Formulation for use in aerosol generating systems

Abstract

The present invention provides a formulation (311) for use in an aerosol generating system. [Solution] The formulation (311) comprises one or more aerosol-forming bodies and one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch, and the formulation (311) has a melting point of 100 to 300 degrees Celsius. An aerosol-generating article (300) for use in an aerosol-generating system, the aerosol-generating article (300) comprises the formulation (311). The aerosol-generating system comprises the formulation (311) and an atomizer (322) configured to generate an aerosol from the formulation (311).

Description

Technical Field

[0001] The present invention relates to a formulation for use in an aerosol generation system. The present invention also relates to an aerosol article comprising a formulation for use in an aerosol generation system, and an aerosol generation system comprising the formulation and an atomizer.

Background Art

[0002] An aerosol generation system for delivering an aerosol to a user typically comprises an atomizer configured to generate an inhalable aerosol from a formulation. Some known aerosol generation systems include a thermal atomizer, such as an electric heater, configured to heat and vaporize the formulation to generate an aerosol. A typical formulation for an aerosol generation system is a nicotine formulation, which may be a liquid nicotine formulation comprising an aerosol former such as glycerin and / or propylene glycol.

[0003] When used in an aerosol generation system, it is desirable to provide a formulation that exhibits a reduced risk of leakage compared to typical formulations.

Summary of the Invention

[0004] A formulation for use in an aerosol generation system is provided. The formulation may comprise one or more aerosol formers. The formulation may comprise one or more polymers. The one or more polymers may be selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch. The formulation may have a melting point between 60°C and 300°C.

[0005] A formulation for use in an aerosol generating system is provided, comprising one or more aerosol-forming bodies and one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch, wherein the formulation has a melting point of 60 to 300 degrees Celsius.

[0006] Aerosol generating articles for aerosol generating systems are also provided, the aerosol generating articles being formulations comprising one or more aerosol-forming bodies and one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch, the formulations having a melting point of 60 to 300 degrees Celsius.

[0007] An aerosol generator is also provided, comprising one or more aerosol-forming bodies and a formulation comprising one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch, wherein the formulation has a melting point between 60 and 300 degrees Celsius.

[0008] An aerosol generating system is also provided, comprising one or more aerosol-forming bodies and a formulation comprising one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch, wherein the formulation has a melting point between 60 and 300 degrees Celsius.

[0009] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release volatile compounds that can form aerosols. Such volatile compounds may be released by heating the aerosol-forming substrate or by other aerosolizing means. The aerosol-forming substrate may be a liquid, and the liquid may be an e-liquid. The liquid may be a solution. The liquid may be a colloid. The colloid may have discontinuous solid particles dispersed in a continuous liquid. The colloid may have discontinuous liquid particles dispersed in a continuous liquid. The colloid may have discontinuous liquid particles dispersed in a continuous solid.

[0010] Unless otherwise stated, the weight percentages of the components of the formulations listed herein are based on the total weight of the formulation.

[0011] Given that the melting point of the formulation is between 60 and 300 degrees Celsius, the formulation is not a liquid at standard temperature and pressure. At standard temperature and pressure, the formulation may be a solid or colloid having, for example, a solid continuous phase and a liquid dispersed phase. Therefore, at standard temperature and pressure, when stored in the storage section of an aerosol generating article, aerosol generating device, or aerosol generating system, the formulation may not flow readily until it is heated.

[0012] Advantageously, due to the melting point of the formulation, it cannot easily leak from an aerosol generating article, aerosol generating device, or aerosol generating system during use, before heating. Therefore, the melting point of the formulation can reduce the risk of leakage, for example, during transport or storage of an aerosol generating article, aerosol generating device, or aerosol generating system containing the formulation. Consequently, the formulation can extend the shelf life of an aerosol generating article, aerosol generating device, or aerosol generating system.

[0013] When the formulation is heated between 60°C and 300°C, at least a portion of the formulation may migrate to or begin to migrate to the liquid phase. If the formulation is a liquid, it can flow readily and be vaporized into an aerosol by a heater in an aerosol generating article, aerosol generating device, or aerosol generating system.

[0014] After use of an aerosol generating article, aerosol generating device, or aerosol generating system, if the formulation cools to below 60 degrees Celsius, the formulation may transition back to a solid or colloid with a solid continuous phase. Advantageously, this phase transition returns the formulation to a non-flowing state, which means a reduced risk of leakage or spillage of the formulation from the aerosol generating article, aerosol generating device, or aerosol generating system during heating cycles.

[0015] The formulation may be solid at standard temperature and pressure.

[0016] The formulation may be a colloid at standard temperature and pressure. The colloid may have a solid continuous phase at standard temperature and pressure. The colloid may have a liquid dispersion phase at standard temperature and pressure. In one embodiment, the colloid may have a solid continuous phase and a liquid dispersion phase at standard temperature and pressure.

[0017] The formulation may contain approximately 10% by weight or more of aerosol-forming material. The formulation may contain approximately 15% by weight or more of aerosol-forming material. The formulation may contain approximately 20% by weight or more of aerosol-forming material. The formulation may contain approximately 25% by weight or more of aerosol-forming material. The formulation may contain approximately 30% by weight or more of aerosol-forming material. The formulation may contain approximately 35% by weight or more of aerosol-forming material. The formulation may contain approximately 40% by weight or more of aerosol-forming material. The formulation may contain approximately 45% by weight or more of aerosol-forming material. The formulation may contain approximately 50% by weight or more of aerosol-forming material. The formulation may contain approximately 55% by weight or more of aerosol-forming material. The formulation may contain approximately 60% by weight or more of aerosol-forming material. The formulation may contain approximately 65% ​​by weight or more of aerosol-forming material. The formulation may contain approximately 70% by weight or more of aerosol-forming material. The formulation may contain approximately 75% by weight or more of aerosol-forming material. The formulation may contain approximately 80% by weight or more of aerosol-forming material.

[0018] The formulation may have an aerosol-forming content of approximately 90% by weight or less. The formulation may have an aerosol-forming content of approximately 85% by weight or less. The formulation may have an aerosol-forming content of approximately 80% by weight or less. The formulation may have an aerosol-forming content of approximately 75% by weight or less. The formulation may have an aerosol-forming content of approximately 70% by weight or less. The formulation may have an aerosol-forming content of approximately 65% ​​by weight or less. The formulation may have an aerosol-forming content of approximately 60% by weight or less. The formulation may have an aerosol-forming content of approximately 55% by weight or less. The formulation may have an aerosol-forming content of approximately 50% by weight or less. The formulation may have an aerosol-forming content of approximately 45% by weight or less. The formulation may have an aerosol-forming content of approximately 40% by weight or less. The formulation may have an aerosol-forming content of approximately 35% by weight or less. The formulation may have an aerosol-forming content of approximately 30% by weight or less. The formulation may contain an aerosol-forming agent content of approximately 25% by weight or less.

[0019] Preferably, the formulation may have an aerosol-forming content between about 20% by weight and about 85% by weight.

[0020] The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 80% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 75% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 70% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 65% ​​by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 60% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 55% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 50% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 45% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 40% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 35% by weight. For example, the formulation may have an aerosol-forming material content between approximately 20% and 25% by weight.

[0021] The formulation may have an aerosol-forming content between approximately 25% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 30% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 35% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 40% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 45% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 50% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 55% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 60% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 20% by weight and approximately 65% ​​by weight. The formulation may have an aerosol-forming content between approximately 70% by weight and approximately 85% by weight. The formulation may have an aerosol-forming content between approximately 75% by weight and approximately 85% by weight. For example, the formulation may have an aerosol-forming content between approximately 80% by weight and approximately 85% by weight.

