Aerosol generation

Abstract

This invention provides a method for producing an aerosol-generating material containing shredded amorphous solid. [Solution] The method comprises (a) forming a layer of slurry containing 1 to 60% by weight of a gelling agent, 0.1 to 50% by weight of an aerosol-forming material, 5 to 50% of a filler in the form of fibers, and 0.1 to 80% by weight of a flavoring and / or active substance, wherein the weights of these are calculated on a dry weight basis; (b) drying the slurry to obtain an amorphous solid; and (c) shredding the amorphous solid to obtain shredded amorphous solid.

Description

[Technical Field]

[0001] The present invention relates to a method for producing an aerosol generating material, an aerosol generating material containing an amorphous solid, a consumable used in a non-combustible aerosol supply system, the consumable containing an aerosol generating material containing an amorphous solid, and a non-combustible aerosol supply system. Background

[0002] Smoking consumables such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Alternatives to these types of consumables release inhalable aerosols or vapors by heating a substrate material without combustion, thereby releasing compounds from the substrate. These are sometimes referred to as non-combustion smoking consumables or aerosol-generating assemblies.

[0003] An example of such a product is a heating device that releases compounds by heating a solid aerosol-generating material without combustion. In some examples, this solid aerosol-generating material may include plant-based materials. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes called heat-not-burn devices, cigarette heating devices, or cigarette heating products. Various different configurations are known for volatilizing at least one component of the solid aerosol-generating material.

[0004] Another example is a hybrid device. These include a liquid source (which may or may not contain nicotine) that vaporizes upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-generating material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to form an inhalation medium. Overview

[0005] According to a first aspect of the present invention, a method is provided for producing an aerosol-generating material containing shredded amorphous solid. This method is a) 1-60% by weight of gelling agent, Aerosol-forming material in an amount of 0.1 to 50% by weight, and 5-50% of the filler is in the form of fibers, and 0.1 to 80% by weight of flavorings and / or active substances, A step of forming a slurry layer containing, wherein the weights of these are calculated on a dry weight basis, b) A step of drying the slurry to obtain an amorphous solid, c) A step of shredding an amorphous solid to obtain shredded amorphous solid, Includes.

[0006] In a further aspect, the present invention provides an aerosol-generating material comprising an amorphous solid. This amorphous solid is 1-60% by weight of gelling agent, 0.1 to 50% by weight of aerosol-forming material, 5-50% of the filler is in the form of fibers, 0.1 to 80% by weight of flavorings and / or active substances, This includes, where these weights are calculated on a dry weight basis. Amorphous solids exist in the form of small fragments.

[0007] In a further embodiment, the present invention provides an aerosol-generating material that can be obtained by using the method described herein.

[0008] In a further embodiment, the present invention provides consumables for use with a non-combustible aerosol supply system comprising an aerosol-generating material as defined elsewhere herein.

[0009] In a further embodiment, the present invention provides a non-combustible aerosol supply system comprising consumables as defined elsewhere herein and a non-combustible aerosol supply device. The non-combustible aerosol supply device comprises an aerosol generating device arranged to generate an aerosol from the consumables when the consumables are used together with the non-combustible aerosol supply device.

[0010] The present invention also provides the use of aerosol-generating materials, as defined elsewhere herein, in consumables used with a non-combustible aerosol supply device. The non-combustible aerosol supply device comprises an aerosol-generating device configured to generate an aerosol from the consumable when the consumable is used with the non-combustible aerosol supply device.

[0011] Features described herein in relation to one aspect of the present invention are expressly disclosed in combination with each of the other aspects, insofar as they can be combined.

[0012] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which are provided for illustrative purposes only with reference to the accompanying drawings. [Brief explanation of the drawing]

[0013] [Figure 1] This is a cross-sectional view of an example of a consumable item. [Figure 2] Figure 1 is a perspective view of the consumables. [Figure 3] This is a cross-sectional elevation view of an example of a consumable part. [Figure 4] Figure 3 is a perspective view of the consumables. [Figure 5] This is a perspective view of an example of a non-combustion type aerosol supply system. [Figure 6] This is a cross-sectional view of an example of a non-combustible aerosol supply system. [Figure 7] This is a perspective view of an example of a non-combustion type aerosol supply system. [Figure 8] This is a flowchart illustrating an exemplary method of the present invention. Detailed explanation

[0014] Preferably, the aerosol-forming material produced by the method of the present invention is in the form of an aerosol-forming "amorphous solid". The aerosol-forming "amorphous solid" may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel". An amorphous solid is a solid material that can hold some fluid, such as a liquid, therein. The amorphous solid can form part of the aerosol-forming material, and the aerosol-forming material contains from 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. In some examples, the aerosol-forming material consists of an amorphous solid.

