Aerosol generation

Abstract

To provide an aerosol generating article that allows the composition of the aerosol or vapor to be altered / enhanced.SOLUTION: Provided is an aerosol generating article 101 for use in an aerosol generating assembly, the aerosol generating article comprising a rod 103 of aerosolizable material circumscribed by a wrapper, where the wrapper comprises an aerosol-forming amorphous solid.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to the generation of aerosols.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use and generate smoke. Some alternatives to these types of smoking articles release inhalable aerosols or vapors by heating a substrate without burning it to release compounds from the substrate. These may be referred to as non-combustible smoking articles or aerosol generating assemblies.

[0003] As an example of such a product, there is a heating device that releases compounds by heating a solid aerosolizable material without burning it. This solid aerosolizable material may optionally include tobacco material. Heating typically volatilizes at least one component of the material that forms an inhalable aerosol. These products are sometimes referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. Various different configurations for volatilizing at least one component of the solid aerosolizable material are known.

[0004] Another example is an electronic cigarette / tobacco heating product hybrid device, also known as an electronic cigarette hybrid device. These hybrid devices contain a feed liquid (with or without nicotine) that is vaporized by being heated to produce an inhalable vapor or aerosol. The device additionally contains a solid aerosolizable material (which may or may not include tobacco material), and the components of this material are entrained in the inhalable vapor or aerosol to produce an inhalable medium.

[0005] Some conventional aerosol generation involves two or more heaters, each configured to heat different parts of the smoking material during use. This allows those different parts of the smoking material to be heated at different times, thereby enabling the formation of an aerosol for an extended period during use.

SUMMARY OF THE INVENTION

[0006] In a first aspect of the present invention, there is provided an aerosol generating article for use in an aerosol generating assembly, the aerosol generating article comprising a rod made of an aerosolizable material surrounded by a wrapper, the wrapper comprising an amorphous solid that forms an aerosol.

[0007] In some embodiments, the wrapper comprises a carrier and the amorphous solid that forms an aerosol is disposed on the carrier.

[0008] A second aspect of the present invention provides an aerosol generating assembly comprising an aerosol generating article according to the first aspect of the present invention and a heater configured to heat but not burn the aerosolizable material and / or the amorphous solid that forms an aerosol.

[0009] Another aspect of the present invention provides a method of manufacturing an aerosol generating article comprising: (a) forming a slurry comprising components of an amorphous solid or a precursor thereof; (b) applying the slurry to a carrier; (c) curing the slurry to form a gel; (d) drying to form an amorphous solid; and (e) disposing a wrapper around the aerosolizable material.

[0010] A further aspect of the invention described herein provides for the use of an aerosol generating article or an aerosol generating assembly in the generation of an inhalable medium.

[0011] Further features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings which are for illustrative purposes only.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]

Figure 1

Figure 2

Figure 2a

Figure 3

Figure 3a

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Mode for Carrying Out the Invention

[0013] The "amorphous solid" that forms the aerosol may also be referred to as "monolithic solid" (i.e., non-fibrous) or "dry gel" separately. The amorphous solid is a solid material that holds a fluid such as a liquid inside it. The amorphous solid may form part of an aerosol-forming material containing an amount of amorphous solid of 50 wt%, 60 wt% or 70 wt% to about 90 wt%, 95 wt% or 100 wt%. In some cases, the aerosol-forming material consists of an amorphous solid.

[0014] In a first aspect of the present invention, there is provided an aerosol generating product for use in an aerosol generating assembly, the aerosol generating product comprising a rod made of an aerosolizable material surrounded by a wrapper, the wrapper comprising an amorphous solid that forms an aerosol. In some embodiments, the wrapper comprises a carrier and the amorphous solid that forms the aerosol is disposed on the carrier.

[0015] The aerosolizable material is heated during use to generate an inhalable aerosol or vapor. The present invention provides an amorphous solid as a component of a wrapper, which may contain volatile components such as nicotine and nicotine derivatives, flavorants, and aerosol generators. These volatile substances in the amorphous solid are volatilized and inhaled during use, and by providing the amorphous solid, the composition of the aerosol or vapor can be changed and / or enhanced.

[0016] In some cases, the aerosol generating article of the first aspect of the present invention includes two sections, and the amount of volatile substances of the amorphous solid in the wrapper portion surrounding the first section is greater than the amount of volatile substances of the amorphous solid in the wrapper portion surrounding the second section.

[0017] During use, the two sections may be heated at different times / speeds. By using two or more sections containing volatile substances derived from different amounts of the amorphous solid, the composition of the inhaled aerosol can be selectively adjusted.

[0018] Such non-uniform distribution of volatile substances derived from the amorphous solid can be carried out in several ways. For example, the amorphous solid composition may differ in the first and second sections.

[0019] When the wrapper includes a carrier or the like, the amount of the amorphous solid per unit area of the carrier in the wrapper portion surrounding the first section is greater than the amount of the amorphous solid per unit area of the carrier in the wrapper portion surrounding the second section. In such a case, the amorphous solid composition may be substantially homogeneous in each section. In particular, in certain cases, the amorphous solid may be substantially triangular in shape and disposed on the carrier. Such an embodiment is illustrated in FIG. 1. The wrapper illustrated in FIG. 1 has a triangular amorphous solid 2 on a carrier layer 4 (the wavy line is provided to indicate that its schematic view is an exploded view. The two layers are adhered). It can be seen that the section of the wrapper adjacent to the first end 8 has a greater amount of the amorphous solid per unit area of the carrier than the section of the wrapper adjacent to the second end 6.

[0020] The inventor has confirmed that in a conventional aerosol generating assembly in which a uniform aerosol generating article is used, the delivery amount of the components of the aerosol decreases as it is used. When only one heater is used in such a conventional device, most of the volatile components of the aerosolizable material are consumed immediately, and the delivery amount of that component generally decreases with each puff.

[0021] In some conventional devices, two or more heaters are used, and these heaters are arranged to heat different portions of the aerosolizable material without first heating a certain portion of the aerosolizable material, thereby leaving the volatile substances in that portion for consumption in the latter half of the product service life. However, the inventor believes that in such a device, heat transfers between different heating regions, causing a decrease in the volatile substances in the regions where direct heating has not yet started. This increases the amount of such volatile substances that are delivered prematurely during the consumption period and decreases the amount of volatile substances for the latter half of the consumption. Therefore, generally, the delivery amount of such volatile components decreases with each puff.

[0022] The inventor has confirmed that an aerosol generating article comprising two sections, wherein the amount of volatile substances derived from the amorphous solid of the wrapper portion surrounding the first section is greater than the amount of volatile substances derived from the amorphous solid of the wrapper portion surrounding the second section, can improve the puff profile and can be used specifically to sustain the release of aerosolizable components during use.

[0023] During use, the first section of the aerosol generating article may be heated after the second section. Optionally, the amount of aerosol delivered per puff may be made constant, and the amount of volatile substances delivered during heating of the second section increases due to heat transfer within the assembly resulting in part from the consumption of volatile substances from the first section. Before heating, the total amount of volatile substances in the first section is greater than that in the second section as a result of the amorphous solid structure. Thus, the partial loss of volatile substances due to heat transfer from the first section is substantially equal to the amount of volatile substances delivered during heating of the two corresponding sections.

[0024] In another case, the increased amount of volatile substances (due to the result of the amorphous solid structure) in the first section can be used to provide an aerosol with a gradually increasing amount of volatile substances delivered per puff. In such cases and where the aerosolizable material includes tobacco, the nicotine and / or tobacco flavor sensation may be made stronger towards the end of the smoking period. This mimics the smoking sensation of combustible smoking articles (such as cigarettes, cigars, etc.) and may improve the acceptability by smokers of the aerosol generating assembly as an alternative to such combustible smoking articles.

