol-forming material comprises one or more discrete portions of aerosol-forming material; The discrete portion is supported by the support portion; At least one of the discrete portions has a detectable characteristic; A consumable product is provided, wherein the detectable characteristic is indicative of at least one product characteristic of the discrete portion.

[0021] A detectable characteristic is a characteristic that is detectable by a human and / or a detection device.

[0022] A product characteristic of a discrete portion is a characteristic of the discrete portion or a characteristic related to one or more of its constituent substances. In some embodiments, a product characteristic is a characteristic of an aerosol generated by an aerosol-generating material of the discrete portion when the aerosol-generating material of the discrete portion is heated. In some embodiments, a product characteristic is a characteristic of the generation of an aerosol when the aerosol-generating material of the discrete portion is heated.

[0023] In one embodiment of the above embodiments, at least two of the discrete portions each have a detectable characteristic, the detectable characteristic of each discrete portion being indicative of at least one product characteristic of that discrete portion, hi some embodiments, all of the discrete portions of the aerosol-forming material have a detectable characteristic.

[0024] In one embodiment of any of the above embodiments, at least one of the discrete portions has a detectable characteristic that is different from the detectable characteristic of at least one other discrete portion, in some embodiments these characteristics, while related, may be different, for example the discrete portions may be different shapes.

[0025] In one embodiment of any of the above embodiments, the detectable characteristic of the discrete portions is indicative of at least one product characteristic of the two or more discrete portions. In such embodiments, the number of discrete portions of aerosol forming material on the consumable having the detectable characteristic is less than the number of discrete portions on the consumable for which the product characteristic is known.

[0026] In some embodiments, there are two possible types of discrete portions of aerosol-forming material: those with at least one detectable property and those without a detectable property. Each of the discrete portions without a detectable property may be positioned on the support such that a position relative to one or more of the discrete portions with at least one detectable property indicates one or more of the respective product properties.

[0027] In one embodiment of any of the above embodiments, at least one discrete portion has at least two detectable characteristics, each detectable characteristic indicative of at least one product characteristic of the discrete portion.

[0028] In one embodiment of any of the above embodiments, the product characteristics include one or both of a composition of the aerosol-forming material in the discrete portions and a volume of the aerosol-forming material in the discrete portions.

[0029] In one embodiment of any of the above embodiments, the composition of the aerosol-forming material in the discrete portions includes one or more of an active agent, a fragrance or flavoring agent, and a sensate.

[0030] In one embodiment of any of the above embodiments, the detectable characteristic comprises one of shape, size, position relative to a reference, position relative to at least one other discrete portion, color in the 390-700 nm wavelength range of the electromagnetic spectrum, absorption spectrum, optical density, translucency, presence of one or more biomarkers, presence of one or more chemical markers, magnetic properties, pH, or mass.

[0031] In one embodiment of any of the above embodiments, the or each detectable characteristic may be indicative of one or more aspects of a manufacturing process for the consumable.

[0032] In one embodiment of any of the above embodiments, the detectable characteristic may be adapted for quality control during the manufacturing process.

[0033] In one embodiment of any of the above embodiments, at least one discrete portion has a detectable characteristic that includes a shape that is one of a substantially circular shape, a polygonal shape, a star shape, a longitudinally extending stripe, a stripe including at least one curve or angle, or a tessellated shape when viewed perpendicular to the surface on which the discrete portion is supported.

[0034] In one embodiment of any of the above embodiments, at least one discrete portion has a detectable characteristic comprising a first shape that is substantially circular, polygonal, star-shaped, longitudinally extending stripes, stripes including at least one curve or angle, or a tessellated shape when viewed perpendicular to a surface on which the discrete portion is supported, and at least one other discrete portion has a detectable characteristic that is different from the first shape and comprises a second shape that is substantially circular, polygonal, star-shaped, longitudinally extending stripes, stripes including at least one curve or angle, or a tessellated shape when viewed perpendicular to a surface on which the discrete portion is supported.

[0035] In one embodiment of any of the above embodiments, the detectable characteristic is selected to be visually discernible by a user.

