Aerosol Delivery Device

Abstract

A non-flammable aerosol delivery device (2) suitable for use with a consumable (18) is disclosed, the device comprising a receptacle (6) for the consumable (18) and a compression element (12), the receptacle (6) configured to allow the consumable (18) to be inserted into and removed from the receptacle (6), and the compression element (12) configured to wipe or apply a compressive force to at least a portion of the consumable (18) while the consumable (18) is being removed from the receptacle (6).

Description

[Technical field]

[0001] The present disclosure relates to the field of non-flammable aerosol delivery devices, and in particular to the construction of such devices, consumables for use with such devices, and aerosol delivery systems that include such devices and consumables.

[0002] Aerosol producing articles release compounds from a substrate material by heating without combustion, thereby releasing inhalable aerosols or vapors, and are sometimes referred to as non-combustible articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases a compound by heating an aerosolizable material, sometimes referred to as a solid aerosol-generating material. Upon heating, at least one component of the material is volatilized, usually forming an inhalable aerosol. These products are sometimes referred to as non-combustion heated devices.

[0004] Another example is hybrid devices, which include a liquid source (which may or may not contain an active ingredient) that is vaporized by heating to produce an inhalable vapor or aerosol, and a solid aerosol-generating material (which may or may not contain botanical matter) whose components are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a non-flammable aerosol delivery device suitable for use with a consumable product, comprising: the device comprising a receptacle for a consumable product and a compression element; the receptacle is configured to allow insertion and removal of the consumable into and from the receptacle; A device is provided in which the compression element is configured to wipe or apply a compressive force to at least a portion of the consumable while the consumable is being removed from the receptacle.

[0006] According to a second aspect of the present disclosure, there is provided an at least partially porous consumable article.

[0007] According to a third aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device according to the first aspect of the present disclosure and a consumable according to the second aspect of the present disclosure.

[0008] According to a fourth aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable according to the second aspect of the present disclosure using an aerosol generation device according to the first aspect of the present disclosure.

[0009] 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]

[0010] [Figure 1] FIG. 1 is a schematic diagram of a first embodiment of a device according to the present disclosure. [Diagram 2] FIG. 2 shows a cross-section of the device of FIG. 1 taken along section line AA'. [Diagram 3] FIG. 2 is a schematic diagram of a first detail of a second embodiment of a device according to the present disclosure. [Figure 4] FIG. 4 shows a second detail of the device of FIG. [Diagram 5] FIG. 4 shows a third detail of the device of FIG. [Figure 6] FIG. 1 is a schematic perspective view of one embodiment of a consumable for use with a device according to the present disclosure. [Figure 7] 7 is a cross-sectional view of the consumable of FIG. 6 taken along section line BB'. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Consumables herein may alternatively be referred to as articles.

[0012] 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.

[0013] 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.

[0014] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitute the aerosol delivery system is not combusted to facilitate delivery of at least one substance to a user.

[0015] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-flammable aerosol delivery devices. Throughout this disclosure, these consumables may be referred to as articles.

[0021] In some embodiments, the non-flammable aerosol delivery system (e.g., the 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.

[0022] 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.

[0023] In some embodiments, consumables for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier. According to a first aspect of the present disclosure, there is provided a non-flammable aerosol delivery device suitable for use with a consumable product, comprising: the device comprising a receptacle for a consumable product and a compression element; the receptacle is configured to allow insertion and removal of the consumable into and from the receptacle; A device is provided in which the compression element is configured to wipe or apply a compressive force to at least a portion of the consumable while the consumable is being removed from the receptacle.

[0024] When a non-flammable aerosol delivery device configured for use in conjunction with a consumable is used, the consumable is disposed within the device, often within a receptacle within the device, which is typically a chamber that includes an opening that allows a user to withdraw aerosol generated within the receptacle from the receptacle, and one or more openings that allow air to enter the receptacle when a user is withdrawing aerosol from the receptacle.