[0025] In some cases, the aerosol generating article includes two sections. In another case, there may be three, four, five or more sections. The amount of volatile substances derived from the amorphous solid of the wrapper portion surrounding each section may be the same or different, provided that the amount thereof for the wrapper portion surrounding the first section is greater than the amount of volatile substances derived from the amorphous solid of the wrapper portion surrounding the second section.

[0026] In some cases, the sections may be arranged axially along the length of the aerosol-generating article. For example, these sections may be in the form of coaxial cylinders arranged along the length of the aerosol-generating article. In another case, these sections may be, for example, prismatic sections that also form cylinders together. For example, if there are two sections, they may be semi-cylinders, and their corresponding flat surfaces may be arranged in contact.

[0027] In some cases, the first section of the aerosol-generating article may be closer to the mouth end of the generating article than the second section. In some cases, the second section of the aerosol-generating article may be closer to the mouth end of the generating article than the first section.

[0028] The aerosolizable material in the aerosol-generating article of the first aspect typically includes tobacco material.

[0029] In some cases, the amorphous solid material forming the aerosol may include embedded heating means such as resistive or inductive heating elements.

[0030] The carrier may be any suitable material that can be used to support the amorphous solid and wrap a rod made of the aerosolizable material. In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, oil-resistant paper, ceramic, carbon allotropes such as graphite and graphene, plastic, or combinations thereof. In some cases, the carrier may include a tobacco material such as a sheet of recycled tobacco, or may consist of a tobacco material such as a sheet of recycled tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, or combinations thereof. In some cases, the carrier itself may be a laminated structure including a layer made of a material selected from the above examples. In some cases, the carrier may function as a flavor carrier. For example, the carrier may be impregnated with a flavorant or a tobacco extract.

[0031] In some cases, the carrier of the aerosol-generating article may include, or may consist of, a porous layer in contact with the amorphous solid. For example, the porous layer may be a layer of paper. In some specific cases, the amorphous solid is arranged to be in direct contact with the porous layer, and the porous (e.g., paper) layer contacts the amorphous solid to form a strong adhesion. The amorphous solid is formed by drying a gel. Without being limited by any theory, it is considered that when the slurry from which the gel is formed is impregnated into the porous layer (e.g., paper) and the gel cures to form a crosslink, the porous layer is partially bonded into the gel. This provides a strong adhesion between the gel and the porous layer (between the dried gel and the porous layer). The porous layer (e.g., paper) may also be used to carry the flavorant. In some cases, preferably, the porous layer may include paper having a porosity of 0 to 300 Gurley units (CU), preferably 5 to 100 CU or 25 to 75 CU.

[0032] In addition, the surface roughness contributes to the strength of the adhesion between the amorphous solid and the carrier. The inventor has found that the roughness of the paper (the surface in contact with the carrier) is preferably 50 to 1000 Bekk seconds, preferably within the range of 50 to 150 Bekk seconds, and more preferably 100 Bekk seconds (measured at an air pressure interval of 50.66 to 48.00 kPa). (The Bekk smoothness tester is a device used to measure the smoothness of the surface of paper through which air leaks between a smooth glass surface and a paper sample at a specific pressure. The time (seconds) for a predetermined amount of air to seep through between these surfaces is the "Bekk smoothness".)

[0033] Conversely, the surface of the carrier opposite to the amorphous solid is arranged in contact with the heater, and a smooth surface transfers heat more efficiently. Therefore, in some cases, the carrier is arranged such that the rougher side contacts the amorphous solid and the smoother surface faces away from the amorphous material.

[0034] In particular, in certain cases, the carrier may be a foil supported by paper, and the layer of paper is the amorphous solid It abuts against the tomography, and the characteristics described in the above paragraph are made possible by this abutment. The lining of the foil is substantially impermeable and controls the flow path of the aerosol. The lining of the metal foil also serves to transfer heat to the gel.

[0035] In another case, the foil layer of the foil supported by paper abuts against the amorphous solid. The foil is impermeable and prevents the water provided in the amorphous solid from being absorbed by the paper, which may weaken the structural integrity of the paper.

[0036] In some cases, the carrier is formed from or includes a metal foil such as aluminum foil. The metal carrier can transfer thermal energy better to the amorphous solid. Additionally or alternatively, the metal foil may function as a susceptor for an induction heating system. In certain embodiments, the carrier includes a metal foil layer and a support layer such as cardboard. In these embodiments, the metal foil layer has a thickness of less than 20 μm, for example, about 1 μm to about 10 μm, preferably about 5 μm.

[0037] In some cases, the carrier may be omitted and the wrapper does not include a carrier. In some cases, the wrapper consists only of the amorphous solid forming the aerosol. This is the case when the amorphous solid forming the aerosol has sufficient strength (such as sufficient tensile strength) to be self-supporting.

[0038] In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventor has discovered that a material with a thickness of 0.2 mm is particularly suitable for this. The amorphous solid may include two or more layers, and the thickness described herein means the total thickness of these layers.

[0039] The inventor has confirmed that if the aerosol-forming amorphous solid is too thick, the heating efficiency will be impaired, which has an adverse effect on the power consumption during use. Conversely, if the aerosol-forming amorphous solid is too thin, handling including the formation of aerosol during production and use becomes difficult, and very thin materials are difficult to cast and are prone to breakage.

[0040] The inventor has confirmed that the thickness of the amorphous solid defined in this specification optimizes the material properties in view of these conflicting matters.

[0041] The thickness defined in this specification is the average thickness of the material. In some cases, the thickness of the amorphous solid may vary within 25%, 20%, 15%, 10%, 5% or 1%.

[0042] The aerosol generating material containing the amorphous solid may have any suitable surface density such as 30 g / m 2 ~120 g / m 2 In some embodiments, the aerosol generating material may have a surface density of about 30 to 70 g / m 2 or about 40 to 60 g / m 2 In some embodiments, the amorphous solid may have a surface density of about 80 to 120 g / m 2 or about 70 to 110 g / m 2 or particularly about 90 to 110 g / m 2 of the surface density.

[0043] In some examples, the sheet-like amorphous solid may have a tensile strength of about 200 N / m to about 900 N / m. In some examples where the amorphous solid does not contain a filler, the amorphous solid 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. In some examples where the amorphous solid contains a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m or 700 N / m to 900 N / m or about 800 N / m.

[0044] The aerosol generating article of the first aspect of the present invention may include an additional cooling element and / or a filter. When a cooling element is included, it acts or functions to cool the gas or aerosol component. In some cases, the cooling element acts to cool the gas component so that the gas component condenses to form an aerosol. The cooling element also acts to keep the extremely hot parts of the device away from the user. When a filter is included, it may include any suitable filter known in the art, such as a cellulose acetate plug.

[0045] In some cases, the cooling element and / or the filter (if included) may be wrapped by a layer that at least partially extends over the rod of the aerosolizable material. This layer may include a carrier and an amorphous solid and may be a wrapper surrounding the aerosolizable material.

[0046] The aerosol generating article may further include ventilation openings. These ventilation openings may be provided in the side wall of the generating article. In some cases, the ventilation openings may be provided in the filter and / or the cooling element. These openings can allow cooling air to be drawn into the generating article during use, which can mix with the heated and volatilized components and thereby cool the aerosol.

[0047] Ventilation increases the generation of visible heated and volatilized components from the generating article when the generating article is heated during use. The heated and volatilized components are visualized by the cooling process of the heated and volatilized components such that supersaturation of the heated and volatilized components occurs. The heated and volatilized components are then formed into droplets, which is also known as nucleation, and ultimately the size of the aerosol particles of the heated and volatilized components increases by further condensation of the heated and volatilized components and solidification of the newly formed droplets from the heated and volatilized components.

[0048] In some cases, the ratio of the cooling air to the total of the heated and volatilized components, which is known as the ventilation rate, is at least 15%. The heated and volatilized components at a ventilation rate of 15% can be made visible by the above-described method. By making the heated and volatilized components visible, the user can confirm that the heated and volatilized components are emitted and added to the sensory experience of the smoking experience.