[0036] In one embodiment of any of the above embodiments, the detectable characteristic is selected to be distinguishable by an automated detector, hi some embodiments, the detector does not physically contact the discrete portions.

[0037] In one embodiment of any of the above embodiments, the aerosol-forming material is in the form of an aerosol-forming film or an aerosol-forming gel.

[0038] An aerosol-forming material is a material that is capable of generating an aerosol when energized, e.g., by heating, irradiating, or in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (e.g., gel) form, and may or may not contain active substances and / or flavorings.

[0039] 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.

[0040] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating material may or may not be soluble. In some embodiments, the aerosol-generating material is substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0041] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. The aerosol-generating film may be substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0042] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, 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.

[0043] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients (e.g., one or more delivery substances) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent.

[0044] The slurry may be adapted such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed by heating.

[0045] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that is capable of retaining some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0046] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0047] In one embodiment of any of the above embodiments, the support has at least two surfaces and all of the discrete portions of aerosol-forming material are supported on one surface of the support.

[0048] In one embodiment of any of the above embodiments, at least three of the discrete portions are supported on a surface of the support in a grid pattern.

[0049] In one embodiment of any of the above embodiments, the support comprises a susceptor.

[0050] In one embodiment of any of the above embodiments, the susceptor is a sheet material.

[0051] In one embodiment of any of the above embodiments, the support is a laminate and the susceptor is a layer of the laminate.

[0052] In one embodiment of any of the above embodiments, the susceptor is a metal foil or film.

[0053] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of a varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, such that the penetration of a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0054] The susceptor may comprise a metal or alloy. The susceptor may comprise a ferromagnetic metal (such as iron) or an iron alloy (such as steel) or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as 410 grade stainless steel, 420 grade stainless steel, 430 grade stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In a paramagnetic conductive material, induction heating occurs solely through resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated solely through hysteresis losses. The susceptor may comprise a commercially available alloy such as Phytherm 230 (composition including 50 wt% Ni, 10 wt% Cr, and the rest of the Fe (weight % = wt %)) or Phytherm 260 (composition including 50 wt% Ni, 9 wt% Cr, and the rest of the Fe).

[0055] In some embodiments of any of the above embodiments, the susceptor may be a metal foil or film, optionally an aluminum foil or film, or an iron foil or film, or alternatively, any conductive material that can be sprayed or deposited onto the material that makes up the support.

[0056] In one embodiment of any of the above embodiments, the support comprises a support material, the support material comprising one or more of paper, cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0057] In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in a non-flammable aerosol delivery device. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support is reusable and the consumable is less susceptible to condensation in a non-flammable aerosol delivery device than consumables with supports that use adsorbent materials for structural purposes.

[0058] In one embodiment of any of the above embodiments, the substrate is a laminate. In such embodiments, the laminate may be formed from multiple sheets of material. In some embodiments, at least two sheets of the laminate are different materials. According to a second aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable product according to the first aspect of the present disclosure, comprising: an aerosol generator configured to heat at least one discrete portion of an aerosol-generating material supported by the consumable; a detector configured to detect a detectable characteristic of at least one discrete portion on the consumable; a memory including a table relating detectable characteristics of the discrete portions to product characteristics of the discrete portions; a controller configured to receive the detected detectable characteristic of the discrete portions, look up a table in a memory, and control operation of the aerosol delivery device based on the at least one product characteristic of the discrete portions; An aerosol delivery device is provided comprising:

[0059] In one embodiment of any of the above embodiments, the aerosol generator is configured to independently heat at least two discrete portions supported at different locations on the consumable, and the detector is configured to detect a detectable characteristic of the two or more discrete portions of the heated aerosol generating material.

[0060] In one embodiment of any of the above embodiments, the heating assembly is configured to releasably hold the consumable in a heating position, and the detector detects a detectable characteristic of at least one discrete portion supported on the consumable when the consumable is moved to the heating position.

[0061] In one embodiment of any of the above embodiments, the aerosol delivery device is configured to operate or function differently in conjunction with discrete portions of aerosol-forming material having different product characteristics.