[0022] The formulation may have an aerosol-forming content between approximately 25% by weight and approximately 80% by weight. The formulation may have an aerosol-forming content between approximately 25% by weight and approximately 75% by weight. The formulation may have an aerosol-forming content between approximately 30% by weight and approximately 70% by weight. The formulation may have an aerosol-forming content between approximately 30% by weight and approximately 65% ​​by weight. The formulation may have an aerosol-forming content between approximately 35% by weight and approximately 60% by weight.

[0023] Preferably, the formulation may have an aerosol former content between about 35% and about 55% by weight. The formulation may have an aerosol former content between about 40% and about 55% by weight. The formulation may have an aerosol former content between about 40% and about 50% by weight. The formulation may have an aerosol former content between about 45% and about 50% by weight.

[0024] The formulation may include one or more aerosol formers selected from the group consisting of 1,3 - butanediol, glycerin, propylene glycol, triethylene glycol, and sorbitol. Glycerin may include vegetable glycerin.

[0025] In some preferred embodiments, one or more aerosol formers include a large amount of glycerin. Glycerin - based formulations have been found to provide better, harder solid materials. Also, by including a small amount of propylene glycol in glycerin - based formulations, a solid with lower rigidity or brittleness than a glycerin - based composition without propylene glycol can be provided.

[0026] Using sorbitol as at least one of the aerosol formers is advantageous because sorbitol is less hygroscopic compared to other aerosol formers, and as a result, the formulation has reduced water absorption from the environment and can be more stable under humid conditions.

[0027] Advantageously, including propylene glycol in the formulation results in a solid or colloidal formulation that is less rigid, less brittle, and easier to form in a plug. These properties improve the subsequent processing and handling of the formulation during the manufacturing process.

[0028] Advantageously, both glycerin and sorbitol may be less volatile than propylene glycol and may evaporate under warm conditions.

[0029] One or more aerosol formers may include a combination of glycerin and propylene glycol. One or more aerosol formers may include a combination of vegetable glycerin and propylene glycol.

[0030] As described below, including propylene glycol in the formulation may improve the vaporization of the formulation, which can lead to the production of more aerosol for a given heating cycle.

[0031] By including propylene glycol in a glycerin-based formulation containing nicotine, since propylene glycol has a lower boiling point (188 °C) compared to glycerin (290 °C), more efficient evaporation of nicotine can also result in an improvement in the nicotine content of the aerosol. However, if there is a large amount of propylene glycol in the formulation, since propylene glycol can evaporate during the heating cycle, the nicotine content of the aerosol will decrease. Therefore, it may be advantageous to have a limited amount of propylene glycol in the nicotine formulation.

[0032] The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the formulation may be 1 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the formulation may be 1.5 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the formulation may be 2 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the formulation may be 2.5 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the formulation may be 3 or more.

[0033] Such a composition has been found to provide a balance of hardness and rigidity or brittleness so as to provide an optimal seal, in addition to the advantageous evaporation characteristics discussed herein.

[0034] One or more aerosol-forming bodies may contain one or more polyhydric alcohols. One or more polyhydric alcohols may contain one or more water-miscible polyhydric alcohols. As used herein, the term “water-miscible polyhydric alcohol” refers to a polyhydric alcohol that is liquid at 20°C and mixes with water in any proportion to form a homogeneous solution.

[0035] Low-density polyethylene may also be used.

[0036] Preferably, one or more polymers are selected from the group consisting of polyvinyl alcohol, polyethylene glycol, polypropylene glycol, and starch.

[0037] It is more preferable that one or more polymers are selected from the group consisting of polyvinyl alcohol, polyethylene glycol, and polypropylene glycol.

[0038] More preferably, one or more polymers are selected from the group consisting of polyvinyl alcohol and polyethylene glycol.

[0039] Most preferably, one or more polymers consist of polyvinyl alcohol.

[0040] All starches consist of varying proportions of amylose and amylopectin. The selection of a particular starch for a formulation may be based on the amylose-to-amylopectin ratio, which depends on the desired function of the starch. The starch may be corn starch or wheat starch. Preferably, the starch is wheat starch.

[0041] Advantageously, compared to wheat starch and corn starch, the use of polyvinyl alcohol in nicotine-containing formulations provides more consistent nicotine delivery to the user.

[0042] Advantageously, compared to cornstarch, the use of wheat starch in nicotine-containing formulations provides more consistent nicotine delivery to the user.

[0043] The formulation may have a polymer content of approximately 0.1 weight percent or more. The formulation may have a polymer content of approximately 0.5 weight percent or more. The formulation may have a polymer content of approximately 1 weight percent or more. The formulation may have a polymer content of approximately 2 weight percent or more. The formulation may have a polymer content of approximately 3 weight percent or more. The formulation may have a polymer content of approximately 4 weight percent or more. The formulation may have a polymer content of approximately 5 weight percent or more. The formulation may have a polymer content of approximately 6 weight percent or more. The formulation may have a polymer content of approximately 7 weight percent or more.

[0044] The formulation may have a polymer content of approximately 10 weight percent or less. The formulation may have a polymer content of approximately 7 weight percent or less. The formulation may have a polymer content of approximately 6 weight percent or less. The formulation may have a polymer content of approximately 5 weight percent or less. The formulation may have a polymer content of approximately 4 weight percent or less. The formulation may have a polymer content of approximately 3 weight percent or less. The formulation may have a polymer content of approximately 2 weight percent or less. The formulation may have a polymer content of approximately 1 weight percent or less.

[0045] The formulation may have a polymer content of approximately 0.5% to approximately 7% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 6% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 5% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 4% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 3% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 2% by weight. The formulation may have a polymer content of approximately 0.5% to approximately 1% by weight.

[0046] The formulation may have a polymer content of approximately 0.1% to approximately 7% by weight. The formulation may have a polymer content of approximately 1% to approximately 7% by weight. The formulation may have a polymer content of approximately 2% to approximately 7% by weight. The formulation may have a polymer content of approximately 3% to approximately 7% by weight. The formulation may have a polymer content of approximately 4% to approximately 7% by weight. The formulation may have a polymer content of approximately 5% to approximately 7% by weight. Nicotine formulations may have a polymer content of approximately 6% to approximately 7% by weight.

[0047] One or more polymers have a weight-average molecular weight (M) of 6000 g / mol or more. w ) may have. One or more polymers may have a weight-average molecular weight of 60,000 g / mol or more. One or more polymers may have a weight-average molecular weight of 100,000 g / mol or more. One or more polymers may have a weight-average molecular weight of 140,000 g / mol or more. One or more polymers may have a weight-average molecular weight of 200,000 g / mol or more.

[0048] One or more polymers may have a weight-average molecular weight of 8,000,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 5,000,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 2,000,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 1,000,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 500,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 200,000 g / mol or less. One or more polymers may have a weight-average molecular weight of 190,000 g / mol or less.

[0049] One or more polymers may have a weight-average molecular weight of 6,000 g / mol to 8,000,000 g / mol. One or more polymers may have a weight-average molecular weight of 60,000 g / mol to 500,000 g / mol. One or more polymers may have a weight-average molecular weight of 100,000 g / mol to 200,000 g / mol. One or more polymers may have a weight-average molecular weight of 140,000 g / mol to 190,000 g / mol.