[0025] The purpose of the receptacle is typically both to hold the consumable in the correct position for use and to contain any aerosols generated during use to prevent them from entering other parts of the device.

[0026] The device generates an aerosol when at least a portion of the consumable is heated to vaporize an aerosol-generating material that forms part of the consumable. At least a portion of the vapor then transitions to an aerosol. The aerosol may be retained in the receptacle for a period of time before being withdrawn from the chamber by a user. Alternatively or additionally, a user using the device may not withdraw all of the aerosol from the receptacle, leaving the receptacle containing residual aerosol.

[0027] It has been found that some of the vapor / aerosol generated within the receptacle will condense within the consumable / receptacle to form condensate. It has also been found that when the consumable is removed from the receptacle after use, the condensate may be drawn or carried away from the receptacle. This may result in the condensate migrating to the outside of the device, to the user, and / or to the user's clothing when the consumable is removed from the receptacle / device. This migration of condensate is undesirable.

[0028] An advantage of the device of the present disclosure is that wiping the surface of the consumable or applying a compressive force to the consumable with a compression element as it is withdrawn from the receptacle has the effect of removing or squeezing some of the condensate out of the consumable before it needs to be handled by a user, thereby reducing or preventing the amount of condensate transferring to the outside of the device, to the user, or to the user's clothing.

[0029] In one embodiment of the above embodiments, the consumable moves relative to the compression element and the receiver as it is removed from the receiver. In some embodiments, the compression element applies a compressive force to only a portion of the consumable at a time, such that the consumable is gradually compressed as it is removed from the receiver. This arrangement has the advantage that the compression element is significantly smaller than the consumable and can take up little space in the device.

[0030] In some alternative embodiments, the compression element applies a compressive force simultaneously to the entire consumable in the process of removing the consumable from the receiver.

[0031] In one embodiment of any of the above embodiments, the compression element at least partially defines a compression zone through which at least a portion of the consumable passes while the consumable is being removed from the receiver. The compression zone is configured such that the consumable is gradually wiped or subjected to a gradually increasing compressive force as it passes through the compression zone, e.g., from one end to the other. In some embodiments, the compression zone has at least two opposing surfaces (opposite each other) with a distance between the opposing surfaces such that compression of the consumable is required to pass between the opposing surfaces, at least one of the opposing surfaces being a volume defined by at least a portion of the compression element.

[0032] In one embodiment of any of the above embodiments, the compression zone is of a fixed size.

[0033] In one embodiment of any of the above embodiments, at least one dimension of the compression zone may be variable. In some embodiments, at least one dimension of the compression zone may vary, with the or each dimension change depending on the size of the consumable.

[0034] In one embodiment of any of the above embodiments, the compression element is biased towards the consumable by a biasing means. According to such an arrangement, the consumable may have a variable dimension in a direction in which the compression element applies a compressive force to the consumable.

[0035] In one embodiment of any of the above embodiments, the compression element is configured to apply a predetermined level of compression to the consumable while the consumable is being removed from the receiver, hi some embodiments, the compression element is biased towards the consumable by a constant force biasing means.

[0036] In one embodiment of any of the above embodiments, the compression element is configured to apply a compressive force within a predetermined range to the consumable while the consumable is being removed from the receiver.

[0037] In one embodiment of any of the above embodiments, the compression element comprises an actuating portion and a fixed portion, the actuating portion being movable toward or away from the fixed portion, In this configuration, the consumable passes between the actuating portion and the fixed portion of the compression element, and the actuating portion of the compression element presses the consumable against the fixed portion upon wiping or application of a compressive force to the consumable.

[0038] In one embodiment of any of the above embodiments, the compression element comprises one or more rollers. The use of one or more rollers reduces frictional forces between the consumable and the compression element while the consumable is being removed from the receiver. In some embodiments, the rollers are configured to rotate freely about an axis to which they are attached. In other embodiments, the rollers are configured to provide resistance to rotation about an axis to which they are attached.