[0062] In one embodiment of any of the above embodiments, the different features of operation of the aerosol delivery device may include, but may not be limited to, operating at one or more different heating temperatures, heating different discrete portions for different heating times, operating with different temperature profiles of the heating assembly for different discrete portions, and allowing different numbers of puffs from different discrete portions before the aerosol delivery device determines that an aerosol-generating material is depleted or exhausted. An aerosol-generating material is depleted or exhausted when all or a predetermined percentage of the aerosol-generating material has been aerosolized, when a desired minimum amount of aerosol cannot be generated in a predetermined heating time, or after a predetermined period of heating of the discrete portions of the aerosol-generating material.

[0063] In one embodiment of any of the above embodiments, the aerosol delivery device is configured to operate most efficiently in terms of power consumption for each discrete portion of aerosol-generating material to be heated. This is possible by using the aerosol delivery device of the present disclosure, since properties such as composition or volume of the discrete portions of aerosol-generating material to be heated may require lower temperatures to achieve sufficient generation of aerosol. By using only the power required to achieve sufficient aerosol generation for each portion, rather than a level of power to achieve sufficient aerosol generation from all the aerosol-generating material, power requirements are reduced. This may result in a longer life of the power source or a longer time between recharging the power source.

[0064] In one embodiment of any of the above embodiments, the aerosol delivery device may be configured to allow a user to select the discrete portions of aerosol-forming material that are heated to generate an aerosol.

[0065] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0066] As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0067] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0068] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0069] The active material may include or be derived from one or more botanical substances or constituents, derivatives or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, marjoram, olive, lemon balm, lemon basil, chives, ribeye, 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 arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0070] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0071] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

[0072] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from rooibos and fennel.

[0073] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0074] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to produce a desired flavour, aroma, or other sensory experience in products intended for adult consumers, where local regulations permit.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, heat, spices, flavors, aromas, flavor ... Belly fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, 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, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamag ... damiene, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, 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.These may be of imitation, synthetic or natural origin, or a mixture thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gel.

[0075] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, 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.

[0076] In some embodiments, the fragrance may include sensates intended to achieve the sensations usually 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 produce a heating, cooling, tingling, or numbing effect.Suitable heating agents may be, but are not limited to, vanillyl ethyl ether.Suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0077] An aerosol-forming material is a material that is capable of generating an aerosol when energized, for example by heating, irradiating, or in any other manner. The aerosol-forming material may be in the form of, for example, a solid, liquid, or gel, and may or may not contain active substances and / or flavorings.

[0078] The aerosol-generating material includes an aerosol forming agent.

[0079] In some embodiments, the aerosol generating agent may include one or more constituents 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 sulfate, 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.

[0080] 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, diacetate, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0081] In some embodiments, the aerosol-generating material may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% 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 aerosol-generating material may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-generating agent.

[0082] In some embodiments, the aerosol-generating material may 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). For example, the aerosol-generating material may comprise from 10 to 60 wt%, 20 to 50 wt%, 25 to 40 wt%, or 30 to 35 wt% of the aerosol-generating agent.

[0083] In some embodiments, the aerosol-forming material may include up to about 80 wt% aerosol-generating agent (DWB), such as about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0084] The aerosol-generating material may also include a gelling agent. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, the gelling agent includes one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginates, pectins, 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 embodiments, the gelling agent includes alginates and / or pectins, which are combined with a hardening agent (such as a calcium source) during formation of the aerosol-generating material. In some embodiments, the aerosol-generating material may include calcium cross-linked alginates and / or calcium cross-linked pectins.

[0085] 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.

[0086] In some embodiments, the cellulose 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.

[0087] 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.

[0088] 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, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0089] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol-forming material in an amount of 10-30 wt % (calculated on a dry weight basis) of the aerosol-forming material. In some embodiments, the only gelling agent present in the aerosol-forming material is alginate. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

[0090] In some embodiments, the aerosol-forming material 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 a gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent.

[0091] In some embodiments, the aerosol-forming material 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 aerosol-forming material may comprise from 20 to 35 wt% or from 25 to 30 wt% of the gelling agent.