[0049] In another example, the ventilation rate is 50% - 85% to further cool the heated and volatilized components. In some cases, the ventilation rate may be at least 60% or 65%.

[0050] A second aspect of the present invention provides an aerosol generating assembly including an aerosol generating article according to the first aspect of the present invention and a heater configured to heat an aerosolizable material and / or an aerosol-forming amorphous solid without burning it.

[0051] The heater is configured to heat the aerosolizable material without burning it. In some cases, the heater may heat the aerosolizable material to 120°C - 350°C without burning it during use. In some cases, the heater may heat the aerosolizable material to 140°C - 250°C without burning it during use. In some cases, during use, substantially all of the amorphous solid is located less than about 4 mm, less than 3 mm, less than 2 mm, or less than 1 mm away from the heater. In some cases, the solid is disposed about 0.010 mm - 2.0 mm, preferably about 0.1 mm - 1.0 mm away from the heater. In some cases, the surface of the amorphous solid may be in direct contact with the heater.

[0052] In some cases, the assembly includes an aerosol-generating article having two sections, and the amount of volatile substances derived from the amorphous solid in the wrapper portion surrounding the first section is greater than the amount of volatile substances derived from the amorphous solid in the wrapper portion surrounding the second section, and the apparatus is configured to provide different heat profiles to each of the different sections. In some cases, the assembly is configured such that heating of the first section of the aerosol-generating article starts after heating of the second section.

[0053] The aerosol-generating assembly according to the second aspect may include at least two heaters, and the heaters are arranged to heat different sections of the aerosol-generating article respectively. In some cases, the aerosol-generating article may include three or more sections, and the assembly may include additional heaters arranged to directly heat one or more sections of the aerosol-generating article respectively. In some cases, the number of heaters is equal to the number of sections of the aerosol-generating article, and the heaters are arranged such that each heater heats one section.

[0054] In some cases, the assembly may be configured such that at least a portion of the aerosolizable material is exposed to a temperature of at least 180 °C or 200 °C for at least 5% of the heating time. In some examples, the aerosolizable material may be exposed to different heat profiles as described in PCT / EP2017 / 068804, a co-pending application the disclosure of which is incorporated herein by reference in its entirety.

[0055] In some specific cases, an assembly is provided that is configured to heat at least two sections of the aerosolizable material separately. By controlling the temperatures of the first and second sections over time such that the temperature profiles of those sections are different, it becomes possible to control the puff profile of the aerosol during use. The heat applied to the two portions of the aerosolizable material may be applied at different times or rates, and by shifting the heating in this way, it becomes possible to generate the aerosol earlier and extend the service life.

[0056] In one particular example, the assembly may be configured such that a first heating element corresponding to a first section of aerosolizable material is immediately heated to a temperature of 240° C. at the start of the consumption experience. This first heating element is maintained at 240° C. for 145 seconds and then lowered to 135° C. (this temperature is maintained for the remainder of the consumption experience). A second heating element corresponding to a second section of the aerosol-generating article is heated to a temperature of 160° C. 75 seconds after the start of the consumption experience. The temperature of the second heating element is raised to 240° C. 135 seconds after the start of the consumption experience (this temperature is maintained for the remainder of the consumption experience). The consumption experience lasts for 280 seconds, at which point both heaters cool to room temperature.

[0057] In some cases, the aerosol-generating assembly according to the second aspect may be a non-combustion heating device also known as a tobacco heating product or a tobacco heating device.

[0058] The heater provided to the assembly according to the second aspect may, in some cases, be a thin-film electrical resistance heater. In another case, the heater may include, for example, an induction heater. The heater may be a combustible heat source or a chemical heating source that undergoes an exothermic reaction to produce heat during use. If there are two or more heaters, each heater may be the same or different.

[0059] Generally, the or each heater is powered by a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and the like. The battery is electrically connected to the heater and supplies power as needed to heat the smoking material (to volatilize the components of the aerosolizable material without burning the aerosolizable material).

[0060] In one example, the heater is in the shape of a substantially hollow cylindrical tube having a hollow internal heating chamber, into which an aerosol-generating article is inserted for heating during use. Different configurations of the heater are possible. For example, the heater may be formed as a single heater or may be formed of a plurality of heaters aligned along the longitudinal axis of the heater. (For the sake of brevity, when the term "heater" is used in this specification, it shall include a plurality of heaters unless the context indicates otherwise.) The heater may be annular or tubular. The heater is sized such that when a substantially aerosolizable material is inserted, it is located within one or more heating elements of the heater and the entire aerosolizable material is heated during use. The heater may be configured such that selected regions of the aerosolizable material are heated independently, for example in sequence (continuously) or together (simultaneously), as required.

[0061] The heater may be surrounded by insulation along at least a portion of its length, which helps to reduce the heat passing from the heater to the outside of the aerosol-generating assembly. This generally reduces heat loss and thus helps to reduce the power required for the heater. The insulation helps to keep the outside of the aerosol-generating assembly cool during operation of the heater.

[0062] Referring to FIGS. 2 and 3, there are shown an internal view and a perspective view, partially cut away, of an example of an aerosol-generating article 101. The article 101 is adapted for use in an apparatus having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the apparatus 51 shown in FIGS. 6 - 8 described below. In use, the article 101 is removably inserted into the apparatus shown in FIG. � at the insertion point 20 of the apparatus.

[0063] The generated product 101 of one example is in the form of a substantially cylindrical rod including a body 103 made of an aerosolizable material and a rod-shaped filter assembly 105. As shown in FIGS. 2a and 3a, the aerosolizable material 103 is surrounded by a wrapper illustrated in FIG. 1 including a carrier 4 and an amorphous solid 2 disposed on the carrier 4. In the illustrated structure, the amorphous solid is visible outside the wrapper. In other structures (not shown), the amorphous solid is disposed on the inner surface of the wrapper. The wrapper may surround the aerosolizable material and at least a part of the filter assembly as shown.

[0064] The filter assembly 105 includes three segments such as a cooling segment 107, a filter segment 109, and a suction port end segment 111. The generated product 101 has a first end 113 also known as a suction port end or proximal end and a second end 115 also known as a distal end. The body 103 made of an aerosolizable material is located toward the distal end 115 of the generated product 101. In one example, the cooling segment 107 is located adjacent to the body 103 made of an aerosolizable material between the body 103 made of an aerosolizable material and the filter segment 109 such that the cooling segment 107 is in contact with the body 103 made of an aerosolizable material and the filter segment 109. In other examples, there may be a gap between the body 103 made of an aerosolizable material and the cooling segment 107 and between the body 103 made of an aerosolizable material and the filter segment 109. The filter segment 109 is located between the cooling segment 107 and the suction port end segment 111. The suction port end segment 111 is located adjacent to the filter segment 109 toward the proximal end 113 of the generated product 101. In one example, the filter segment 109 is in contact with the suction port end segment 111. In one embodiment, the total length of the filter assembly 105 is 37 mm to 45 mm, more preferably the total length of the filter assembly 105 is 41 mm.

[0065] In one example, the rod 103 made of aerosolizable material has a length of 34 mm to 50 mm, preferably 38 mm to 46 mm, and preferably 42 mm.

[0066] In one example, the overall length of the generated article 101 is 71 mm to 95 mm, preferably 79 mm to 87 mm, and preferably 83 mm.

[0067] The axial end of the body 103 made of aerosolizable material is visible at the distal end 115 of the generated article 101. However, in other embodiments, the distal end 115 of the generated article 101 may include an end member (not shown) that covers the axial end of the body 103 made of aerosolizable material. In some cases, the end member may be part of the wrapper described herein.