[0039] In one embodiment of any of the above embodiments, the compression element comprises a pair of rollers between which the consumable passes while being removed from the receiver.

[0040] In one embodiment of any of the above embodiments, the compression element comprises one or more wiper blades. In some embodiments, the wiper blades are made of an elastically deformable material, such as, but not limited to, silicone rubber.

[0041] In one embodiment of any of the above embodiments, at least one portion of the compression element is biased towards a different portion of the compression element while the consumable is being removed from the receiver.

[0042] In one embodiment of any of the above embodiments, the compression element is configured to allow insertion and removal of the consumable into and from the receiver through the compression element, wherein the compression element applies a first compressive force to the consumable when the consumable is inserted into the receiver and the compression element applies a second compressive force to the consumable when the consumable is removed from the receiver, the second compressive force being greater than the first compressive force. Alternatively, the consumable is subjected to a greater compressive force while being removed from the receiver than while being inserted into the receiver.

[0043] In some embodiments, the compression element comprises an arm having a first end and a second end, the first end of the arm configured to wipe or apply a compressive force to the consumable, and the second end of the arm pivotally attached to a portion of the device via a pivotable mounting element, the arm and pivotable mounting element configured and arranged such that insertion of the consumable through the compression element into the receiver causes the arm to pivot about the pivotable mounting to move the first end of the arm away from the consumable, and removal of the consumable through the compression element from the receiver causes the arm to pivot about the pivotable mounting to move the first end of the arm toward the consumable. In some embodiments, the first end of the arm is biased towards the consumable or a position of the consumable when inserted into or removed from the receiver.

[0044] In one embodiment of any of the above embodiments, a portion of the compression element is formed from a resilient flexible material, a first portion of the resilient flexible element is configured to wipe or apply a compressive force to the consumable, and a second portion of the resilient flexible element is fixed to a fixed portion of the device, the resilient flexible element configured and arranged such that insertion of the consumable through the compression element into the receiver pushes the resilient flexible element to move the first portion away from the consumable, and removal of the consumable through the compression element from the receiver moves the first portion of the resilient flexible element toward the consumable. In some embodiments, the first portion of the resilient flexible element is biased towards the consumable or the position of the consumable when inserted into or removed from the receiver.

[0045] In one embodiment of any of the above embodiments, the receiver is configured to allow the consumable to be inserted through the first opening and to be removed through the second opening.

[0046] In one embodiment of any of the above embodiments, the receptacle is configured to allow insertion and removal of the consumable through a single opening.

[0047] In one embodiment of any of the above embodiments, the compression element is disposed in or adjacent to the opening through which the consumable is removed from the receptacle.

[0048] In one embodiment of any of the above embodiments, the device comprises a liquid recovery element configured to recover liquid wiped or squeezed from the consumable by the compression element as the consumable is removed from the receiver.

[0049] In one embodiment of any of the above embodiments, the liquid recovery element comprises a liquid storage element, whereby the recovered condensate can be held in place until ready for disposal by the user.

[0050] In one embodiment of any of the above embodiments, the liquid recovery element can be emptied by a user.

[0051] In one embodiment of any of the above embodiments, the liquid recovery element is user replaceable.

[0052] According to a second aspect of the present disclosure, there is provided a consumable for use with a device according to the first aspect of the present disclosure, wherein at least a portion of the consumable is deformable by compression. In some embodiments, the consumable is at least partially deformable by compression after use. The deformability of at least a portion of the consumable may cause condensate to be squeezed out of the consumable when a compression element is configured to apply a compressive force to at least a portion of the consumable while the consumable is being removed from the receiver. In one embodiment of any of the above embodiments, the consumable is at least partially elastically deformable by compression. In one embodiment of any of the above embodiments, at least a portion of the consumable is configured to absorb condensation.

[0053] In one embodiment of any of the above embodiments, at least a portion of the consumable is porous.

[0054] In one embodiment of any of the above embodiments, at least the porous portion of the consumable is deformable by compression.