[0092] In some cases, the aerosol-forming material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the aerosol-forming material may include from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0093] For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material. For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material.

[0094] By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler). By way of example, the aerosol-forming material may comprise a 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 aerosol-forming material (i.e., not taking into account the amount of filler).

[0095] In some examples, the alginate is included in the gelling agent in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises alginate in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material by dry weight, in some examples, the aerosol-forming material comprises alginate in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the aerosol-forming material.

[0096] In some examples, the pectin is included in the gelling agent in an amount of about 3-15 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises pectin in an amount of about 3-15 wt% of the aerosol-forming material by dry weight, hi some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0097] In some examples, the guar gum is present in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of about 3-40 wt% of the aerosol-generating material by dry weight. In some examples, the aerosol-generating material comprises guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the aerosol-generating material.

[0098] For example, the alginate is present in an amount of at least about 50 wt% of the gelling agent. For example, the aerosol-forming material includes alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is usually greater than 1:1. That is, the alginate is present in an amount greater than the amount of pectin. For example, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

[0099] The aerosol-generating material may be formed by (a) forming a slurry containing components of the aerosol-generating material or a precursor thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form the aerosol-generating material.

[0100] (b) Forming the slurry layer typically involves spraying, casting, or extruding the slurry. For example, the slurry layer may be formed by electrospraying the slurry. For example, the slurry layer may be formed by casting the slurry.

[0101] In some instances, (b), and / or (c), and / or (d) occur at least partially simultaneously (e.g., in an electrospray). In some instances, (b), (c), and (d) occur sequentially.

[0102] In some instances, the slurry may be applied to a support such that a layer is formed on the support. By way of example, the slurry may include a gelling agent, an aerosol-forming material, and an active agent. The slurry may include these components in any of the proportions described herein for the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis): a gelling agent and optionally a filler, the amount of gelling agent and 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; and may also include

[0103] Hardening the gel (c) may include providing a hardening agent to the slurry, for example the slurry may include sodium, potassium or ammonium alginate as a gel precursor and the addition of a hardening agent to the slurry including a calcium source (such as calcium chloride) to form a calcium alginate gel.

[0104] By way of example, the sclerosing agent may include or consist of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the sclerosing agent may include or consist of calcium formate and / or calcium lactate. In certain examples, the sclerosing agent may include or consist of calcium formate. The inventors have determined that when calcium formate is employed as a sclerosing agent, the aerosol generating material typically exhibits higher tensile strength and resistance to elongation.

[0105] The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount is about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that if too little hardening agent is added, the components of the aerosol-generating material may not be stable and may drop out of the aerosol-generating material. The inventors have also found that if too much hardening agent is added, the aerosol-generating material may become very sticky and difficult to handle.

[0106] If the aerosol-forming material does not contain tobacco, it may be necessary to apply more stiffening agent. Thus, in some cases, the total amount of stiffening agent may be 0.5 to 12 wt %, such as 5 to 10 wt %, calculated on a dry weight basis. Suitably, 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 aerosol-forming material will generally not contain any tobacco.

[0107] As an example, applying the hardener to the slurry includes spraying the hardener onto the slurry, such as onto the top surface of the slurry.

[0108] 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 together by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. Alginates with a high G monomer content have been found to gel more readily with the addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-glucuronic acid (G) units.

[0109] For example, drying (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (WWB) of the water in the slurry. For example, drying (d) 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 aerosol-generating material has a thickness of 0.2 mm.

[0110] In some examples, the slurry solvent consists essentially of or consists of water, hi some examples, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB).

[0111] In instances where the solvent comprises water, the dry weight content of the slurry may correspond to the dry weight content of the aerosol-forming material, such that any discussion herein of solid components is expressly disclosed in conjunction with the slurry aspects of the invention.

[0112] The aerosol-forming material may include a flavoring. The aerosol-forming material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavoring. In some cases, the aerosol-forming material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0113] The aerosol-forming material may include a bulking agent.

[0114] In some embodiments, the aerosol-forming material contains 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%.

[0115] In other embodiments, the aerosol forming material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. Optionally, the aerosol forming material contains less than 1 wt% of a filler, and optionally no filler.