[0015] Throughout the description, the amorphous solids of the aerosol-forming materials are formed from dry gels. The inventors have found that using the component ratios described herein means that as the gel cures, the flavor compounds are stabilized within the gel matrix and it becomes possible to achieve a higher flavor addition amount than in non-gel compositions. Flavored (e.g., menthol) is stabilized at high concentrations and the product has a good shelf life.

[0016] In some examples, the amorphous solid contains from 5 to 50 wt%, 10 to 40 wt% or 15 to 30 wt% filler. In some such examples, the amorphous solid contains at least 1 wt% filler, such as 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. In an exemplary embodiment, the amorphous solid contains from 5 to 25 wt% of a filler containing fibers. Preferably, the filler consists of fibers or is in the form of fibers.

[0017] In some embodiments, the amorphous solid contains less than 60 wt% filler, such as from 1 wt% to 60 wt%, or from 5 wt% to 50 wt%, or from 5 wt% to 30 wt%, or from 10 wt% to 20 wt% filler.

[0018] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, for example, 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight of filler.

[0019] In other embodiments, the amorphous solid comprises less than 20% by weight, preferably less than 10% by weight, or less than 5% by weight of filler.

[0020] The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain examples, the amorphous solid does not contain calcium carbonate such as chalk.

[0021] Preferably, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or cellulose derivatives (methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC), etc.). While we do not wish to be bound by theory, it is thought that including a fibrous filler in an amorphous solid can increase the tensile strength of the material. Furthermore, it has been found that including a fibrous filler improves the handling of the amorphous solid during manufacturing. In particular, the resulting amorphous solid is less "sticky," and as a result, shredding during manufacturing is easier. Therefore, including a fibrous filler can increase manufacturing efficiency and reduce the probability of machine stoppages during shredding. Including a fibrous filler in an amorphous solid also means that when the amorphous solid is shredded, the probability of it clumping together (e.g., agglomerating) is lower. When the shredded amorphous solid is included in a consumable, the reduced agglomeration optimizes the distribution of the shredded amorphous solid in the consumable. Therefore, each consumable is likely to contain a similar amount of shredded amorphous solid, which can improve the homogeneity of the flavoring amount within a batch of consumables and / or within a given consumable.

[0022] Therefore, as described above, the present invention provides a method for producing an aerosol-generating material containing shredded amorphous solid. This method is a) 1-60% by weight of gelling agent, Aerosol-forming material in an amount of 0.1 to 50% by weight, and 5-50% of the filler is in the form of fibers, and 0.1 to 80% by weight of flavorings and / or active substances, A step of forming a slurry layer containing, wherein the weights of these are calculated on a dry weight basis, b) A step of drying the slurry to obtain an amorphous solid, c) A step of shredding an amorphous solid to obtain shredded amorphous solid, Includes.

[0023] In some embodiments, the slurry is dried to obtain an amorphous solid, resulting in the formation of an amorphous solid sheet. Preferably, the amorphous solid sheet may be wound onto a bobbin or cut into flags, thereby facilitating transport or storage. In some such embodiments, the amorphous solid sheet is unwound from the bobbin and then shredded. Preferably, the shredded amorphous solid is then incorporated into consumables as described elsewhere herein.

[0024] Amorphous solids containing fibrous fillers are typically more suitable for transport and long-term packaging, allowing for simplification of the manufacturing process of consumables. Parts of amorphous solids that do not contain fibrous fillers and are in contact with each other (e.g., a stack of amorphous solid flags, or adjacent portions of amorphous solid wound on a bobbin) may be compacted together during storage, meaning that a step to separate these portions of amorphous solid must be performed before they can be processed to be included in the consumables (e.g., some of the amorphous solids are separated manually). In contrast, portions of amorphous solids containing fibrous fillers are typically more resilient during storage and transport, and they can be processed without costly and time-consuming manual separation steps (e.g., they can be fed directly to machinery from the flag stacks or bobbins).