[0055] In one embodiment of any of the above embodiments, at least a portion of the consumable comprises one or more of cellulose acetate, airlaid paper, cotton-based material, shredded paper, and cut rag tobacco, or a mixture of two or more of these materials. In some embodiments, a porous portion of the consumable is formed from one or a mixture of two or more of these materials.

[0056] In one embodiment of any of the above embodiments, one or more of the cellulose acetate, airlaid paper, cotton-based material, shredded paper, and cut rag tobacco are longitudinally stretched strips or strips, and the strips or strips are twisted together to form a matrix of the strips or strips.

[0057] In one embodiment of any of the above embodiments, at least the porous portion of the consumable is deformable by compression.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0067] 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.

[0068] 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 Fe (weight % = wt%) or Phytherm 260 (composition including 50 wt% Ni, 9 wt% Cr, and the rest Fe).

[0069] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0070] 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.

[0071] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0072] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] The aerosol generating material includes an aerosol generating agent. 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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%.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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).

[0095] 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.

[0096] 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).

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] (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.

[0103] 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.

[0104] 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 In a second example, the slurry contains (on a dry weight basis): a gelling agent and optionally a filler, the amount of gelling agent and filler together being about 11-40 wt% of the slurry; an aerosol-forming material in an amount of about 12-42 wt % of the slurry; Optionally, an active material in an amount of about 32-70 wt % of the slurry; and may also include

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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).

[0113] 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.

[0114] 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%, 30-45 wt%, or 7-14 wt% of flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0115] The aerosol-forming material may include a bulking agent.

[0116] 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%.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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)).

[0121] 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.

[0122] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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).

[0129] 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.

[0130] 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.

[0131] 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%.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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).

[0138] 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).

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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 an aerosol-forming material, the aerosol-forming material comprising: 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.

[0143] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of 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 comprises an aerosol-forming material comprising: 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.

[0144] 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.

[0145] 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.

[0146] 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).

[0147] 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).

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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.

[0152] 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.

[0153] 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%.

[0154] 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.

[0155] 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.

[0156] In some examples, the aerosol-generating material in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the aerosol-generating material may have a tensile strength of about 600 N / m to about 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material comprising the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

[0157] The aerosol-forming material, including the aerosol-forming material, has a density of 30 g / m 2 ~350g / m 2 In some cases, the mass per unit area of ​​the sheet may be 50 to 250 g / m 2 , or about 70 to 210 g / m 2 , or about 90 to 190 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.

[0158] 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.

[0159] As used herein, the term "sheet" refers to an element having a width and length that is substantially greater than its thickness. The major surface of a sheet is the surface along which both the width and length dimensions extend when the sheet is flat. A sheet may be, for example, a strip.

[0160] 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 improve the aerosol-generating material and 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 the article that includes the aerosol-generating material.

[0161] 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 colors, and pharmaceutical grade colors. 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, 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.

[0162] 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).

[0163] 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.

[0164] In the following discussion of the accompanying drawings, when an identical element is present in more than one embodiment, the same reference number is used for that element throughout, and when similar elements are present, like reference numbers (the same number plus a multiple of 100) are used.

[0165] 1 and 2, non-flammable aerosol delivery device 2 includes a case 4 in which a receiver 6, a passageway 8, a compression element 12, and a condensate storage tank 32 are disposed.

[0166] The receptacle 6 defines a volume within the case 4 into which the consumable 18 can be introduced and removed. The consumable 18 may be introduced into and removed from the receptacle 6 through an opening at an end of the receptacle 6 and an adjacent opening 20 in the case 4.

[0167] A passageway 8 extends from the end of receptacle 6 remote from opening 20 and terminates in a mouthpiece 10 that is attached to the exterior of case 4. When using device 2, a user will draw aerosol from receptacle 6, through passageway 8 and out of mouthpiece 10.