[0116] In some cases, the aerosol-forming material 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 aerosol-forming material comprises between 5 and 25 wt% filler.

[0117] When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may also include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0118] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0119] Without being bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material, which may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the sheet defines a rod of aerosolizable material.

[0120] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0121] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0122] In some embodiments, the aerosol-forming material further comprises an active agent. For example, the aerosol-forming material optionally further comprises tobacco material and / or Nichicon. In some embodiments, the aerosol-forming material further comprises powdered tobacco, and / or nicotine, and / or tobacco extract.

[0123] In some cases, the aerosol-forming material may comprise between 5 and 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the aerosol-forming material may comprise between 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% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol-forming material may comprise between 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% (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the aerosol-forming material may include 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 aerosol-forming material may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0124] In some cases, the aerosol-forming material includes an active agent such as a tobacco extract. In some cases, the aerosol-forming material may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the aerosol-forming material may include 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 aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco extract. The tobacco extract may contain nicotine in a concentration such that the aerosol-forming material contains 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 may be present in the aerosol-forming material other than the nicotine from the tobacco extract.

[0125] In some embodiments, the aerosol-forming material does not include tobacco material and does include nicotine. In some cases, the aerosol-forming material 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 aerosol-forming material may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0126] 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).

[0127] The aerosol-generating composition may include one or more active agents. In some examples, the aerosol-generating material includes one or more active agents (e.g., up to about 20 wt% of the aerosol-generating material). For example, the aerosol-generating material includes active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0128] The active substances may include physiologically and / or olfactory active substances that are included in the aerosol forming composition to achieve a physiological and / or olfactory response.

[0129] 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%.

[0130] The tobacco material may be in any form, but is typically shredded (e.g., cut into small pieces). Shredded tobacco material is advantageous because it can be mixed with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of tobacco material and aerosol-forming material throughout.

[0131] By way of example, 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 determined that relatively large amounts of laminar tobacco can be used in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Laminar tobacco typically provides superior sensory properties. By way of example, the tobacco material comprises laminar 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 examples, 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.

[0132] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia, and / or Burley, and / or Oriental.

[0133] 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.

[0134] Optionally, the aerosol-forming material may additionally include an emulsifier to emulsify the molten flavoring during preparation. For example, the aerosol-forming material may include about 5 wt% to about 15 wt%, preferably about 10 wt% (calculated on a dry weight basis) of an emulsifier. The emulsifier may include gum acacia.

[0135] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0136] The aerosol-forming material may have any suitable water content, such as between 1 wt% and 15 wt%. Preferably, the water content of the aerosol-forming material is between about 5 wt%, 7 wt%, or 9 wt% and about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

[0137] In some cases, the aerosol-forming material may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally an active agent.

[0138] In some cases, the aerosol-forming materials may consist essentially of or consist of gelling agent, water, aerosol-forming agent, flavorings, and optionally tobacco materials and / or a nicotine source.

[0139] By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, an active substance, and water.By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, and water.

[0140] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents. In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 0.1 to 80 wt% of fragrance, Including, These weights are calculated on a dry weight basis.

[0141] In some embodiments, the amorphous solid comprises 1-80 wt % (dry weight basis) of a flavoring. In some embodiments, the aerosol-forming material comprises: 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% fragrance, Including, These weights are calculated on a dry weight basis. In an alternative embodiment, the aerosol-forming material is: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10 to 60 wt % of a gelling agent; Including, These weights are calculated on a dry weight basis. In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 20 to 60 wt % of an aerosol generating agent; 10-60 wt% tobacco extract; Including, These weights are calculated on a dry weight basis.

[0142] In some embodiments, the aerosol-generating material comprises 20-35 wt.% gelling agent, 10-25 wt.% aerosol-forming material, 5-25 wt.% fiber-containing filler, and 35-50 wt.% flavoring and / or active agent.

[0143] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, tobacco extract, water, and optional flavorings. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginate and / or pectin, tobacco extract, and water.

[0144] In some embodiments, the aerosol-generating material may have a composition (DWB) as follows: a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt%, a tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, and an 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).