[0025] Preferably, the slurry and / or amorphous solid contains 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 slurry and / or amorphous solid may contain 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent. In exemplary embodiments, the slurry and / or amorphous solid contains about 20 wt%, 22 wt%, 24 wt%, or 25 to about 30 wt%, 32 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the slurry and / or amorphous solid contains 20 to 35 wt%, or 25 to 30 wt% of a gelling agent.

[0026] In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises a hydrophilic colloid. In some examples, the gelling agent comprises alginates and / or pectin, which may be combined with a curing agent (such as a calcium source) during the formation of an amorphous solid. In some examples, the amorphous solid may comprise calcium crosslinked alginates and / or calcium crosslinked pectin.

[0027] In some embodiments, the gelling agent comprises an alginate, which is present in the slurry and / or amorphous solid in an amount of 10–30% by weight, 20–35% by weight, or 25–30% by weight (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the slurry and / or amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one further gelling agent, such as pectin.

[0028] In some embodiments, the method further includes the step of applying a curing agent to a layer of slurry. In some embodiments, the curing agent is a calcium solution. In some of these embodiments, the calcium solution is a calcium lactate solution. In further such embodiments, the calcium solution is sprayed onto the layer of slurry.

[0029] In some embodiments, the slurry and / or amorphous solid may contain a gelling agent comprising carrageenan.

[0030] As a result of including a gelling agent in the slurry, an aerosol-generating material is formed from the dried gel. The inventors have found that by including a gel in the aerosol-generating material, flavoring compounds, such as menthol, are stabilized within the gel matrix, making it possible to achieve a higher amount of flavoring added than in non-gel compositions. The added flavoring (e.g., menthol) is stabilized at high concentrations, and the product has a good shelf life.

[0031] Preferably, the slurry and / or amorphous solid contains about 0.1% by weight, 0.5% by weight, 1% by weight, 3% by weight, 5% by weight, 7% by weight, or 10% to about 50% by weight, 45% by weight, 40% by weight, 35% by weight, 30% by weight, or 25% by weight of aerosol-forming material (all calculated on a dry weight basis). In exemplary embodiments, the slurry and / or amorphous solid contains 10 to 25% by weight of aerosol-forming material. The aerosol-forming material may act as a plasticizer. In some examples, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-forming material contains glycerol, is essentially made from glycerol, or consists of glycerol. The inventors have found that if the plasticizer content is too high, the amorphous solid may absorb water, resulting in a material that does not produce a satisfactory consumer experience during use. They have also found that if the plasticizer content is too low, the amorphous solid may become brittle and easily break. The plasticizer content specified herein provides amorphous solid flexibility that allows the sheet to be wound onto a bobbin, which may be useful in the manufacture of consumables or in transporting the sheet before shredding.

[0032] In some embodiments, the slurry and / or amorphous solid may contain up to about 80% by weight, 70% by weight, 60% by weight, 55% by weight, 50% by weight, or 45% by weight of flavorings. In some examples, the slurry and / or amorphous solid may contain at least about 0.1% by weight, 1% by weight, 10% by weight, 20% by weight, 30% by weight, 35% by weight, or 40% by weight of flavorings (all calculated on a dry weight basis). For example, the slurry and / or amorphous solid may contain 1-80% by weight, 10-80% by weight, 20-70% by weight, 30-60% by weight, 35-55% by weight, or 30-45% by weight of flavorings. In the exemplary embodiment, the slurry and / or amorphous solid contains 35-50% by weight of flavorings. In some examples, the flavorings contain menthol, are essentially made from menthol, or consist of menthol.

[0033] In some embodiments, the slurry and / or amorphous solid may instead or further contain an active substance. For example, in some examples, the slurry and / or amorphous solid may further contain tobacco material and / or nicotine. In some examples, the slurry and / or amorphous solid may contain 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some examples, the slurry and / or amorphous solid may contain about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% by weight to about 70% by weight, 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight (calculated on a dry weight basis) of the active substance. In some examples, the slurry and / or amorphous solid may contain about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% by weight to about 70% by weight, 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight (calculated on a dry weight basis) of tobacco material. For example, the slurry and / or amorphous solid may contain 10-50% by weight, 15-40% by weight, or 20-35% by weight of tobacco material. In some examples, the slurry and / or amorphous solid may contain about 1% by weight, 2% by weight, 3% by weight, or 4% by weight to about 20% by weight, 18% by weight, 15% by weight, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the slurry and / or amorphous solid may contain 1-20% by weight, 2-18% by weight, or 3-12% by weight of nicotine.