[0050] The formulation may have a melting point of 60 degrees Celsius or higher. The formulation may have a melting point of 80 degrees Celsius or higher. The formulation may have a melting point of 100 degrees Celsius or higher. The formulation may have a melting point of 120 degrees Celsius or higher. The formulation may have a melting point of 140 degrees Celsius or higher. The formulation may have a melting point of 160 degrees Celsius or higher. The formulation may have a melting point of 180 degrees Celsius or higher. The formulation may have a melting point of 200 degrees Celsius or higher. The formulation may have a melting point of 220 degrees Celsius or higher. The formulation may have a melting point of 240 degrees Celsius or higher. The formulation may have a melting point of 260 degrees Celsius or higher. The formulation may have a melting point of 270 degrees Celsius or higher. The formulation may have a melting point of 280 degrees Celsius or higher. The formulation may have a melting point of 300 degrees Celsius or higher.

[0051] The formulation may have a melting point of 300 degrees Celsius or less. The formulation may have a melting point of 280 degrees Celsius or less. The formulation may have a melting point of 270 degrees Celsius or less. The formulation may have a melting point of 260 degrees Celsius or less. The formulation may have a melting point of 240 degrees Celsius or less. The formulation may have a melting point of 220 degrees Celsius or less. The formulation may have a melting point of 200 degrees Celsius or less. The formulation may have a melting point of 180 degrees Celsius or less. The formulation may have a melting point of 160 degrees Celsius or less. The formulation may have a melting point of 140 degrees Celsius or less. The formulation may have a melting point of 120 degrees Celsius or less. The formulation may have a melting point of 100 degrees Celsius or less. The formulation may have a melting point of 80 degrees Celsius or less. The formulation may have a melting point of 60 degrees Celsius or less.

[0052] The formulation may have a melting point between 60°C and 280°C. The formulation may have a melting point between 60°C and 270°C. The formulation may have a melting point between 60°C and 260°C. The formulation may have a melting point between 60°C and 240°C. The formulation may have a melting point between 60°C and 220°C. The formulation may have a melting point between 60°C and 200°C. The formulation may have a melting point between 60°C and 180°C. The formulation may have a melting point between 60°C and 160°C. The formulation may have a melting point between 60°C and 140°C. The formulation may have a melting point between 60°C and 120°C. The formulation may have a melting point between 60°C and 100°C. The formulation may have a melting point between 60 degrees Celsius and 80 degrees Celsius.

[0053] The formulation may have a melting point between 80°C and 300°C. The formulation may have a melting point between 100°C and 300°C. The formulation may have a melting point between 120°C and 300°C. The formulation may have a melting point between 140°C and 300°C. The formulation may have a melting point between 160°C and 300°C. The formulation may have a melting point between 180°C and 300°C. The formulation may have a melting point between 200°C and 300°C. The formulation may have a melting point between 220°C and 300°C. The formulation may have a melting point between 240°C and 300°C. The formulation may have a melting point between 260°C and 300°C. The formulation may have a melting point between 270°C and 300°C. The formulation may have a melting point between 280°C and 300°C.

[0054] The formulation may have a melting point between 180°C and 300°C. The formulation may have a melting point between 180°C and 280°C. The formulation may have a melting point between 180°C and 270°C. The formulation may have a melting point between 180°C and 260°C. The formulation may have a melting point between 180°C and 240°C. The formulation may have a melting point between 180°C and 220°C. The formulation may have a melting point between 180°C and 200°C.

[0055] The formulation may have a melting point between 80°C and 270°C. The formulation may have a melting point between 100°C and 270°C. The formulation may have a melting point between 120°C and 270°C. The formulation may have a melting point between 140°C and 270°C. The formulation may have a melting point between 160°C and 270°C. The formulation may have a melting point between 200°C and 270°C. The formulation may have a melting point between 220°C and 270°C. The formulation may have a melting point between 240°C and 270°C. The formulation may have a melting point between 260°C and 270°C.

[0056] The formulation may have a melting point between 190°C and 270°C. The formulation may have a melting point between 190°C and 260°C. The formulation may have a melting point between 200°C and 260°C. The formulation may have a melting point between 200°C and 250°C. The formulation may have a melting point between 210°C and 250°C. The formulation may have a melting point between 210°C and 240°C. The formulation may have a melting point between 220°C and 240°C. The formulation may have a melting point between 220°C and 230°C.

[0057] The formulation may have a boiling point of 180 degrees Celsius or higher. The formulation may have a boiling point of 200 degrees Celsius or higher. The formulation may have a boiling point of 220 degrees Celsius or higher. The formulation may have a boiling point of 240 degrees Celsius or higher. The formulation may have a boiling point of 260 degrees Celsius or higher. The formulation may have a boiling point of 270 degrees Celsius or higher. The formulation may have a boiling point of 280 degrees Celsius or higher. The formulation may have a boiling point of 300 degrees Celsius or higher.

[0058] The formulation may have a boiling point of 300 degrees Celsius or lower. The formulation may have a boiling point of 280 degrees Celsius or lower. The formulation may have a boiling point of 270 degrees Celsius or lower. The formulation may have a boiling point of 260 degrees Celsius or lower. The formulation may have a boiling point of 240 degrees Celsius or lower. The formulation may have a boiling point of 220 degrees Celsius or lower. The formulation may have a boiling point of 200 degrees Celsius or lower. The formulation may have a boiling point of 180 degrees Celsius or lower.

[0059] The formulation may have a boiling point between 180°C and 300°C. The formulation may have a boiling point between 200°C and 300°C. The formulation may have a boiling point between 220°C and 300°C. The formulation may have a boiling point between 240°C and 300°C. The formulation may have a boiling point between 260°C and 300°C. The formulation may have a boiling point between 270°C and 300°C. The formulation may have a boiling point between 280°C and 300°C.

[0060] The formulation may have a boiling point between 180°C and 300°C. The formulation may have a boiling point between 180°C and 280°C. The formulation may have a boiling point between 180°C and 270°C. The formulation may have a boiling point between 180°C and 260°C. The formulation may have a boiling point between 180°C and 240°C. The formulation may have a boiling point between 180°C and 220°C. The formulation may have a boiling point between 180°C and 200°C.

[0061] The formulation may have a boiling point between 180°C and 270°C. The formulation may have a boiling point between 200°C and 270°C. The formulation may have a boiling point between 220°C and 270°C. The formulation may have a boiling point between 240°C and 270°C. The formulation may have a boiling point between 260°C and 270°C.

[0062] The formulation may be heat-treated after it has been formed.

[0063] The formulation may be heat-treated at a temperature of approximately 50 degrees Celsius or higher. The formulation may be heat-treated at a temperature of approximately 75 degrees Celsius or higher. The formulation may be heat-treated at a temperature of approximately 100 degrees Celsius or higher. The formulation may be heat-treated at a temperature of approximately 125 degrees Celsius or higher. The formulation may be heat-treated at a temperature of approximately 150 degrees Celsius or higher.

[0064] The formulation may be heat-treated at a temperature of approximately 200 degrees Celsius or lower. The formulation may be heat-treated at a temperature of approximately 175 degrees Celsius or lower. The formulation may be heat-treated at a temperature of approximately 150 degrees Celsius or lower. The formulation may be heat-treated at a temperature of approximately 125 degrees Celsius or lower. The formulation may be heat-treated at a temperature of approximately 100 degrees Celsius or lower.

[0065] The formulation may be heat-treated at a temperature between approximately 75°C and approximately 200°C. The formulation may be heat-treated at a temperature between approximately 75°C and approximately 175°C. The formulation may be heat-treated at a temperature between approximately 75°C and approximately 150°C. The formulation may be heat-treated at a temperature between approximately 75°C and approximately 125°C. The formulation may be heat-treated at a temperature between approximately 75°C and approximately 100°C.