[0145] In one embodiment, the aerosol forming material comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (DWB).

[0146] The "thickness" of an aerosol-generating material refers to the shortest distance between a first surface and a second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second surface of the sheet opposite the first planar surface of the sheet.

[0147] In some cases, the layer of aerosol-forming material for forming the aerosol 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 may be in the range of about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm.

[0148] In some cases, the aerosol-forming material may have a thickness of from about 0.015 mm to about 1.0 mm. Suitably, 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.

[0149] A material having a thickness of 0.2 mm is particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses given herein refer to the combined thicknesses of these layers.

[0150] It has been found that if the aerosol-generating material is too thick, it will heat less efficiently, which will have a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it will be difficult to manufacture and handle. If the material is too thin, it will be more difficult to mold and may even be fragile, compromising aerosol formation during use.

[0151] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0152] In some examples, the aerosol-generating material in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, such as when the aerosol-generating material does not include a filler, the aerosol-generating material may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m.

[0153] Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet, which is then chopped and incorporated into an aerosol product. In some instances, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of around 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 an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0154] In some examples, the aerosol-generating material in sheet form may have a tensile strength of around 200 N / m to around 2600 N / m. In some examples, the aerosol-generating material may have a tensile strength of around 600 N / m to around 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 is formed and incorporated into an aerosol-generating consumable as a sheet.

[0155] The aerosol-generating material is 30 g / m 2 ~120g / m 2 In some cases, the mass per unit area of ​​the sheet may be 80 to 120 g / m 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 (which has a density similar to that of cut rag tobacco so that mixtures of these materials do not easily separate). Optionally, the mass per unit area of ​​the sheet is about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be adapted to be used to wrap an aerosolizable material such as tobacco.

[0156] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis represent the totality of the extract, or slurry, or material, excluding water, and may include ingredients that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis represent all ingredients, including water.

[0157] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched to other components of the aerosol-generating material or other components of an article that includes the aerosol-generating material.

[0158] A variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are 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 may be caramel, giving the aerosol-generating material a brown appearance. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components of the aerosol-generating material, such as the tobacco material. In some embodiments, the colorant is added to the aerosol-generating material such that it is visually indistinguishable from other ingredients in the aerosol-generating material.

[0159] The colorant may be incorporated into the aerosol-forming material during formation (e.g., during formation of a slurry containing the materials that make up the aerosol-forming material) or may be applied after formation of the aerosol-forming material (e.g., by spraying onto the aerosol-forming material).

[0160] 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 discrete portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0161] 1, the aerosol delivery device 2 includes a casing 4 within which a heating assembly 6 is disposed. The heating assembly 6 is comprised of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator used in conjunction with a susceptor.

[0162] The heating chamber 8 defines a mouth 12 at a first end of the heating chamber 8. At an opposite end of the heating chamber 8 is an opening 14. The opening 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

[0163] A detector 20 is attached to the wall defining the heating chamber 8 adjacent the mouth 12 of the heating chamber 8. The detector 20 is in data communication with a controller 22 via suitable data transmission means, represented in Figure 1 by wires 26, but which may take the alternative form, such as, but not limited to, known data interfaces.

[0164] The controller 22 is in data communication with a memory 24. The memory 24 includes a table that associates a detectable characteristic of a discrete portion 42 of aerosol forming material supported on the consumable item 40 with one or more physical properties of that portion that are indicated by the detectable characteristic of that discrete portion of aerosol forming material.

[0165] The controller 22 is powered by a power source 28 via wires 32. The power source 28 may be a battery. The power source 28 may also be rechargeable.

[0166] The controller 22 is also in electronic communication with the heater 10 via communication lines 30. The communication lines 30 may be wires for transmitting electricity to and from the heater 10 for sending and receiving data and / or command signals.

[0167] In another example not shown, the heating assembly is configured to heat two or more discrete portions of aerosol generating material supported at different locations on the consumable, and the detector is configured to detect a detectable characteristic of the discrete portions of aerosol generating material on the consumable.