[0068] The body 103 made of aerosolizable material is joined to the filter assembly 105 by an annular tipping paper (not shown), which is substantially located around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the body 103 made of aerosolizable material. In one example, the tipping paper is made of a standard tipping base paper of 58 GSM. In one example, the length of the tipping paper is 42 mm to 50 mm, preferably 46 mm.

[0069] In one example, the cooling segment 107 is an annular tube that is located around and defines a void within the cooling segment. The void provides a chamber through which the heated and volatilized components generated from the body 103 made of aerosolizable material flow. The cooling segment 107 is hollow to provide a chamber for the aerosol deposit that is rigid enough to withstand the axial compressive forces and bending moments that occur during manufacture and while the generated article 101 is inserted into the device 51 during use. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0070] The cooling segment 107 provides physical movement between the aerosolizable material 103 and the filter segment 109. The physical movement provided by the cooling segment 107 provides a temperature gradient along the length of the cooling segment 107. In one example, the cooling segment 107 is configured such that the temperature difference between the heated and volatilized component entering the first end of the cooling segment 107 and the heated and volatilized component exiting the second end of the cooling segment 107 is at least 40°C. In one example, the cooling segment 107 is configured such that the temperature difference between the heated and volatilized component entering the first end of the cooling segment 107 and the heated and volatilized component exiting the second end of the cooling segment 107 is at least 60°C. This temperature difference across the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosolizable material 103 when the aerosolizable material 103 is heated by the device 51. If there is no physical movement between the filter segment 109, the body 103 made of the aerosolizable material, and the heating element of the device 51, the temperature-sensitive filter segment 109 will be damaged during use and will not be able to efficiently perform its required function.

[0071] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is 20 mm to 30 mm, particularly 23 mm to 27 mm, particularly 25 mm to 27 mm, and preferably 25 mm.

[0072] The cooling segment 107 is made of paper, which means it is composed of a material that does not generate problematic compounds such as, for example, toxic compounds when used adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spirally wound paper tube can meet the strict dimensional accuracy requirements regarding the length, outer diameter, roundness, and straightness of the tube for a manufacturing process performed at high speed.

[0073] In another example, the cooling segment 107 is a recess resulting from a rigid plug wrapper or tipping paper. The rigid plug wrapper or tipping paper is manufactured to have a rigidity sufficient to withstand the axial compressive forces and bending moments that occur during manufacture and while the product 101 is inserted into the device 51 during use.

[0074] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated and volatilized components of the aerosolizable material. In one example, the filter segment 109 is made of a monoacetate material such as cellulose acetate. The filter segment 109 reduces the cold stimulus from the heated and volatilized components without dropping the quality of the heated and volatilized components to a level that the user is dissatisfied with.

[0075] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be disposed substantially centrally within the filter segment 109 across the diameter of the filter segment 109 and along the length of the filter segment 109. In another case, the capsule may be offset in one or more dimensions. The capsule may optionally contain a volatile component such as a flavorant or aerosol generating agent when included.

[0076] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the entire filter segment 109, which in turn controls the draw resistance of the product 101. Thus, the selection of the material for the filter segment 109 is important in controlling the draw resistance of the product 101. Additionally, the filter segment performs a filtering function in the product 101.

[0077] In one example, the filter segment 109 is made of an 8Y15 grade filter material, which provides a filtering effect for the heated and volatilized components and reduces the size of the condensed aerosol droplets resulting from the heated and volatilized components.

[0078] The filter segment 109 provides an insulating effect by further cooling the heated and volatilized components that have exited the cooling segment 107. This further cooling effect lowers the temperature when the user's lips touch the surface of the filter segment 109.

[0079] In one example, the length of the filter segment 109 is from 6 mm to 10 mm, preferably 8 mm.

[0080] The mouthpiece end segment 111 is an annular tube that surrounds and defines a void within the mouthpiece end segment 111. The void provides a chamber for the heated and volatilized components flowing from the filter segment. The mouthpiece end segment 111 is hollow to provide a chamber for aerosol deposits that is rigid enough to withstand the axial compressive forces and bending moments that occur during manufacture and when the product is inserted into the device 51 during use. In one example, the wall thickness of the mouthpiece end segment 111 is about 0.29 mm. In one example, the length of the mouthpiece end segment 111 is from 6 mm to 10 mm, preferably 8 mm.

[0081] The mouthpiece end segment 111 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while maintaining critical mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements regarding the tube length, outer diameter, roundness, and straightness of the manufacturing process that is carried out at high speed.

[0082] The mouthpiece end segment 111 provides the function of preventing any liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0083] Of course, in one example, the mouthpiece end segment 111 and the cooling segment 107 may be formed of a single tube, and the filter segment 109 is located within the tube that separates the mouthpiece end segment 111 and the cooling segment 107.

[0084] Referring to FIGS. 4 and 5, a cross-sectional view and a perspective view of a part of the generated product 301 of an example with a cutout are shown. The reference numerals shown in FIGS. 4 and 5 are equivalent to those shown in FIGS. 2 and 3, but 200 is added.

[0085] In the example of the generated product 301 shown in FIGS. 4 and 5, the ventilation area 317 is provided inside the generated product, and air can flow from the outside of the generated product 301 to the inside of the generated product 301. In one example, the ventilation area 317 is in the form of one or more ventilation holes formed through the outer layer of the generated product 301. The ventilation holes are located in the cooling segment 107 to assist in cooling the generated product 301. In one example, the ventilation holes 317 include one or more rows of holes, and preferably the rows of holes are circumferentially arranged around the generated product in a cross-section substantially perpendicular to the longitudinal axis of the generated product 301.

[0086] As described above, the wrapper illustrated in FIG. 1 may surround the aerosolizable material and, if necessary, part or all of the filter assembly. Although not shown, the ventilation area 317 may of course be provided in the wrapper illustrated in FIG. 1 in some embodiments. In some other cases, such as when the wrapper in FIG. 1 does not extend over the entire length of the aerosol-generating product, the ventilation holes may be provided in the outer layer of the generated product at positions where the wrapper in FIG. 1 is not disposed.

[0087] In one example, there are 1 to 4 rows of ventilation holes for ventilating the generated product 301. Each row of ventilation holes has 12 to 36 ventilation holes 317. The ventilation holes 317 have a diameter of, for example, 100 to 500 μm. In one example, the axial spacing between the rows of ventilation holes 317 is 0.25 mm to 0.7 5 mm, preferably 0.5 mm.

[0088] In one example, the size of the ventilation holes 317 is uniform. In another example, the sizes of the ventilation holes 317 are different. The ventilation holes can be provided using one or more of any suitable techniques, such as laser techniques, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before it is formed within the product 301. The ventilation holes 317 are arranged to effectively cool the product 301.

[0089] In one example, the row of ventilation holes 317 is located at least 11 mm from the proximal end 313 of the product, preferably 17 mm to 20 mm from the proximal end 313 of the product 301. The position of the ventilation holes 317 is arranged such that the user does not block the ventilation holes 317 during use of the product 301.

[0090] By providing a row of ventilation holes 17 mm to 20 mm away from the proximal end 313 of the product 301, as is apparent from FIGS. 7 and 8, when the product 301 is fully inserted into the device 51, the ventilation holes 317 can be arranged outside the device 51. By arranging the ventilation holes outside the device, unheated air can enter the product 301 from outside the device 51 through the ventilation holes, assisting in cooling the product 301.

[0091] The cooling segment 307 is sized such that when the product is fully inserted into the device 51, a portion of the cooling segment 307 is inserted into the device 51. The length of the cooling segment 307 provides a first function of creating a physical gap between the heater device of the device 51 and the heat-sensitive filter device 309 when the product 301 is inserted into the device, and a second function of being arranged outside the device 51 and allowing the ventilation holes 317 to be arranged within the cooling segment. As can be seen from FIGS. 7 and 8, most of the cooling member 307 is located within the device 51. However, there is a portion of the cooling member 307 that extends outside the device 51. The ventilation holes 317 are located in this portion of the cooling member 307 that extends outside the device 51.