[0066] The formulation may be heat-treated at a temperature between approximately 50°C and approximately 175°C. The formulation may be heat-treated at a temperature between approximately 100°C and approximately 175°C. The formulation may be heat-treated at a temperature between approximately 125°C and approximately 175°C. The formulation may be heat-treated at a temperature between approximately 150°C and approximately 175°C.

[0067] The formulation may be heat-treated in an oven. The formulation may be heat-treated in a ventilated oven.

[0068] Advantageously, heat treatment of the formulation after its formation can reduce its expansion. Heat treatment of the formulation can improve crosslinking between one or more polymers and one or more aerosol-forming bodies.

[0069] The formulation may contain one or more organic acids. In some embodiments, one or more organic acids may be water-soluble organic acids. As used herein in connection with the present invention, the term "water-soluble organic acid" refers to an organic acid that is water-soluble at about 100 mg / mL or more, preferably about 500 mg / mL or more, more preferably about 750 mg / mL or more, and most preferably about 1000 mg / mL or more at 20°C.

[0070] Unless otherwise stated, the water solubility values ​​listed herein are water solubility measured based on the prior test of OECD (1995), Test No. 105: Water Solubility, OECD Guidelines for the Testing of Chemicals, Section 1, OECD Publishing, Paris, https: / / doi.org / 10.1787 / 9789264069589-en. In the stepwise procedure, an increasing volume of distilled water is added to 0.1 g of the sample (solid material must be crushed) in a 10 ml graduated cylinder with a glass stopper at 20°C. However, if the substance is an acid, the sample is added to the distilled water in the first step. After each addition of a certain amount of water, the mixture was shaken for 10 minutes and visually checked for any undissolved portions of the sample. If the sample or a portion of the sample remains undissolved after adding 10 ml of water, the experiment is continued in a 100 ml graduated cylinder. The approximate solubility at which complete dissolution of the sample occurs in that volume of water is shown in Table 1 below.

[0071] When solubility is low, it may take a long time for the substance to dissolve, and at least 24 hours should be allowed. If the substance is still not dissolved after 24 hours, the graduated cylinder is placed in an ultrasonic bath at 40°C for 15 minutes, followed by another 24 hours (up to a maximum of 96 hours). If the substance is still not dissolved, the solubility is considered to be below the limit or to be insoluble. [Table 1]

[0072] Advantageously, if the formulation contains nicotine, the inclusion of organic acids in the formulation may improve the delivery of nicotine to the user.

[0073] Advantageously, the inclusion of organic acids in a formulation can provide a plasticizing effect, which can improve the mechanical properties of the formulation.

[0074] The formulation may contain approximately 0.1% by weight or more of organic acids. The formulation may contain approximately 0.5% by weight or more of organic acids. The formulation may contain approximately 1% by weight or more of organic acids. The formulation may contain approximately 1.5% by weight or more of organic acids. The formulation may contain approximately 2% by weight or more of organic acids. The formulation may contain approximately 2.5% by weight or more of organic acids. The formulation may contain approximately 3% by weight or more of organic acids. The formulation may contain approximately 3.5% by weight or more of organic acids. The formulation may contain approximately 4% by weight or more of organic acids. The formulation may contain approximately 4.5% by weight or more of organic acids. The formulation may contain approximately 5% by weight or more of organic acids.

[0075] The formulation may have an organic acid content of approximately 10 weight percent or less. The formulation may have an organic acid content of approximately 5 weight percent or less. The formulation may have an organic acid content of approximately 4.5 weight percent or less. The formulation may have an organic acid content of approximately 4 weight percent or less. The formulation may have an organic acid content of approximately 3.5 weight percent or less. The formulation may have an organic acid content of approximately 3 weight percent or less. The formulation may have an organic acid content of approximately 2.5 weight percent or less. The formulation may have an organic acid content of approximately 2 weight percent or less. The formulation may have an organic acid content of approximately 1.5 weight percent or less. The formulation may have an organic acid content of approximately 1 weight percent or less. The formulation may have an organic acid content of approximately 0.5 weight percent or less.

[0076] The formulation may have an organic acid content between approximately 0.1% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 0.5% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 1% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 1.5% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 2% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 2.5% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 3% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 3.5% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 4% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 4.5% by weight and approximately 5% by weight.

[0077] The formulation may have an organic acid content between approximately 0.1% by weight and approximately 8% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 5% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 4.5% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 4% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 3.5% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 3% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 2.5% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 2% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 1.5% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 1% by weight. The formulation may have an organic acid content between approximately 0.1% by weight and approximately 0.5% by weight.

[0078] The formulation may have an organic acid content between approximately 0.5% by weight and approximately 4.5% by weight. The formulation may have an organic acid content between approximately 1% by weight and approximately 4.5% by weight. The formulation may have an organic acid content between approximately 1.5% by weight and approximately 4.5% by weight. The formulation may have an organic acid content between approximately 1.5% by weight and approximately 4% by weight. The formulation may have an organic acid content between approximately 2% by weight and approximately 4% by weight. The formulation may have an organic acid content between approximately 2% by weight and approximately 3.5% by weight. The formulation may have an organic acid content between approximately 2.5% by weight and approximately 3.5% by weight. The formulation may have an organic acid content between approximately 2.5% by weight and approximately 3% by weight.

[0079] One or more organic acids may include one or more polycarboxylic acids, one or more monocarboxylic acids, or a combination of monocarboxylic acids and polycarboxylic acids.

[0080] One or more organic acids may be selected from the group consisting of malonic acid, citric acid, 2-ethylbutyric acid, acetic acid, adipic acid, benzoic acid, butyric acid, cinnamic acid, cycloheptane-carboxylic acid, fumaric acid, glycolic acid, hexanoic acid, lactic acid, levulinic acid, malic acid, myristic acid, octanoic acid, oxalic acid, propanoic acid, pyruvic acid, succinic acid, and undecanoic acid.

[0081] In some embodiments, one or more organic acids are selected from the group consisting of malonic acid, citric acid, lactic acid, benzoic acid, levulinic acid, fumaric acid, and acetic acid.

[0082] In some embodiments, one or more organic acids are selected from the group consisting of malonic acid, citric acid, lactic acid, fumaric acid, and acetic acid.

[0083] Most preferably, one or more organic acids consist of lactic acid.

[0084] The preparation may contain one or more metal salts.

[0085] The bonding between one or more metal salts in a formulation and one or more aerosol-forming compounds can increase the boiling point of one or more aerosol-forming compounds. When the formulation contains nicotine, this can be advantageous in that, when used in an aerosol-generating system, it may increase the vaporization efficiency of nicotine from the formulation compared to a typical liquid nicotine formulation that does not contain one or more metal salts.

[0086] One or more metal salts may be selected from the group consisting of metal alginate, metal benzoate, metal cinnamate, metal cycloheptanecarboxylate, metal levulinate, metal propanoate, metal stearate, and metal undecanoate.

[0087] It is preferable that one or more metal salts are selected from the group consisting of metal cinnamate, metal cycloheptanecarboxylate, metal levulinate, metal propanoate, metal stearate, and metal undecanoate.

[0088] Preferably, one or more metal salts are selected from the group consisting of metal benzoate, metal cinnamate, metal cycloheptanecarboxylate, metal levulinate, metal propanoate, metal stearate, and metal undecanoate.

[0089] It is preferable that one or more metal salts are selected from the group consisting of metal cinnamate, metal cycloheptanecarboxylate, metal stearate, and metal undecanoate.

[0090] One or more salts may be salts of any suitable metal.

[0091] Preferably, one or more metal salts are alkali metal salts.

[0092] It is more preferable that one or more metal salts are sodium salts.