[0168] 2, the consumable 40 supports a number of discrete portions 44, 46 of the aerosol-forming material 42. The discrete portions 44, 46 are supported on a support 48. The support 48 is a laminate material comprised of a support layer 50 and a susceptor 52.

[0169] The support layer 50 is a cardboard sheet having a first surface (not visible) and a second surface 60. An edge 58 extends between the first surface and the second surface 60 of the support layer 50.

[0170] In other examples not shown, the support layer 50 comprises one or more sheets or substrates of paper, paperboard, cardboard, recycled materials, plastic materials, ceramic materials, composites, glass, metals, or alloys.

[0171] In other examples not shown, the consumable may be circular in shape or any other shape other than rectangular as shown in FIG.

[0172] The susceptor 52 is an aluminum foil sheet having a first surface 54 and a second surface (not visible). An edge 56 extends between the first surface 54 and the second surface.

[0173] The second surface of the susceptor is attached to the first surface of the support layer 50. The first surface 54 of the susceptor 52 and the second surface 60 of the support layer 50 are the first and second surfaces, respectively, of the support 48. Reference herein to the first surface 54 is a reference to the first surface 54 of the susceptor 52, the first surface of the support 48, or both, as the context of such reference requires. Reference herein to the second surface 60 is a reference to the second surface 60 of the support layer 50, the second surface of the support 48, or both, as the context of such reference requires.

[0174] The discrete portions 44, 46 are supported by the first surface 54 and are arranged thereon in a square grid pattern. The discrete portions 44 are square in shape in the plane of the first surface 54, are formed of an aerosol-generating material of a first composition, and include a first volume of the aerosol-generating material. The discrete portions 46 are circular in shape in the plane of the first surface 54, are formed of an aerosol-generating material of a second composition, and include a second volume of the aerosol-generating material. The first and second compositions are different, as are the first and second volumes. In the exemplary consumable shown in FIG. 2, the discrete portions 44 are each blue and the discrete portions 46 are each yellow. As a result, the colors of the discrete portions 44, 46 are highly contrasting colors, which are easily distinguishable by a human or machine viewer of the consumable 40.

[0175] Similarly, discrete portions 44 , 46 are square and circular, respectively, which are also easily discernible by a human or machine viewer of consumable 40 .

[0176] In other examples not shown, each or many of the discrete portions of aerosol-generating material may have, in the plane of the surface on which they are supported, an alternative shape to the above examples, including, but not limited to, a polygon, a star, longitudinally extending stripes, stripes including at least one curve or angle, or a tessellated shape.

[0177] In the example shown, each of the discrete portions of aerosol-forming material 44, 46 is in the form of an aerosol-forming film. In another example, not shown, each of the discrete portions of aerosol-forming material is in the form of an aerosol-forming gel.

[0178] In use, when a user wishes to use the aerosol delivery device 2, the user inserts the consumable 40 into the heating chamber 8 via the mouth 12 of the heating chamber 8. The consumable 40 is inserted such that the discrete portions 44, 46 are between the detector 20 and the support portion 48 when the consumable 40 passes through the mouth 12. The detector 20 uses known techniques to detect the shape and color of the discrete portions 44, 46 as they pass the detector 20, as well as their position relative to the edge of the consumable that was originally inserted into the mouth 12.

[0179] The detector transmits data regarding the detected shape, color, and relative position of the discrete portions via wires 26 to the controller 22. The controller 22 then searches a table stored in memory 24 and compares the shape and color to the table entries. This comparison determines how the controller 22 will function or operate the heater 10 for each discrete portion 44, 46 when a user smokes with the aerosol delivery device 2 and the particular discrete portion is heated.

[0180] In the example of an aerosol delivery device 2 shown in FIG. 1, the device 2 is configured such that a user's interaction with the device 2 (through the use of components not shown) can determine which discrete portions 44, 46 will be heated during the next puff or puffs.

[0181] The various embodiments described herein are presented only as aids in understanding and teaching the features of the claims. These embodiments are provided as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, features, structures, and / or other aspects described herein should not be considered as 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 can be utilized and improved without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. The present disclosure may also include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A consumable for use with an aerosol delivery device, the consumable comprising: a support portion; and an aerosol-forming material having one or more discrete portions of aerosol-forming material, the discrete portion is supported by the support portion; At least one discrete portion has a detectable characteristic; A consumable product, wherein the detectable characteristic is indicative of at least one product characteristic of the discrete portion.