[0168] Also disposed within case 4 are power supply 14, heater 22, and control unit 16. Heater 22 is adjacent receptacle 6 and is used to heat consumable 18, or at least a portion thereof, when consumable 18 is present in receptacle 6. Heater 22 is powered by power supply 14 (e.g., a rechargeable battery) via suitable wiring (not shown). The heater, and optionally other functions of the device, are controlled by control unit 16 via suitable circuitry (not shown).

[0169] 2, the compression element 12 comprises a first roller 24 and associated first biasing means 26, and a second roller 28 and associated biasing means 30. The first and second biasing means 26, 30 each have a first end acting on the case 4 or other fixed element therein and a second end engaged with an axle (not shown) of the respective associated roller 24, 28. The first and second biasing means 26, 30 each bias the respective associated first and second roller 24, 28 towards the other side. The first and second biasing means 26, 30 and the respective associated roller 24, 28 extend between the rollers and together define a compression zone in which the consumable 18 is subjected to a compression force from the first and second biasing means 26, 30 and the respective associated roller 24, 28.

[0170] When the consumable 18 is introduced into the receiver 6, a user of the device presses the consumable 18 through the opening 20 and against the first and second rollers 24, 28. The consumable 18 enters the receiver 6 by pushing past the first and second rollers 24, 28.

[0171] Once the consumable 18 has been placed in the receptacle 6, the device is ready for use by a user. When the user activates the device via the control unit 16, the heater 22 heats at least a portion of the consumable 18. The heating of at least a portion of the consumable 18 causes an aerosol-generating material (not shown) that forms part of the consumable 18 to vaporize, and the atmosphere in the receptacle 6 becomes a mixture of air and vapour. At least a portion of the vapour then transitions from vapour to aerosol droplets (not shown), and the atmosphere in the receptacle 6 becomes a mixture of air, aerosol and vapour. The device 2 is then ready for the user to inhale atmosphere from the receptacle 6 through the passageway 8 and mouthpiece 10.

[0172] Heating of the aerosol-generating material generates vapors of the desired components of the aerosol as well as water vapor. At least a portion of the water vapor and other vapors / aerosols is expected to condense within the receiver to form a condensate. The longer the water vapor and other vapors / aerosols are held in the receiver 6, the greater the probability of condensation and the larger the volume of condensate.

[0173] It is expected that the consumables 18 will become at least partially covered with such condensation.

[0174] Once the consumable 18 has been used up, a user may wish to remove the consumable 18 and replace it with a new consumable 18. To remove the consumable 18, the user would pull the consumable 18 from the receptacle 6 through the opening 20. As the consumable is pulled from the receptacle 6, a portion of the consumable 18 in the receptacle 6 passes between the first and second rollers 24, 28. These rollers are biased towards one another, thereby exerting a compressive force on the portion of the consumable 18 between the first and second rollers 24, 28. This causes any condensation on or within the consumable 18 to migrate onto the first and second rollers 24, 28 or to be retained on the receptacle 6 side of the first and second rollers 24, 28.

[0175] One or more condensate collection means (not shown) are provided adjacent the first and second rollers 24, 28 and are fluidly connected to the condensate storage tank 32 via one or more conduits 34. The condensate collection means may comprise one or more scrapers to assist in the transfer of condensate from the first and second rollers 24, 28 to the condensate collection means. Additionally or alternatively, the condensate collection means comprises an open receptacle into which condensate may fall or flow when the device 2 is held in the intended use orientation and the consumable 18 is withdrawn from the receptacle 6. The compression element 12 has the effect of reducing the transfer of condensate to the user or the user's clothing when the consumable 18 is removed from the case 4.

[0176] 3, 4 and 5, device 102 has the same general structure as device 2 described in relation to Figures 1 and 2 above, except in relation to compression element 112. Compression element 112 comprises an arm 134 having a first end pivotally attached to case 4 via pivot 136 and lug 138. Attached to or integral with the other end of arm 134 is an axle 140 about which roller 124 may rotate. Roller 124 is configured to resist rotation about axle 140. The resistance to rotation is due to friction between axle 140 and roller 124, meaning that the roller does not rotate freely about axle 140.