[0093] Preferably, the volatile barrier comprises one or more non-carbohydrate sodium salts.

[0094] Metal salts with high molecular weights may improve the aforementioned advantages regarding nicotine vaporization efficiency and solid layer formation rate. However, if the molecular weight of the metal salt is excessively high, properties such as solubility begin to be negatively affected. Advantageously, including sodium stearate in the formulation may provide an optimal balance between maintaining solubility and improving nicotine vaporization efficiency and solid layer formation rate.

[0095] The formulation more preferably contains one or more sodium salts selected from the group consisting of sodium benzoate, sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propanoate, sodium stearate, and sodium undecanoate.

[0096] It is preferable that one or more metal salts be selected from the group consisting of sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propanoate, sodium stearate, and sodium undecanoate.

[0097] It is preferable that one or more sodium salts are selected from the group consisting of sodium benzoate, sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propanoate, sodium stearate, and sodium undecanoate.

[0098] It is preferable that one or more metal salts be selected from the group consisting of sodium cinnamate, sodium cycloheptanecarboxylate, sodium stearate, and sodium undecanoate.

[0099] The formulation most preferably contains sodium stearate.

[0100] Advantageously, the inclusion of one or more metal stearates in the formulation improves its mechanical properties.

[0101] Advantageously, the covalent bonds between one or more metal stearates in the formulation and one or more aerosol-forming compounds can further increase the boiling point of one or more aerosol-forming compounds. When the formulation contains nicotine, this may, advantageously, increase the vaporization efficiency of nicotine from the nicotine formulation when used in an aerosol-generating system, compared to typical liquid nicotine formulations that do not contain one or more metal stearates.

[0102] The formulation may contain a metal salt content of approximately 0.1 weight percent or more. The formulation may contain a metal salt content of approximately 0.25 weight percent or more. The formulation may contain a metal salt content of approximately 0.5 weight percent or more. The formulation may contain a metal salt content of approximately 0.75 weight percent or more. The formulation may contain a metal salt content of approximately 1 weight percent or more. The formulation may contain a metal salt content of approximately 1.25 weight percent or more. The formulation may contain a metal salt content of approximately 1.5 weight percent or more. The formulation may contain a metal salt content of approximately 1.75 weight percent or more.

[0103] The formulation may have a metal salt content of approximately 5 weight percent or less. The formulation may have a metal salt content of approximately 3 weight percent or less. The formulation may have a metal salt content of approximately 2 weight percent or less. The formulation may have a metal salt content of approximately 1.75 weight percent or less. The formulation may have a metal salt content of approximately 1.5 weight percent or less. The formulation may have a metal salt content of approximately 1.25 weight percent or less. The formulation may have a metal salt content of approximately 1 weight percent or less. The formulation may have a metal salt content of approximately 0.75 weight percent or less. The formulation may have a metal salt content of approximately 0.5 weight percent or less.

[0104] The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 5 weight percent. The nicotine formulation may have a metal salt content between approximately 0.1 weight percent and approximately 3 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 2 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 1.75 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 1.5 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 1.25 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 1 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 0.75 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 0.5 weight percent. The formulation may have a metal salt content between approximately 0.1 weight percent and approximately 0.25 weight percent.

[0105] The formulation may have a metal salt content between approximately 0.25% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 0.5% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 0.75% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 1% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 1.25% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 1.5% by weight and approximately 2% by weight. The formulation may have a metal salt content between approximately 1.75% by weight and approximately 5% by weight.

[0106] The preparation may contain nicotine. The preparation may contain liquid nicotine.

[0107] Nicotine may be a nicotine base. Nicotine may be a nicotine salt. The preparation may contain natural nicotine. The preparation may contain synthetic nicotine.

[0108] Nicotine salts may be formed using one or more organic acids. Nicotine preparations may contain one or more organic acids.

[0109] Nicotine may be provided as a tobacco extract that may contain other tobacco components, such as tobacco flavoring components.

[0110] The formulation may contain approximately 0.5% by weight or more of nicotine. The formulation may contain approximately 1% by weight or more of nicotine. The formulation may contain approximately 1.5% by weight or more of nicotine. The formulation may contain approximately 2% by weight or more of nicotine. The formulation may contain approximately 3% by weight or more of nicotine. The formulation may contain approximately 5% by weight or more of nicotine.

[0111] The formulation may have a nicotine content of approximately 10 weight percent or less. The formulation may have a nicotine content of approximately 8 weight percent or less. The formulation may have a nicotine content of approximately 5 weight percent or less. The formulation may have a nicotine content of approximately 3 weight percent or less. The formulation may have a nicotine content of approximately 2 weight percent or less. The formulation may have a nicotine content of approximately 1 weight percent or less.

[0112] The formulation may have a nicotine content between approximately 0.5% by weight and approximately 10% by weight. The formulation may have a nicotine content between approximately 0.5% by weight and approximately 8% by weight. The formulation may have a nicotine content between approximately 0.5% by weight and approximately 5% by weight. The formulation may have a nicotine content between approximately 0.5% by weight and approximately 3% by weight. The formulation may have a nicotine content between approximately 0.5% by weight and approximately 2% by weight. The formulation may have a nicotine content between approximately 0.5% by weight and approximately 1% by weight.

[0113] The formulation may have a nicotine water content of approximately 1% to approximately 5% by weight. The formulation may have a nicotine water content of approximately 2% to approximately 5% by weight. The formulation may have a nicotine water content of approximately 3% to approximately 5% by weight. The formulation may have a nicotine water content of approximately 4% to approximately 5% by weight.

[0114] The formulation may have a nicotine water content of approximately 1% to approximately 2% by weight. The formulation may have a nicotine water content of approximately 2% to approximately 3% by weight. The formulation may have a nicotine water content of approximately 3% to approximately 5% by weight. The formulation may have a nicotine water content of approximately 2% to approximately 4% by weight. The formulation may have a nicotine water content of approximately 1% to approximately 4% by weight.

[0115] The formulation may contain water.

[0116] The formulation may have a water content of approximately 10% by weight or more. The formulation may have a water content of approximately 20% by weight or more. The formulation may have a water content of approximately 30% by weight or more. The formulation may have a water content of approximately 40% by weight or more. The formulation may have a water content of approximately 50% by weight or more. The formulation may have a water content of approximately 60% by weight or more.

[0117] The formulation may have a water content of approximately 70% by weight or less. The formulation may have a water content of approximately 60% by weight or less. The formulation may have a water content of approximately 50% by weight or less. The formulation may have a water content of approximately 40% by weight or less. The formulation may have a water content of approximately 30% by weight or less. The formulation may have a water content of approximately 20% by weight or less.

[0118] The formulation may have a water content between approximately 20% by weight and approximately 70% by weight. The formulation may have a water content between approximately 20% by weight and approximately 60% by weight. The formulation may have a water content between approximately 20% by weight and approximately 50% by weight. The formulation may have a water content between approximately 20% by weight and approximately 40% by weight. The formulation may have a water content between approximately 20% by weight and approximately 30% by weight.

[0119] The formulation may have a water content between approximately 30% by weight and approximately 60% by weight. The formulation may have a water content between approximately 40% by weight and approximately 60% by weight. The formulation may have a water content between approximately 50% by weight and approximately 50% by weight.

[0120] The formulation may have a water content between approximately 10% by weight and approximately 70% by weight. The formulation may have a water content between approximately 30% by weight and approximately 50% by weight.

[0121] The aerosol generation system may include an aerosol generating article.

[0122] The aerosol generating article may include an atomizer configured to generate an aerosol from the formulation.

[0123] The aerosol-generating item may be a cartridge.