[0092] Referring now more particularly to FIGS. 6 - 8, there is shown an example of an apparatus 51 configured to heat an aerosolizable material and volatilize at least one of its components to form an aerosol, typically for inhalation. The apparatus 51 is a heating device that heats the aerosolizable material without burning it to release compounds.

[0093] The first end 53 may here also be referred to as the inlet or proximal end 53 of the apparatus 51, and the second end 55 may here also be referred to as the distal end of the apparatus 51. The apparatus 51 has an on / off button 57 that enables the apparatus 51 as a whole to be turned on and off in response to user requirements.

[0094] The apparatus 51 includes a housing 59 for positioning and protecting the various internal components of the apparatus 51. In the example shown, the housing 59 includes an integral sleeve 11 that surrounds the periphery of the apparatus 51 and is closed at the top by an upper panel 17 that generally defines the "top" of the apparatus 51 and at the bottom by a bottom panel 19 that generally defines the "bottom" of the apparatus 51. In another example, the housing includes a front panel, a rear panel, and a set of opposing side panels in addition to the upper panel 17 and the bottom panel 19.

[0095] The upper panel 17 and / or the bottom panel 19 may be removably fixed to the integral sleeve 11 so as to be easily accessible inside the apparatus 51, or may be "permanently" fixed to the integral sleeve 11 so that, for example, the user cannot access the inside of the apparatus 51. In one example, the panels 17 and 19 are made of a plastic material including glass fiber - filled nylon, formed by injection molding for example, and the integral sleeve 11 is made of aluminum, although other materials and other manufacturing methods may be used. The upper panel 17 of the apparatus 51 has an opening 20 at the inlet end 53 of the apparatus 51 through which, in use, the articles 101, 301 containing the aerosolizable material are inserted into and removed from the apparatus 51 by the user.

[0096]

[0097] ​ The housing 59 has a heater device 23, a control circuit 25, and a power supply 27 located or fixed therein. In this example, the heater device 23, the control circuit 25, and the power supply 27 are adjacent to each other laterally (i.e., adjacent when viewed from the end), and the control circuit 25 is located between the heater device 23 and the power supply 27, but other arrangements are possible.

[0098] The control circuit 25 may include a controller such as a microprocessor device configured and arranged to control the heating of the aerosolizable material in the generated products 101, 301, as further described below.

[0099] The power supply 27 may be, for example, a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically connected to the heater device 23 to supply power when needed and under the control of the control circuit 25, to heat the aerosolizable material of the generated product (to volatilize the aerosolizable material without burning it as described).

[0100] The advantage of arranging the power supply 27 adjacent to the side of the heater device 23 is that a physically large power supply 25 can be used without making the entire device 51 overly long. Naturally, generally a physically large power supply 25 has a large capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.), and can extend the battery life of the device 51.

[0101] In one example, the heater device 23 is in the shape of a substantially hollow cylindrical tube having a hollow internal heating chamber 29, into which the generated products 101, 301 containing aerosolizable material are inserted for heating during use. Different configurations of the heater device 23 are also possible. For example, the heater device 23 may include a single heating element, or may be formed of a plurality of heating elements aligned along the longitudinal axis of the heater device 23. The or each heating element may be annular or tubular, or may be at least partially annular or partially tubular at its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating devices are also possible, including, for example, induction heating, an infrared heater element that heats by infrared irradiation, or a resistive heating element formed, for example, by a resistive electric winding.

[0102] In one particular example, the heater device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater device 23 is dimensioned such that when the generated products 101, 301 are inserted into the device 51, substantially the entire aerosolizable material 103, 303 of the generated products 101, 301 is inserted within the heater device 23.

[0103] The or each heating element may be configured such that a selected region of the aerosolizable material is heated independently, for example sequentially (over time as described above) or together (simultaneously) as required.

[0104] The heater device 23 of this example is surrounded by a heat insulating material 31 along at least a part of its length. The heat insulating material 31 helps to reduce the heat passing from the heater device 23 to the outside of the device 51. This generally reduces heat loss and thus helps to suppress the electric power required for the heater device 23. Also, the heat insulating material 31 helps to keep the outside of the device 51 cool during the operation of the heater device 23. In one example, the heat insulating material 31 may be a sleeve with a double wall, which provides a low pressure region between the two walls of the sleeve. That is, the heat insulating material 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially degassed to minimize heat transfer by conduction and / or convection. Other configurations of the insulating material 31 are possible, including using, in addition to or instead of the double-walled sleeve, a heat insulating material containing, for example, any suitable foamed material.

[0105] The housing 59 may further include various internal support structures 37 for supporting not only the heating device 23 but also all internal components.

[0106] The device 51 further includes a collar 33 that extends around the opening 20 and projects into the interior of the housing 59 therefrom, and a substantially tubular chamber 35 located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example is arranged at intervals along the outer surface of the chamber 35 and includes a plurality of cooling fins 35f arranged around the outer surface of the chamber 35, respectively. When the generated products 101, 301 are inserted into at least a part of the length of the hollow chamber 35 of the device 51, a gap is formed between the hollow chamber 35 and the generated products 101, 301. The gap 36 covers at least a part of the cooling segment 307 and exists all around the circumference of the generated products 101, 301.

[0107] Color 33 is arranged circumferentially around the opening 20 and includes a plurality of protrusions 60 protruding into the opening 20. The protrusions 60 take up space within the opening 20 such that at the location of the protrusions 60, the opening width of the opening is smaller than the opening width of the opening 20 at a position where there are no openings 60. The protrusions 60 are configured to engage with the generated products 101, 301 inserted into the device to assist in fixing the generated products within the device 51. The opening spaces (not shown) defined by adjacent pairs of protrusions 60 and the generated products 101, 301 form a ventilation path around the outer periphery of the generated products 101, 301. These ventilation paths allow the hot vapor escaping from the generated products to exit the device 51 and allow cold air to flow into the device 51 around the generated products 101, 301 within the void 36.

[0108] During operation, the generated products 101, 301 are removably inserted into the insertion point 20 of the device 51 as shown in FIGS. 6 - 8. Referring particularly to FIG. 7, in one example, the bodies 103, 303 made of aerosolizable material located towards the distal ends 115, 315 of the generated products 101, 301 are entirely housed within the heater device 23 of the device 51. The proximal ends 113, 313 of the generated products 101, 301 extend from the device 51 and function as a mouthpiece assembly for the user.

[0109] During operation, the heater device 23 heats the generated products 101, 301 and volatilizes at least one component of the aerosol - forming composition from the bodies 103, 303 made of aerosolizable material.

[0110] The main flow path for the components heated and volatilized from the bodies 103 and 303 made of aerosolizable materials extends to the user through the axially oriented generated articles 101 and 301, the cooling segments 107 and 307, the chamber filter segments 109 and 309 inside the cooling segments, and the suction port end segments 111 and 313. In one example, the temperature of the components heated and volatilized from the body made of aerosolizable materials can be 60°C to 250°C, which may be higher than the acceptable inhalation temperature for the user. When the components heated and volatilized move through the cooling segments 107 and 307, the components cool down, and some of the volatilized components liquefy on the inner surface of the cooling segments 107 and 307.

[0111] In the example of the generated article 301 shown in FIGS. 4 and 5, cold air can enter the cooling segment 307 through the ventilation holes 317 formed in the cooling segment 307. This cold air mixes with the components heated and volatilized, further cooling the components heated and volatilized.

[0112] Aerosol-forming material composition

[0113] In some cases, the amorphous solid may contain 1 to 60 wt% of a gelling agent, and these weights are calculated on a dry weight basis.

[0114] Preferably, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 27 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 1 to 50 wt%, 5 to 40 wt%, 10 to 30 wt% or 15 to 27 wt% of a gelling agent.