[0177] Biasing means 126 is attached to and extends between an anchor 142 on case 4 and a location 144 on arm 134 between pivot 136 and shaft 140. In Figures 3 and 4, location 144 is shown to be approximately midway between pivot 136 and shaft 140, although other locations on arm 134 are possible. Biasing means 126 is configured with means (not shown) for limiting the extension of the biasing means to a maximum extension.

[0178] In this embodiment, the biasing means 126 comprises a compression spring, a first connector extending between the anchor 142 and one end of the compression spring, and a second connector extending between a location 144 on the arm 134 and the other end of the compression spring. The biasing means 126 is configured such that, when the compression spring is in an uncompressed state, the biasing means 126 is at its maximum extension and positions the arm 134 such that the roller 124 is located in a space through which the consumable 18 passes at least partially upon insertion into and removal from the receptacle 6.

[0179] The lug 138, arm 134, roller 124 and biasing means 126 are positioned relative to the opening 20 in the case 4 such that in direction D (the direction in which the consumable 18 moves when introduced into the case), the pivot 136 is between the opening 20 and a position 144 on the arm 134.

[0180] When the consumable 18 is introduced into the receptacle 6, it is guided at least in part into the receptacle 6 by the base plate 146. The base plate 146 is in a fixed position and defines a continuous surface from the opening 20 in the case 4 to a position within the receptacle 6 adjacent the mouth of the conduit 34.

[0181] When the consumable 18 is introduced into the receiver 6, the first end 80A of the support portion 80 of the consumable 18 is introduced into the opening 20 of the case 4 (see Figs. 6 and 7 for further details of the consumable 18). The consumable 18 slides along the surface of the base plate 146 in a direction D (shown in Fig. 6) toward the receiver 6. When the consumable 18 comes adjacent to the roller 124, which is biased into the path of the consumable 18 by the biasing means 126, the roller 124 is caused to swing the arm 134 about the pivot 136, causing the roller 124 to deviate from the path of the consumable 18 and compressing the biasing means 126. As shown in Fig. 4, the roller 124 then slides or rolls along the surface of the consumable 18 as the consumable is introduced into the receiver 6. The consumable may be elastically deformed by the biasing of the roller 124 against the consumable by the biasing means 126.

[0182] 5, once the entire portion of the consumable 18 supporting the aerosol-generating material is in the receptacle 6, the portion of the consumable 18 over which the roller 124 has slid or rolled will no longer place the arm 134 in a position in which the biasing means 126 is compressed, and the biasing means 126 will return the arm 134 to a position in which the biasing means is not compressed. The roller 124 then locks the consumable 18 in the desired position for use of the device.

[0183] When use of the device and consumable 18 is complete, the user may wish to replace the used consumable 18 with a new consumable 18. To this end, the user grasps the end 80B of the consumable and pulls it out of the opening 20. As the consumable 18 is pulled out of the receiver 6, it first comes adjacent to the roller 124. Now, because the consumable 18 is moving in a direction opposite to direction D, the roller 124 and arm 136 do not swing about the pivot 136 to deviate from the path of the consumable 18. The force on the roller 124, when the biasing means 126 is not at its maximum extension, causes the arm 134 to swing in a counterclockwise direction about the pivot 136 (as seen in FIG. 5 ) towards the base plate 146. Because the biasing means 126 acts to prevent the roller 124 from moving when pushed by the consumable 18, the roller 124 applies a compressive force to the portion of the consumable 18 it is pushing against.

[0184] 6, as the consumable 18 is withdrawn from the receiver 6, the rollers 124 apply a compression zone 148 to the consumable 18 gradually as the consumable 18 passes between the rollers 124 and the base plate 146. This forces condensate 150 trapped in the consumable 18 towards the first end 80A of the consumable. As the first end 80A of the consumable 18 approaches the compression zone 148, the condensate 150 is squeezed out of the consumable 18 and flows as liquid 152 into the conduit 34 and then into the storage tank 32 (not shown in FIGS. 3-6).