[0124] The cartridge containing the formulation and atomizer may also be called a "cartomizer."

[0125] The atomizer may be a heated atomizer.

[0126] As used herein, the term “thermal atomizer” describes an atomizer configured to heat a formulation to generate an aerosol.

[0127] The aerosol generating article may include any suitable type of thermal atomizer. For example, the thermal atomizer may include a heater. The thermal atomizer may include an electric heater. In one example, the thermal atomizer may include an electric heater that includes a resistive heating element. In another example, the thermal atomizer may include an electric heater that includes an inductive heating element.

[0128] The heater may include a heating element. The heating element may be a grid element. The heating element may be a grid layer. The heating element may be a mesh element. The heating element may be a mesh layer. In such embodiments, the formulation may flow into the gaps forming the grid or mesh.

[0129] The atomizer may be a non-thermal atomizer.

[0130] As used herein, the term “non-thermal atomizer” describes an atomizer configured to generate an aerosol from a formulation by means other than heating.

[0131] The aerosol generating article may be equipped with any suitable type of non-thermal atomizer. For example, the non-thermal atomizer may be an impact jet atomizer. In another example, the non-thermal atomizer may be an ultrasonic atomizer. In yet another example, the non-thermal atomizer may be a vibrating mesh atomizer.

[0132] The aerosol-generating article may include a porous material for hosting the formulation. The porous material may be crimped.

[0133] The aerosol generation system may include an aerosol generating device.

[0134] The aerosol generator may include a storage section for containing the formulation.

[0135] The aerosol generator may include a housing that defines a device cavity configured to receive at least a portion of the aerosol generating article.

[0136] The aerosol generator may include an atomizer configured to generate an aerosol from the formulation.

[0137] The atomizer may be a heated atomizer.

[0138] As used herein, the term “thermal atomizer” describes an atomizer configured to heat a formulation to generate an aerosol.

[0139] The aerosol generator may include any suitable type of thermal atomizer. For example, the thermal atomizer may include a heater. The thermal atomizer may include an electric heater. In one example, the thermal atomizer may include an electric heater that includes a resistive heating element. In another example, the thermal atomizer may include an electric heater that includes an induction heating element.

[0140] The heater may include a heating element. The heating element may be a grid element. The heating element may be a grid layer. The heating element may be a mesh element. The heating element may be a mesh layer. In such embodiments, the formulation may flow into the gaps forming the grid or mesh.

[0141] The aerosol generator may include a porous material for hosting the formulation. The porous material may be crimped.

[0142] The present invention further provides an atomizer configured to generate an aerosol from a formulation, and an aerosol generating system comprising the formulation according to the present invention.

[0143] The atomizer may be a heated atomizer.

[0144] The aerosol generation system may be equipped with any suitable type of thermal atomizer.

[0145] A thermal atomizer may be equipped with an electric heater. For example, a thermal atomizer may be equipped with an electric heater that includes a heating element, which may be a resistive heating element or an inductive heating element.

[0146] The heating element may be a grid, mesh element, or layer. In such embodiments, the formulation may flow into the gaps forming the grid or mesh element.

[0147] The aerosol generating system may comprise an aerosol generating article according to the present invention, which includes a formulation, and an aerosol generating device comprising a housing that defines a device cavity configured to receive at least a portion of the aerosol generating article.

[0148] The aerosol generating system may comprise a consumable aerosol generating article according to the present invention, which includes a formulation, and a reusable aerosol generating device having a housing that defines a device cavity configured to receive at least a portion of the aerosol generating article.

[0149] The aerosol generator may include a battery and a control device.

[0150] The aerosol generating system may include an aerosol generating article according to the present invention, which includes a formulation and an atomizer, and an aerosol generating device having a housing that defines a device cavity configured to receive at least a portion of the aerosol generating article.

[0151] The aerosol generating system may include an aerosol generating article according to the present invention, which includes a formulation, and an aerosol generating device having a housing that defines a device cavity configured to receive at least a portion of the aerosol generating article and an atomizer.

[0152] The aerosol generating system may include a porous material for hosting the formulation. The porous material may be crimped.

[0153] To avoid misunderstanding, the above-mentioned characteristics relating to formulations may also, where appropriate, relate to aerosol-generating articles, aerosol-generating devices, and aerosol-generating systems. Similarly, the above-mentioned characteristics relating to aerosol-generating articles may also, where appropriate, relate to aerosol-generating devices and aerosol-generating systems, and vice versa.

[0154] Embodiments of the present invention will be described with reference to the following examples and accompanying drawings, for illustrative purposes only. [Brief explanation of the drawing]

[0155] [Figure 1] Figure 1 is a schematic cross-sectional side view of an aerosol generating system comprising an aerosol generating device and an aerosol generating article containing a formulation according to the present invention. [Figure 2] Figure 2 is a schematic cross-sectional side view of the aerosol generating system of Figure 1, in which the aerosol generating article is inserted into the aerosol generating device. [Figure 3] Figure 3 is a schematic cross-sectional side view of another aerosol generating system equipped with an aerosol generating article containing the formulation according to the present invention. [Figure 4] Figure 4 is a schematic cross-sectional side view of an aerosol-generating article containing the formulation according to the present invention, before heating of the aerosol-forming substrate. [Figure 5] Figure 5 is a schematic cross-sectional side view of an aerosol-generating article containing the formulation according to the present invention during heating of the aerosol-forming substrate. [Figure 6] Figure 6 is a graph showing the average aerosolized mass per inhalation in mg for a range of aerosol-forming compositions. [Figure 7] Figure 7 is a graph showing the average nicotine content per puff in mg for a range of aerosol-forming compositions. [Figure 8]Figure 8 is a graph showing the average nicotine percentage for a range of aerosol-forming compositions. [Modes for carrying out the invention]

[0156] Aerosol generating systems for delivery to users typically comprise an atomizer configured to generate an inhalable aerosol from a formulation. Some known aerosol generating systems include thermal atomizers, such as electric heaters, configured to heat and vaporize the formulation to generate an aerosol. Typical formulations for aerosol generating systems are nicotine formulations, which may be liquid nicotine formulations containing aerosol-forming agents such as glycerin and / or propylene glycol.

[0157] An aerosol generating system may comprise an aerosol generating device and an aerosol generating article containing a formulation. A typical aerosol generating system may suffer from the problem of undesirable leakage of the formulation from the aerosol generating article. Leakage of the formulation can occur in many different situations, such as when there is too much formulation in the storage compartment of the aerosol generating article, when the material forming one or more components of the aerosol generating article or system does not hold the formulation as designed, pressure changes at high altitudes during air transport, or high temperatures due to hot weather.

[0158] It would be desirable to provide a formulation that exhibits a reduced risk of leakage from aerosol-generating articles or systems compared to typical nicotine formulations.

[0159] Figures 1 and 2 show an aerosol generation system including an aerosol generator 10 and an aerosol generating article 20. In this example, the aerosol generating article 20 is a cartridge.

[0160] The aerosol generator 10 is configured to receive an aerosol generating article 20 in a cavity 18. The aerosol generating article 20 includes a housing 24. The housing 24 defines a storage section 22. The storage section 22 has a storage opening that can be covered by a removable cover 26. The aerosol forming substrate is located inside the storage section 22. The aerosol forming substrate inside the storage section 22 may be a formulation according to the present invention.

[0161] In the examples shown in Figures 1 and 2, the aerosol generating article 20 includes an atomizer configured to generate an aerosol from the formulation in the storage section 22. The atomizer may be a thermal atomizer. In the examples shown in Figures 1 and 2, the atomizer is an electric heater 30. In another example, the atomizer may be a different type of atomizer, such as a non-thermal atomizer.