[0115] In some embodiments, the gelling agent comprises a hydrophilic colloid. In some embodiments, the gelling agent comprises one or more compounds selected from alginates, pectins, starches (and derivatives), celluloses (and derivatives), rubbers, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum acacia, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. Optionally, the gelling agent comprises alginate and / or pectin and may be mixed with a curing agent (such as a calcium source) during the formation of the amorphous solid. Optionally, the amorphous solid may comprise alginate cross-linked with calcium and / or pectin cross-linked with calcium.

[0116] In some embodiments, the gelling agent comprises an alginate, and the alginate is included in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent included in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and a further gelling agent such as at least one pectin.

[0117] In some embodiments, the amorphous solid may comprise a gelling agent comprising carrageenan.

[0118] Preferably, the amorphous solid may contain from about 5 wt%, 10 wt%, 15 wt% or 20 wt% to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt% or 35 wt% (calculated on a dry weight basis) of an aerosol generating agent. The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may contain from 5 to 60 wt%, 10 to 50 wt% or 20 to 40 wt% of an aerosol generating agent. In some cases, the aerosol generating agent contains one or more compounds selected from erythritol, propylene glycol, glycerin, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent contains glycerin, consists essentially of glycerin or consists of glycerin. The inventor has confirmed that if the content of the plasticizer is too high, the amorphous solid will absorb water and become a material that does not produce a suitable consumer experience during use. The inventor has confirmed that if the content of the plasticizer is too low, the amorphous solid will become brittle and prone to breakage. The amount of plasticizer specified herein provides flexibility to the amorphous solid so that the amorphous solid sheet can be wound around a bobbin useful for the manufacture of aerosol generating articles.

[0119] In some cases, the amorphous solid contains an active substance. For example, in some cases, the amorphous solid additionally contains tobacco material and / or nicotine. For example, the amorphous solid may additionally contain powdered tobacco and / or nicotine and / or tobacco extract. In some cases, the amorphous solid may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid may contain 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% or 40 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine.

[0120] In some cases, the amorphous solid contains one or more active substances and flavoring agents. In some cases, the amorphous solid contains one or more of nicotine, tobacco extract, and flavoring agents.

[0121] In some cases, the amorphous solid contains an active substance such as a tobacco extract. In some cases, the amorphous solid may contain 5 to 60 wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the amorphous solid may contain about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 55 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the tobacco extract. For example, the amorphous solid may contain 5 to 60 wt%, 10 to 55 wt% or 25 to 55 wt% of the tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid contains 1 wt%, 1.5 wt%, 2 wt% or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine. In some cases, there is no nicotine in the amorphous solid other than that obtained from the tobacco extract.

[0122] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such cases, the amorphous solid may contain about 1 wt%, 2 wt%, 3 wt% or 4 wt% to about 20 wt%, 15 wt%, 10 wt% or 5 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20 wt% or 2 to 5 wt% of nicotine.

[0123] In some cases, the amorphous solid may contain a flavorant. Preferably, the amorphous solid may contain about 60 wt% or less, 50 wt% or less, 40 wt% or less, 30 wt% or less, 20 wt% or less, 10 wt% or less, or 5 wt% or less of the flavorant. In some cases, the amorphous solid may contain at least 0.1 wt%, about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% of the flavorant (calculated on a dry weight basis). For example, the amorphous solid may contain 0.1 - 60 wt%, 1 - 60 wt%, 5 - 60 wt%, 10 - 60 wt%, 20 - 50 wt%, or 30 - 40 wt% of the flavorant. In some cases, the flavorant (if any) contains menthol, consists essentially of menthol, or consists of menthol. In some cases, the amorphous solid does not contain a flavorant.

[0124] In some cases, the total content of the active substance and / or the flavorant 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 the active substance (e.g., tobacco material and / or nicotine) and the flavorant may be less than about 80 wt%, less than 70 wt%, less than 60 wt%, less than 50 wt%, or less than 40 wt% (calculated on a dry weight basis).

[0125] 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%, less than 12 wt%, or less than 10 wt% water calculated on a wet weight basis (WWB). In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water. In some cases, the amorphous solid contains about 1 wt% to about 15 wt% or about 5 wt% to about 15 wt% water calculated on a wet weight basis. Preferably, the moisture content of the amorphous solid is about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%.

[0126] The amorphous solid may be made from a gel, and the gel may additionally contain a solvent in an amount of 0.1 to 50 wt%. However, the inventor has confirmed that when the flavorant contains a soluble solvent, the stability of the gel decreases and the flavorant crystallizes out of the gel. Therefore, in some cases, the gel does not contain a solvent in which the flavorant is soluble.

[0127] In some embodiments, the amorphous solid contains a filler of less than 60 wt%, such as 1 wt% to 60 wt% or 5 wt% to 50 wt% or 5 wt% to 30 wt% or 10 wt% to 20 wt%.

[0128] In other embodiments, the amorphous solid contains a filler of less than 20 wt%, preferably less than 10 wt% or less than 5 wt%. In some cases, the amorphous solid contains a filler of less than 1 wt%, and in some cases, it does not contain a filler.

[0129] When a filler is included, it may include one or more of suitable inorganic adsorbents such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler may include one or more organic fillers such as wood pulp, cellulose, and cellulose derivatives. In particular specific cases, the amorphous solid contains calcium carbonate such as chalk. In specific embodiments where a filler is included, the filler is fibrous. For example, the filler may be a fibrous filler such as wood pulp, hemp fiber, cellulose, or cellulose derivative. Without wishing to be bound by any theory, it has been confirmed that incorporating a fibrous filler into the amorphous solid increases the tensile strength of the material. This is particularly advantageous in examples where the amorphous solid is provided as a sheet, such as when the amorphous solid sheet surrounds a rod made of an aerosolizable material.

[0130] In some embodiments, the amorphous solid does not contain tobacco fiber. In certain embodiments, the amorphous solid does not contain fibrous material.

[0131] ​

[0132] In some embodiments, the aerosol generating material does not contain tobacco fibers. In certain embodiments, the aerosol generating material does not contain fibrous materials.

[0133] In some embodiments, the aerosol generating substrate does not contain tobacco fibers. In certain embodiments, the aerosol generating substrate does not contain fibrous materials.

[0134] In some embodiments, the aerosol generating article does not contain tobacco fibers. In certain embodiments, the aerosol generating article does not contain fibrous materials.

[0135] In some cases, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol forming agent, one or more active substances (such as tobacco material and / or nicotine source), water and optionally flavorants.

[0136] Method for manufacturing a wrapper

[0137] The wrapper may be manufactured by a method comprising (a) forming a slurry comprising components of an amorphous solid or a precursor thereof, (b) applying the slurry to a carrier, (c) curing the slurry to form a gel, and (d) drying to form an amorphous solid.

[0138] Forming the layer of slurry in step (b) may include, for example, spraying, casting or extruding the slurry. In some cases, the layer is formed by electrospraying the slurry. In some cases, the layer is formed by casting a sleeve.

[0139] In some cases, steps (b) and / or (c) and / or (d) may be performed at least partially simultaneously (for example, while electrospraying). In some cases, these steps may be performed sequentially.

[0140] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, for example about 14 to 16 Pa·s at 46.5°C.

[0141] The step (c) of curing the gel may include adding a curing agent to the slurry. For example, the slurry may contain sodium alginate, potassium alginate or ammonium alginate as a gel precursor and a calcium source (such as calcium chloride), and may contain a curing agent added to the slurry to form a calcium alginate gel.

[0142] The total amount of the curing agent such as the calcium source may be 0.5 to 5 wt% (calculated on a dry weight basis). The inventor has discovered that if the addition amount of the curing agent is too small, the resulting gel cannot stabilize the gel components, and as a result, these components will spill out of the gel. The inventor has discovered that if the addition amount of the curing agent is too large, the resulting gel will be sticky and difficult to handle.