[0185] In an alternative embodiment, not shown, the device 102 is as described above, except that the roller 124 is replaced with a wiper blade that wipes condensation from the surface of the consumable 18 as the consumable 18 is withdrawn from the receptacle 6.

[0186] 7 and 8, the consumable 18 is comprised of a support 80, a cover 82, discrete portions of aerosol-generating material 84, and a compressible absorbent material 86. The support 80 may be formed of a single material or may be a laminate of two or more layers of material. The support 80 has first and second ends 80A, 80B, and supports a plurality of discrete portions of aerosol-generating material 84 at the first end 80A. These portions 84 are arranged in a regular array on a surface 88 of the support 80.

[0187] Overlying the discrete portions 84 of aerosol-generating material is a compressible absorbent material 86. The cover 82 is secured to a surface 88 of the support 80 adjacent an edge of the support 80 extending between the first and second ends 80A, 80B of the support 80. The support surface 88 and the cover 82 together define a passageway that is filled with the discrete portions 84 of aerosol-generating material and the compressible absorbent material 86.

[0188] The support 80 is formed at least in part from a non-absorbent material that constitutes a surface 88 of the support, such that condensation resulting from use of the consumable is not absorbed into the support 80 through the surface 88 of the support. In some non-illustrated examples of consumables 18 of the present disclosure, the surface 88 may be treated to be non-absorbent prior to application of the discrete portions 84 of aerosol-forming material. In the consumable 18 of Figures 5 and 6, the support is a laminate having a paper layer and an aluminum foil layer (the layers of the laminate are not shown), with the aluminum foil layer making up the surface 88 of the support 80.

[0189] The compressible absorbent material 86 is a mixture of one or more of cellulose acetate, airlaid paper, cotton-based material, shredded paper, and cut rag tobacco. The one or more of the cellulose acetate, airlaid paper, cotton-based material, shredded paper, and cut rag tobacco are in the form of longitudinally stretched strips or strips that are twisted together to form a three-dimensional matrix that is porous and capable of absorbing and retaining condensation that occurs in the receiver.

[0190] The cover 82 is formed of a non-rigid, porous material and is supported by a compressible absorbent material 86 to prevent the cover 82 from collapsing into the discrete portions 84 of aerosol-forming material.

[0191] The cover 82 covers a portion of the support portion 80 extending from the first end 80A toward, but not reaching, the second end 80B. Between the cover 82 and the second end 80B is a portion of the support portion 80 that does not support discrete portions of aerosol-generating material 84 and is not overlapped by the compressible absorbent material 86. This portion serves as a handle for a user to insert or remove the consumable 18 from the receptacle 6.

[0192] The above description is by way of example only, and those skilled in the art will recognize that modifications may be made to the described embodiments without departing from the scope of the disclosed invention. Still other modifications within the scope of the invention will be apparent to those skilled in the art in light of a review of the present disclosure.

[0193] Various aspects of the devices and consumables disclosed in the various embodiments may be used alone or in combination, or in various configurations not specifically discussed in the above embodiments. Thus, the present disclosure is not limited in its application to the details and configurations of the components described in the above description or drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although specific embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made without departing from the invention in its broader aspects. The scope of the following claims is not limited by the embodiments described in the above examples, but is to be accorded the broadest reasonable interpretation consistent throughout this specification.

Claims

1. 1. A non-flammable aerosol delivery device suitable for use with a consumable product, comprising: the device comprising a receptacle for a consumable product and a compression element; the receptacle is configured to allow insertion and removal of a consumable into and from the receptacle; A device, wherein the compression element is configured to wipe or apply a compressive force to at least a portion of the consumable while the consumable is being removed from the receptacle.

2. The device of claim 1 , wherein the consumable moves relative to the compression element and the receiver when the consumable is removed from the receiver.