[0162] In the examples shown in Figures 1 and 2, the aerosol generating article 20 contains an aerosol-forming substrate and an atomizer, and may therefore be called a “cartomizer.”

[0163] The aerosol-generating article 20 can be replaced by the user when the aerosol-forming substrate provided in the storage unit 22 is depleted.

[0164] Figure 1 shows the aerosol generating article 20 immediately before insertion into the aerosol generating device 10. Arrow 1 in Figure 1 indicates the direction of insertion of the aerosol generating article 20 into the aerosol generating device 10.

[0165] The aerosol generator 10 is portable and has a size comparable to a conventional cigar or cigarette. The aerosol generator 10 comprises a main body 11 and a mouthpiece portion 12. The main body 11 includes a battery 14 such as a lithium iron phosphate battery, a control device 16, and a cavity 18.

[0166] The mouthpiece portion 12 is connected to the main body 11 by a hinge connection portion 21 and is movable between the open position shown in Figure 1 and the closed position shown in Figure 2. The mouthpiece portion 12 is fixed in the open position to allow insertion and removal of the aerosol generating article 20, and is fixed in the closed position when the aerosol generating system is used to generate aerosols.

[0167] The mouthpiece portion 12 is equipped with multiple air inlets 13 and outlets 15. During use, the user inhales or inhales air through the outlets 15, drawing air from the air inlets 13 through the mouthpiece portion to the outlets 15, and then into the user's mouth or lungs. An internal baffle 17 is provided to force the air to flow through the mouthpiece portion 12 and over the aerosol generating article 20.

[0168] The housing 24 contains a capillary material immersed in an aerosol-forming substrate. In this embodiment, the capillary material is installed adjacent to the electric heater 30.

[0169] The cavity 18 has a circular cross-section and is sized to accommodate the housing 24 of the aerosol generating article 20. An electrical connector 19 is provided on the side of the cavity 18 to provide an electrical connection between the control device 16, the battery 14, and the corresponding electrical contacts of the aerosol generating article 20. This configuration allows power to be supplied to the electric heater 30.

[0170] Figure 2 shows the aerosol generating article 20 inserted into the cavity 18 of the aerosol generating device 10. In this position, the electrical connector 19 is positioned against the corresponding electrical contacts on the aerosol generating article 20. The cover 26 is completely removed and the mouthpiece portion 12 is moved to the closed position.

[0171] The mouthpiece portion 12 is held in the closed position by a clasp mechanism (not shown). It will be apparent to those skilled in the art that other suitable mechanisms for holding the mouthpiece in the closed position may be used, such as a snap-on or magnetic closure.

[0172] The mouthpiece portion 12 in the closed position keeps the aerosol generating article 20 in electrical contact with the electrical connector 19, regardless of the orientation of the aerosol generating system, so that good electrical connection is maintained during use.

[0173] When the aerosol generator 10 is activated by the user during use, the electric heater 30 melts and aerosolizes at least a portion of the aerosol-forming substrate in the storage section 22. As the user inhales or sucks in the outlet 15, air flows through the air inlet 13 over the electric heater 30 and the capillary material. The air flowing over the electric heater 30 and the capillary material entrains vaporized aerosol components from the vaporized aerosol-forming substrate. The air containing the entrained aerosol-forming substrate then flows out to the user through the outlet 15. This airflow regime is shown in Figure 2.

[0174] Figure 3 shows an alternative embodiment of an aerosol generating system including an aerosol generating article 200. In this example, the aerosol generating article 200 is the “lipstick” forward mechanism for the aerosol generating article 200. The aerosol generating article 200 includes a body 212. The body 212 defines a storage section 210. The storage section 210 has a storage section opening 215. The aerosol forming substrate 211 is located inside the storage section 210. A heater 222 is located close to the storage section opening 215. In this example, the body 212 includes a ring or rotating element 251 coupled to a movable rigid base 213. The ring or rotating element 251 converts rotational motion into lateral motion via a spiral or helical groove 214. Pins (not shown) connect the rigid base 213 to the spiral or helical groove 214 to provide lateral motion of the aerosol forming substrate 211. The aerosol-forming substrate 211 is a formulation according to the present invention and may flow into and through the mesh layer of the heater 222.

[0175] In an alternative embodiment (not shown), the aerosol generating system may include an automatic mechanism for moving or advancing the aerosol-forming substrate 211 toward the heater 222. In such an alternative embodiment, the control device 253 of the aerosol generating device 200 may activate an actuator or advance mechanism to detect that the heater 222 is not in contact with the aerosol-forming substrate 211, and then advance the aerosol-forming substrate 211 and the rigid base 213 toward the heater 222. The actuator or advance mechanism may be provided on the aerosol generating article 200.

[0176] Figures 4 and 5 are schematic cross-sectional views of the alternative aerosol generating article 300. Figure 4 shows the aerosol generating article 300 before use by a user. The aerosol generating article 300 includes a body 312 defining a storage section 310 having a storage section opening 315. The aerosol forming substrate 311 is placed inside the storage section 310. The aerosol generating article 300 includes a heater 322 located across the storage section opening 315. In this example, the heater 322 has a heating element in the form of a mesh layer 323. The aerosol generating article 300 also includes a moving element 324. The moving element 324 is preferably formed of a porous material. In the embodiment of Figure 4, the moving element 324 is formed from a layer of glass fibers. The moving element 324 provides control over the flow of the aerosol forming substrate 311 from the storage section 310 to the mesh layer 313 of the heater 322. In this example, the aerosol forming substrate 311 is the formulation according to the present invention. [Examples]

[0177] The formulation according to the present invention (Example A) is prepared having the composition shown in Table 1. The formulation of Example A is solid at standard temperature and standard pressure. [Table 2]

[0178] The formulation of Example A is prepared as follows. (1) Heat one or more aerosol-forming bodies to a temperature between approximately 100°C and 120°C using a hot plate stirrer. (2) Add one or more polymers to one or more aerosol-forming bodies while stirring constantly, and then continue heating the mixture at a temperature between approximately 85°C and approximately 95°C until the mixture becomes clear. (3) Add water to the clear mixture. (4) While constantly stirring, reduce the heating temperature of the mixture to approximately 50°C, and add nicotine and organic acid to the mixture. (5) Pour the heated mixture into the mold, and then cool and set the mixture to form the formulation.

[0179] When used as an aerosol-forming substrate 311 in the aerosol-generating article 300 shown in Figures 4 and 5, an example of the use of the formulation according to the present invention as an aerosol-forming substrate will be described with reference to the formulation of Example A.

[0180] Figure 4 shows the aerosol-forming substrate 311 at standard temperature and pressure. Figure 5 shows the aerosol-forming substrate 311 at high temperature when heated by heater 322.

[0181] In the examples shown in Figures 4 and 5, the aerosol-forming substrate 311 is solid at standard temperature and pressure because its melting point is between 60°C and 300°C. In another embodiment, the aerosol-forming substrate 311 is colloidal at standard temperature and pressure. The colloid may have a solid continuous phase and a liquid dispersed phase.

[0182] Therefore, before the heater 322 is activated, the aerosol-forming substrate 311 is in a solid phase.

[0183] In Figure 1, the aerosol generating article 300 is inserted into the aerosol generating device 10.

[0184] Next, the aerosol generator 300 is activated by the user. The activation of the aerosol generator 10 involves activating the heater 322 of the aerosol generating article 300. The activation of the heater 322 heats a portion of the aerosol generating substrate 311 contained within the moving element 324. In this example, the heater 322 is activated for six minutes at a power of 0.8 watts. In one embodiment, the heater 322 may be activated at different power levels. In another embodiment, the heater 322 may be activated over different time periods.