[0143] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10 to 600 kDa). Alginic acid is a copolymer in which β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) are linked by (1,4)-glycosidic bonds to form a polysaccharide. The addition of calcium crosslinks the alginate to form a gel. The inventor has discovered that alginates with a high G monomer content easily form gels by adding a calcium source. Therefore, in some cases, the gel precursor may contain an alginate in which at least 40%, 45%, 50%, 55%, 60% or 70% of the monomer units of the alginic acid copolymer are α-L-guluronic acid (G) units.

[0144] The slurry itself may also form part of the present invention. In some cases, the slurry solvent may consist essentially of water or may consist of water. In some cases, the slurry may contain about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% of the solvent (WWB).

[0145] When the solvent consists of water, the content in the dry weight of the slurry coincides with the content in the dry weight of the amorphous solid. Therefore, the discussions in this specification regarding the solid composition are to be clearly disclosed in combination with the slurry aspect of the present invention.

[0146] Exemplary Embodiments

[0147] In some embodiments, the amorphous solid contains menthol.

[0148] In some such embodiments, the amorphous solid has a composition (DWB) such as a gelling agent (preferably including alginate, more preferably including alginate and pectin) in an amount of about 20 wt% to about 40 wt% or about 25 wt% to 35 wt%, menthol in an amount of about 35 wt% to about 60 wt% or about 40 wt% to 55 wt%, and an aerosol generator (preferably including glycerin) in an amount of about 10 wt% to about 30 wt% or about 15 wt% to about 25 wt% (DWB).

[0149] In one embodiment, the amorphous solid contains about 32 - 33 wt% of an alginate / pectin gelling agent blend, about 47 - 48 wt% of a flavoring agent, and about 19 - 20 wt% of a glycerin aerosol generator (DWB).

[0150] The amorphous solids of these embodiments may have any suitable moisture content. For example, the amorphous solid may have a moisture content of about 2 wt% to about 10 wt%, or about 5 wt% to about 8 wt% or about 6 wt%.

[0151] Preferably, the amorphous solid is generated in a sheet form and has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0152] In some further embodiments, the amorphous solid has a composition (DWB) of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt% of a gelling agent (preferably including alginate, more preferably including alginate and pectin), about 10 wt% to about 50 wt% or about 15 wt% to 40 wt% of menthol, about 5 wt% to about 40 wt% or about 10 wt% to about 35 wt% of an aerosol generating agent (preferably including glycerin), and up to 60 wt%, for example 5 wt% to 20 wt% or about 40 wt% to 60 wt% (DWB), of any filler.

[0153] In one of these embodiments, the amorphous solid includes about 11 wt% of an alginate / pectin gelling agent blend, about 56 wt% of a wood pulp filler, about 18% of a menthol flavorant, and about 15 wt% of glycerin (DWB).

[0154] In another example of these embodiments, the amorphous solid includes about 22 wt% of an alginate / pectin gelling agent blend, about 12 wt% of a wood pulp filler, about 36 wt% of a menthol flavorant, and about 30 wt% of glycerin (DWB).

[0155] In some of the above embodiments, the sheet is provided on a carrier including paper. In some other embodiments, the sheet is provided on a carrier including a metal foil, preferably an aluminum metal foil. In some such embodiments, the amorphous solid abuts the metal foil.

[0156] In one embodiment, the sheet forms part of a laminate material having layers (preferably including paper) attached to the top and bottom surfaces of the sheet. Preferably, the sheet of the amorphous solid has a thickness of about 0.015 mm to about 1 mm.

[0157] In some embodiments, the amorphous solid contains a flavoring agent that does not contain menthol. In these embodiments, the amorphous solid has a composition (DWB) such as a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 35 wt%, or about 20 wt% to about 35 wt%, a flavoring agent in an amount of about 0.1 wt% to about 40 wt, about 1 wt% to about 30 wt%, or about 1 wt% to about 20 wt%, or about 5 wt% to about 20 wt%, an aerosol generating agent (preferably including glycerin) in an amount of about 15 wt% to about 75 wt%, or about 30 wt% to about 70 wt%, or about 50 wt% to about 65 wt%, and any filler (preferably wood pulp) in an amount of less than about 60 wt%, or less than about 20 wt%, or less than about 10 wt%, or about 5 wt% (preferably the amorphous solid does not contain a filler).

[0158] In one of these embodiments, the amorphous solid contains about 27 wt% of an alginate gelling agent, about 14 wt% of a flavoring agent, and about 57 wt% of a glycerin aerosol generating agent (DWB).

[0159] In another example of these embodiments, the amorphous solid contains about 29 wt% of an alginate gelling agent, about 9 wt% of a flavoring agent, and about 60 wt% of glycerin (DWB).

[0160] In some embodiments, the amorphous solid contains a tobacco extract. In these embodiments, the amorphous solid has a composition (DWB) such as 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 glycerin) 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).

[0161] In one embodiment, the amorphous solid comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerin (DWB).

[0162] The amorphous solids of these embodiments may have any suitable moisture content. For example, the amorphous solid may have a moisture content of about 5 wt% to about 15 wt%, or about 7 wt% to about 13 wt%, or about 10 wt%.

[0163] Preferably, in any of the embodiments comprising these tobacco extracts, the amorphous solid has a thickness of about 50 μm to about 200 μm or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0164] The slurry for forming this amorphous solid may also form part of the present invention. In some cases, the slurry may have an elastic modulus (also referred to as storage elastic modulus) of about 5 to 1200 Pa, and in some cases, the slurry may have a viscosity coefficient (also referred to as loss coefficient) of about 5 to 600 Pa.

[0165] Definition

[0166] The active substance used in the present invention is a physiologically active material intended to achieve or enhance a physiological reaction. The active substance may be selected, for example, from nutraceuticals, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0167] In some embodiments, the active substance includes nicotine.

[0168] In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0169] As described herein, the active substance may include one or more components, derivatives or extracts of cannabis such as one or more cannabinoids or terpenes.

[0170] Cannabinoids are a group of natural or synthetic compounds that act on intracellular cannabinoid receptors (i.e., CB1 and CB2) in the brain to suppress neurotransmitter release. Cannabinoids may be those that occur naturally in plants such as cannabis (phytocannabinoids), those that occur naturally in animals (zoocannabinoids), or those that are artificially manufactured (synthetic cannabinoids). Cannabis seeds exhibit at least 85 different phytocannabinoids and are divided into subclasses including cannaguerols, cannabinochromenes, cannabidiols, tetrahydrocannabinols, cannabinols, cannabinodiols, and other cannabinoids. Cannabinoids found in the genus Cannabis include, but are not limited to, cannabigerol (CBG), cannabinochromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabinocyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabinochromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0171] As described herein, the active substance may include or be derived from a plant or its components, derivatives or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from a plant such as an extract, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may be synthetically obtained and added to the plant It may contain existing active compounds. The material may be in the form of liquids, gases, solids, powders, dusts, crushed particles, grains, pellets, chips, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, Cryptomeria japonica, Cannabis sativa, cocoa, hemp, Perilla frutescens, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, Humulus japonicus, hibiscus, laurel, licorice, matcha, mate tea, orange peel, papaya, rose, sage, green tea or black tea, thyme, star anise, cinnamon, coffee, aniseed, basil, laurel leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, nasturtium flowers, vanilla, Aspergillus oryzae, Artemisia princeps, turmeric, turmeric, sandalwood, coriander, bergamot, neroli, Gymnadenia conopsea, blackcurrant, corydalis, pimento, mace, Damiana, Alchemilla vulgaris, olive, lemon balm, lemon basil, chive, Perilla frutescens, vervain, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. Mint may be selected from the following mint species (Mentha canadensis, Mentha spicata, Mentha arvensis, Mentha piperita, Mentha suaveolens, Mentha x piperita var. citrata, Mentha spicata var. crispa, Mentha canadensis var. piperascens, Mentha longifolia, Mentha suaveolens var. alopecuroides, Mentha pulegium, Mentha spicata var. crispa and Malva sylvestris).