2. There are two or more discrete portions, and at least two of the discrete portions each have a detectable characteristic; The consumable product of claim 1 , wherein the detectable characteristic of each discrete portion is indicative of at least one product characteristic of that discrete portion.

3. The consumable of claim 2 , wherein at least one of the discrete portions has a detectable characteristic that is different from the detectable characteristic of at least one other discrete portion.

4. The consumable product of claim 1 , wherein the detectable characteristic of the discrete portions is indicative of at least one product characteristic of two or more discrete portions.

5. The consumable product of claim 1 , wherein at least one discrete portion has at least two detectable characteristics, each detectable characteristic indicative of at least one product characteristic of the discrete portion.

6. The consumable product of claim 1 , wherein product characteristics include one or both of a composition of the aerosol-forming material in the discrete portions and a volume of the aerosol-forming material in the discrete portions.

7. The consumable product of claim 6 , wherein the composition of the aerosol-forming material in the discrete portions includes one or more of an active agent, a fragrance or flavoring agent, and a sensate.

8. 10. The consumable of claim 1, wherein the detectable characteristic comprises one of shape, size, position relative to a reference, position relative to at least one other discrete portion, color in the 390-700 nm wavelength range of the electromagnetic spectrum, absorption spectrum, optical density, translucency, presence of one or more biomarkers, presence of one or more chemical markers, magnetic properties, pH, or mass.

9. 10. The consumable of claim 1, wherein at least one discrete portion has a detectable characteristic that includes a shape that is one of a substantially circular, polygonal, star-shaped, longitudinally extending stripes, stripes including at least one curve or angle, or a tessellated shape when viewed perpendicular to a surface on which the discrete portion is supported.

10. 2. The consumable of claim 1, wherein at least one discrete portion has a detectable characteristic comprising a first shape that is substantially circular, polygonal, star-shaped, longitudinally extending stripes, stripes containing at least one curve or angle, or a tessellated shape when viewed perpendicular to a surface on which the discrete portion is supported, and at least one other discrete portion has a detectable characteristic comprising a second shape that is different from the first shape and comprises a substantially circular, polygonal, star-shaped, longitudinally extending stripes, stripes containing at least one curve or angle, or a tessellated shape when viewed perpendicular to a surface on which the discrete portion is supported.

11. The consumable product of claim 1 , wherein the detectable characteristic is selected to be visually discernible by a user.

12. 10. The consumable of claim 1, wherein the detectable characteristic is selected to be discernible by an automated detector, optionally without physical contact between the detector and the discrete portion.

13. The consumable product of claim 1 , wherein the aerosol-forming material is in the form of an aerosol-forming film or an aerosol-forming gel.

14. 10. The consumable product of claim 1, wherein the support has at least two surfaces, and the discrete portions of the aerosol-forming material are all supported on one surface of the support.

15. The consumable of claim 1 , wherein at least three of the discrete portions are supported on a surface of the support portion in a grid pattern.

16. The consumable of claim 1 , wherein the support comprises a susceptor.

17. The consumable of claim 16 , wherein the susceptor is a sheet material.

18. 18. The consumable of claim 16 or 17, wherein the support is a laminate and the susceptor is a layer of the laminate.

19. 18. The consumable of claim 16 or 17, wherein the susceptor is a metal foil or film.

20. 10. An aerosol delivery device for use with the consumable product of claim 1, comprising: an aerosol generator configured to heat at least one discrete portion of the aerosol-forming material supported by the consumable; a detector configured to detect a detectable characteristic of at least one discrete portion on the consumable; a memory including a table relating detectable characteristics of the discrete portions to product characteristics of the discrete portions; a controller configured to receive the detected detectable characteristic of the discrete portions, search the table in the memory, and control operation of the aerosol delivery device based on at least one product characteristic of the discrete portions; An aerosol delivery device comprising:

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