[0185] When heater 322 is activated with 0.8 watts of power for six minutes, the temperature of the mesh layer 323 rises to approximately 200 degrees Celsius.

[0186] Heating the aerosol-forming substrate 311 contained within the moving element 324 increases the temperature of at least a portion of the aerosol-forming substrate 311, causing the heated portion of the aerosol-generating substrate 311 to melt into a liquid.

[0187] Figure 5 shows an example in which the entire aerosol-forming substrate 311 transitions to a liquid state through heating by the heater 322. In another embodiment, at least a portion, or only a portion, of the aerosol-forming substrate 311 melts into a liquid when the heater 322 is activated. For example, a portion of the aerosol-forming substrate 311 adjacent to the heater 322 may melt into a liquid, while the remaining portion of the aerosol-forming substrate 311 may remain as a solid.

[0188] The temperature of the aerosol-forming substrate 311 increases until at least a portion of the molten aerosol-forming substrate 311 contained within the mobile element 324 vaporizes into an aerosol.

[0189] The aerosol may then be inhaled by the user through outlet 15.

[0190] After the first heating cycle of heater 322 is completed, the aerosol-forming substrate 311 is cooled. The aerosol-forming substrate 311 returns to a solid state, as shown in Figure 4.

[0191] The aerosol-generating article 300 may be used several times before the aerosol-generating substrate 311 contained in the storage section 310 is completely consumed. Therefore, the aerosol-generating article 300 may experience multiple heating cycles. Consequently, during use, the aerosol-forming substrate may experience multiple phase changes.

[0192] Advantageously, the aerosol-forming substrate 311 is stored as a solid or substantially solid colloid in the storage unit 310. Because the aerosol-forming substrate 311 is stored as a solid, it is far less likely to leak or spill out of the storage unit 310 than a liquid aerosol-forming substrate 311. With this in mind, an aerosol-generating article, aerosol-generating device, or aerosol-generating system comprising the aerosol-forming substrate 311 comprising the formulation according to the present invention has an improved shelf life.

[0193] Furthermore, the aerosol-forming substrate 311 comprising the formulation according to the present invention melts into a liquid when heated during a normal heating cycle of an aerosol-generating article, aerosol-generating device, or aerosol-generating system. This means that the aerosol-forming substrate can flow as a normal liquid aerosol-forming substrate and vaporize normally into the aerosol. As will be discussed, depending on the specific design of the aerosol-generating article, aerosol-generating device, and aerosol-generating system, either a portion of the aerosol-forming substrate or the entire aerosol-forming substrate may melt during the heating cycle.

[0194] Furthermore, when the aerosol-forming substrate 311, which is made up of the formulation according to the present invention, cools after the heating cycle, it returns to a solid state and can no longer flow out of the storage section 310. This prevents leakage of the aerosol-forming substrate 311 between uses of the aerosol-generating article, aerosol-generating device, or aerosol-generating system.

[0195] Figure 6 shows the average aerosolized mass in mg per inhalation for a range of different aerosol-forming compositions, as the weight percentage of propylene glycol (PG) varies relative to the weight percentage of vegetable glycerin (VG). For example, the "25% PG vs. VG" data is for a formulation containing an aerosol-forming composition with 25 wt% propylene glycol and 75 wt% vegetable glycerin.

[0196] Figure 7 is a graph showing the average nicotine content in mg per puff for a range of different aerosol-forming compositions as the weight percentage of propylene glycol (PG) changes relative to the weight percentage of vegetable glycerin (VG). For example, the "25% PG vs. VG" data is for a formulation containing an aerosol-forming composition with 25 weight percent propylene glycol and 75 weight percent vegetable glycerin.

[0197] Figure 8 is a graph showing the average nicotine percentage for a range of different aerosol-forming compositions as the weight percentage of propylene glycol (PG) changes relative to the weight percentage of vegetable glycerin (VG). For example, the "25% PG vs VG" data is for a formulation containing an aerosol-forming composition with 25 weight percent propylene glycol and 75 weight percent vegetable glycerin.

[0198] The data in the graph shows, as discussed earlier, that including propylene glycol as an aerosol-forming agent in nicotine-containing formulations improves the nicotine content of the aerosol. For example, the maximum weight percentage of nicotine is achieved when the aerosol-forming agent contains 5 weight percent propylene glycol. This improvement may be due to the more efficient vaporization of nicotine because propylene glycol has a lower boiling point (188°C) compared to glycerin (290°C).

[0199] However, if a large amount of propylene glycol is present in the formulation (e.g., 25% by weight propylene glycol), the propylene glycol can evaporate during the heating cycle, thus reducing the nicotine content of the aerosol. Therefore, it is advantageous to have a limited amount of propylene glycol in the nicotine formulation.

[0200] The exemplary embodiments described above are not intended to limit the scope of the claims. Other embodiments consistent with the exemplary embodiments described above will be apparent to those skilled in the art. Features described in reference to one embodiment may also be applicable to other embodiments.

Claims

1. A formulation for use in an aerosol generating system, wherein the formulation is One or more aerosol-forming bodies, It comprises one or more polymers selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch. The formulation having a melting point of 100 degrees Celsius to 300 degrees Celsius.

2. The formulation according to claim 1, wherein the formulation has a melting point of 180 degrees Celsius to 270 degrees Celsius.

3. The formulation according to claim 1 or claim 2, wherein the formulation has an aerosol-forming material content of 20% to 85% by weight.

4. The formulation according to claim 3, wherein the formulation has an aerosol-forming material content of 35% to 55% by weight.

5. The formulation according to any one of claims 2 to 4, wherein the one or more aerosol-forming bodies contain one or more water-miscible polyhydric alcohols.

6. The formulation according to claim 5, wherein one or more water-miscible polyhydric alcohols are selected from the group consisting of plant glycerol, propylene glycol, and sorbitol.

7. A formulation according to any one of claims 1 to 6, comprising one or more organic acids.

8. The formulation according to claim 7, wherein the formulation has an organic acid content of less than 10 percent by weight.

9. The formulation according to claim 7 or 8, wherein the one or more organic acids are selected from the group consisting of malonic acid, citric acid, 2-ethylbutyric acid, acetic acid, adipic acid, benzoic acid, butyric acid, cinnamic acid, cycloheptane-carboxylic acid, fumaric acid, glycolic acid, hexanoic acid, lactic acid, levulinic acid, malic acid, myristic acid, octanoic acid, oxalic acid, propanoic acid, pyruvic acid, succinic acid, and undecanoic acid.

10. The formulation according to claim 9, wherein the one or more organic acids are selected from the group consisting of malonic acid, citric acid, lactic acid, benzoic acid, levulinic acid, fumaric acid, and acetic acid.

11. The formulation according to any one of claims 1 to 10, wherein the formulation has a polymer content of about 0.5 weight percent or more.

12. A formulation according to any one of claims 1 to 11, comprising one or more metal salts.

13. The formulation according to claim 12, wherein the one or more metal salts are selected from the group consisting of metal alginate, metal cinnamate, metal cycloheptanecarboxylate, metal levulinate, metal propanoate, metal stearate, and metal undecanoate, and preferably the one or more metal salts are selected from the group consisting of metal cinnamate, metal cycloheptanecarboxylate, metal stearate, and metal undecanoate.

14. An aerosol generating article for use in an aerosol generating system, comprising a formulation according to any one of claims 1 to 13.

15. an aerosol generation system, A preparation according to any one of claims 1 to 13, A system comprising: an atomizer configured to generate an aerosol from the aforementioned formulation.

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