[0172] In some embodiments, the plant is selected from eucalyptus, Cryptomeria japonica, cocoa and hemp.

[0173] In some embodiments, the plant is selected from rooibos and Perilla frutescens.

[0174] As used herein, the terms "flavoring agent" and "flavor enhancer" are permitted by local regulations and are used to produce tastes, scents or other somatic sensory stimuli desired by adult consumers. They are natural-occurring flavor materials, plants, plant extracts, synthetically obtained materials or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phoebe leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, koji, strawberry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, daikon, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chat, naswar, kinma, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, neroli, strawberry flower, cassia, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pimento, ginger, coriander, coffee, mugwort, peppermint oil from any species of the genus Mentha).Eucalyptus, cypress, cocoa, lemongrass, rooibos, flax, ginkgo, fern, hibiscus, laurel, mate tea, orange peel, rose, tea such as green tea or black tea, thyme, byakushin, nasturtium flower, basil, laurel leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, chrysanthemum, turmeric, cilantro, ginger, blackcurrant, bugleweed, allspice, mace, damiana, ylang-ylang, olive, lemon balm, lemon basil, chive, Japanese butterbur, vervain, tarragon, limonene, thymol, camphor), seasonings, bitter 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, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, plants or odor suppressants. These materials may be imitation, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid such as an oil, a solid such as a powder or a gas.

[0175] The flavoring preferably contains one or more mint flavorings and preferably contains peppermint oil from any species of the genus Mentha. The flavoring preferably contains menthol, consists essentially of menthol, or consists of menthol.

[0176] In some embodiments, the flavoring contains menthol, spearmint and / or peppermint.

[0177] In some embodiments, the flavoring contains flavor components of cucumber, blueberry, citrus and / or redberry.

[0178] In some embodiments, the flavoring contains eugenol.

[0179] In some embodiments, the flavoring contains flavor components extracted from tobacco.

[0180] In some embodiments, the flavorant comprises flavor components extracted from cannabis.

[0181] In some embodiments, the flavorant may include a sensory agent, which is chemically induced and recognized by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of olfactory or gustatory nerves, and they may include agents that give a heating, cooling, tingling, or numbing sensation. Suitable heat agents include, but are not limited to, vanillyl ethyl ether, and suitable coolants include, but are not limited to, eucalyptol and WS-3.

[0182] As used herein, the term "aerosol generating agent" means an agent that promotes the generation of an aerosol. The aerosol generating agent may promote the generation of an aerosol by promoting initial vaporization and / or condensation of the gas into a drawable solid and / or liquid aerosol.

[0183] Suitable aerosol generating agents include, but are not limited to, polyols such as erythritol, sorbitol, glycerin, and glycols such as propylene glycol or triethylene glycol, monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerin derivatives, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, and myristic acid esters including isopropyl myristate, and esters such as aliphatic carboxylic acid esters including methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. The aerosol generating agent preferably has a composition that does not dissolve menthol. The aerosol generating agent preferably contains glycerin, consists essentially of glycerin, or consists of glycerin.

[0184] In this specification, the term "tobacco material" means any material including tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco or tobacco substitutes. Tobacco material may include one or more of powdered tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stalks, reclaimed tobacco and / or tobacco extracts.

[0185] The tobacco used to make the tobacco material may be any suitable tobacco including single grades or blends including Virginia and / or Burley and / or Oriental, cuttings or whole leaves. Also other processed stalk materials such as tobacco particles "fine powder" or dust, expanded tobacco, stalks, expanded stalks and cut and rolled stalks may be used. The tobacco material may be powdered tobacco or reclaimed tobacco material. The reclaimed tobacco material may be tobacco fibers and may be formed by casting, Ford linear papermaking methods with subsequent addition of tobacco extracts or extrusion.

[0186] In this specification, the term "volatile substance" means any component of an inhaled aerosol including, but not limited to, aerosol generators, flavorants, tobacco flavorings and aromas and nicotine. Terms such as "volatile substances derived from amorphous solids" and "tobacco volatile substances" represent members of aerosol generating articles in which volatile substance / aerosolizable components are disposed or obtained.

[0187] In this specification, the term "rod" means an elongate body generally of a shape suitable for use in an aerosol generating assembly. In some cases the rod is substantially cylindrical.

[0188] The weight percentages (expressed 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. The weight expressed on a dry weight basis means the total of the extract or slurry or material amount other than water, and may include components that are themselves liquid at room temperature and room pressure, such as glycerol. Conversely, the weight percentage on a wet weight basis means all components including water.

[0189] To avoid misunderstanding, when "comprises" is used in the specification to define the invention or a feature of the invention, embodiments are also disclosed in which the invention or feature can be defined using "consists essentially of" or "consists of" instead of "comprises". When referring to a material "comprising" a particular feature, it means that those features are contained, included or held in that material.

[0190] The above embodiments should be understood as examples useful for explaining the present invention. Of course, any feature described for any one embodiment may be used alone or in combination with any other described feature, or in combination with any one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention as defined in the appended claims.

Claims

1. An aerosol generating article for use in an aerosol generating assembly, the aerosol generating article comprising a rod made of aerosolizable material surrounded by a wrapper, the wrapper being an article comprising an amorphous solid that forms an aerosol.

2. The aerosol generating article according to claim 1, wherein the wrapper comprises a carrier, and the amorphous solid that forms an aerosol is disposed on the carrier.

3. The aerosol generating article according to claim 2, wherein the carrier comprises a layer of paper.

4. The aerosol generating article according to claim 3, wherein the amorphous solid is in direct contact with the layer of paper.

5. The aerosol generating article comprises two sections, The aerosol generating article according to any one of claims 1 to 4, wherein the amount of volatile substance of the amorphous solid in the wrapper portion surrounding the first section is greater than the amount of volatile substance of the amorphous solid in the wrapper portion surrounding the second section.

6. The aerosol generating article comprises two sections, The aerosol generating article according to claim 2 or, when dependent on claim 2, according to any one of claims 3 to 5, wherein the amount of amorphous solid per unit area of the carrier in the wrapper portion surrounding the first section is greater than the amount of amorphous solid per unit area of the carrier in the wrapper portion surrounding the second section.

7. The aerosol generating article according to claim 6, wherein the amorphous solid is disposed on a substantially triangular carrier.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the amorphous solid comprises one or more active substances and flavorants.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the aerosolizable material comprises tobacco material.

10. An aerosol generating assembly comprising the aerosol generating article according to any one of claims 1 to 9 and a heater configured to heat the aerosolizable material and / or the amorphous solid that forms an aerosol without burning it.

11. The amount of volatile substance of the amorphous solid in the wrapper portion surrounding the first section is greater than the amount of volatile substance of the amorphous solid in the wrapper portion surrounding the second section, The aerosol generating assembly according to claim 10, wherein the device is configured to provide different heat profiles to each of the different sections.

12. The aerosol generating assembly according to claim 11, characterized in that heating of the first section of the aerosol generating article is configured to start after heating of the second section.

13. The aerosol generating assembly according to claim 11 or 12, characterized in that it comprises at least two heaters, the heaters being arranged to heat different sections of the aerosol generating article respectively.

14. A method for manufacturing an aerosol generating article according to any one of claims 1 to 9, comprising: (a) forming a slurry containing components of an amorphous solid or a precursor thereof; (b) applying the slurry to a carrier; (c) curing the slurry to form a gel; (d) drying the gel to form an amorphous solid; and (e) arranging a wrapper so that the wrapper surrounds an aerosolizable material.

15. The method according to claim 14, characterized in that step (c) comprises adding a curing agent to the slurry.

Images