3. 3. The device of claim 1 or 2, wherein the compression element at least partially defines a compression zone through which at least a portion of the consumable passes while the consumable is being removed from the receptacle, the compression zone being configured such that wiping or application of the compression force occurs as the consumable passes through the compression zone.

4. The device of claim 3 , wherein the compression zone is of fixed dimension.

5. The device of claim 3 , wherein at least one dimension of the compression zone is variable.

6. The device of claim 3 , wherein at least one dimension of the compression zone is variable, the or each dimension variation being dependent on a dimension of the consumable.

7. A device according to any preceding claim, wherein the compression element is biased towards the consumable by a biasing means.

8. The device of any one of claims 1 to 7, wherein the compression element is configured to apply a predetermined compressive force to the consumable while the consumable is being removed from the receptacle.

9. 8. The device of claim 1, wherein the compression element is configured to apply a compressive force within a predetermined range to the consumable while the consumable is being removed from the receiver.

10. The device according to any one of claims 1 to 9, wherein the compression element comprises an actuating portion and a fixed portion, the actuating portion being capable of approaching or retracting relative to the fixed portion.

11. The device according to any one of claims 1 to 10, wherein the compression element comprises one or more rollers.

12. The device of claim 11 , wherein the compression element comprises a pair of rollers between which the consumable passes while being removed from the receptacle.

13. A device according to any preceding claim, wherein at least one portion of the compression element is biased towards a different portion of the compression element while the consumable is being removed from the receptacle.

14. 14. The device of any one of claims 1 to 13, wherein the compression element is configured to enable insertion and removal of the consumable into and from the receptacle through the compression element, the compression element applying a first compression force to the consumable when the consumable is inserted into the receptacle and the compression element applying a second compression force to the consumable when the consumable is removed from the receptacle, the second compression force being greater than the first compression force.

15. The device of any one of claims 1 to 13, wherein the receiver is configured to allow the consumable to be inserted through a first opening and to allow the consumable to be removed through a second opening.

16. The device of any one of claims 1 to 14, wherein the receptacle is configured to allow insertion and removal of the consumable through a single opening.

17. 17. The device of claim 15 or 16, wherein the compression element is located in or adjacent to the opening through which the consumable is removed from the receptacle.

18. A device according to any one of claims 1 to 17, wherein the device comprises a liquid recovery element configured to recover liquid wiped or squeezed from the consumable by the compression element as the consumable is removed from the receiver.

19. The device of claim 18 , wherein the liquid recovery element comprises a liquid storage element.

20. The device of claim 19, wherein the liquid recovery element is emptied by a user.

21. The device of claim 19 , wherein the liquid recovery element is user replaceable.

22. A consumable for use with a device according to any preceding claim, wherein at least a part of the consumable is deformable by compression.

23. 23. The consumable of claim 22, wherein at least a portion of the consumable is elastically deformable upon compression.

24. 24. The consumable of claim 22 or 23, wherein at least a portion of the consumable is configured to absorb condensation.

25. 25. The consumable of claim 24, wherein at least a portion of the consumable is porous.

26. 26. The consumable of claim 25, wherein at least the porous portion of the consumable is deformable by compression.

27. 27. The consumable of any one of claims 22-26, wherein at least a portion of the consumable comprises cellulose acetate, airlaid paper, a cotton-based material, shredded paper, and cut rag tobacco, or a mixture of two or more of these materials.

28. 28. The consumable product of claim 27, wherein the one or more of cellulose acetate, airlaid paper, cotton-based material, shredded paper, and cut rag tobacco are longitudinally oriented strips or strips, the strips or strips being intermixed to form a matrix of the strips or strips.

29. An aerosol delivery system comprising an aerosol delivery device according to any one of claims 1 to 21 and a consumable product according to any one of claims 22 to 28.

30. A method for generating an aerosol from a consumable product according to any one of claims 22 to 28, using an aerosol generation device according to any one of claims 1 to 21.

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