[0034] In some examples, the slurry and / or amorphous solid contains an active substance such as tobacco extract. In some examples, the slurry and / or amorphous solid may contain 5 to 60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the slurry and / or amorphous solid may contain about 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% to about 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight (calculated on a dry weight basis) of tobacco extract. For example, the slurry and / or amorphous solid may contain 10 to 50% by weight, 15 to 40% by weight, or 20 to 35% by weight of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the slurry and / or amorphous solid contains 1% by weight, 1.5% by weight, 2% by weight, or 2.5% by weight to about 6% by weight, 5% by weight, 4.5% by weight, or 4% by weight (calculated on a dry weight basis). In some examples, nicotine other than that derived from the tobacco extract may not be present in the amorphous solid.

[0035] In some embodiments, the slurry and / or amorphous solid does not contain tobacco material but contains nicotine. In some such examples, the slurry and / or amorphous solid may contain about 1% by weight, 2% by weight, 3% by weight, or 4% by weight to about 20% by weight, 18% by weight, 15% by weight, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the slurry and / or amorphous solid may contain 1 to 20% by weight, 2 to 18% by weight, or 3 to 12% by weight of nicotine.

[0036] In some examples, the total content of active substances and / or flavorings may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight of the slurry and / or amorphous solid. In some examples, the total content of active substances and / or flavorings may be less than about 90% by weight, 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight (all calculated on a dry weight basis).

[0037] In some examples, the slurry and / or amorphous solid may further contain an emulsifier, which emulsifies the flavoring during preparation. For example, the slurry and / or amorphous solid may contain about 5% to about 15% by weight, preferably about 10% by weight, of an emulsifier (calculated on a dry weight basis). The emulsifier may include acacia gum.

[0038] In some embodiments, the amorphous solid is a hydrogel containing less than about 20% by weight of water on a wet weight basis. In some examples, the hydrogel may contain less than 15% by weight, 12% by weight, or 10% by weight of water on a wet weight basis. In some examples, the hydrogel may contain at least about 1% by weight, 2% by weight, or at least about 5% by weight of water (WWB).

[0039] In some embodiments, the slurry is 20-35% by weight of gelling agent, 10-25% by weight of aerosol-forming material, 5-25% of fibrous filler, 35-50% by weight of flavorings and / or active substances, This includes, where these weights are calculated on a dry weight basis.

[0040] In some embodiments, the amorphous solid is 20-35% by weight of gelling agent, 10-25% by weight of aerosol-forming material, 5-25% of fibrous filler, 35-50% by weight of flavorings and / or active substances, This includes, where these weights are calculated on a dry weight basis.

[0041] In some examples, the aerosol-generating material may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The aerosol-generating material may include two or more layers, and the thickness described herein refers to the total thickness of these layers.

[0042] In some examples, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may consist of two or more layers, and the thickness described herein refers to the total thickness of these layers.

[0043] The inventors have found that if the aerosol-generating material or amorphous solid is too thick, the heating efficiency is impaired. This negatively affects the power consumption during use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it becomes difficult to manufacture and handle. Very thin materials are more difficult to cast, are brittle, and may impair aerosol formation during use.

[0044] The inventors have found that the thickness of the aerosol-generating material as defined herein optimizes the material properties, taking these competing considerations into account.

[0045] The thicknesses specified herein are the average thickness of the material. In some examples, the thickness of the amorphous solid may vary by only 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0046] In some embodiments, the consumable comprises an aerosol-generating material described herein, where the amorphous solid is in the form of fine fragments. In such embodiments, the amorphous solid may be formed from shredded sheets. In the exemplary consumable, the aerosol-generating material comprises an amorphous solid that has been shredded and mixed with shredded tobacco material, for example, the aerosol-generating material comprises a blend of shredded amorphous solid and tobacco material. In some examples where the tobacco material is fine-cut and the aerosol-generating material is shredded sheets, the cut width of the amorphous solid is about 90-110% of the cut width of the tobacco material. That is, the aerosol-generating material comprising the amorphous solid and tobacco material has a similar cut width or shred width. The inventors have identified that a better blend of the amorphous solid and tobacco material is possible by configuring the amorphous solid and tobacco material to have a similar cut width. For example, shredded amorphous solid sheets and shredded rag tobacco having similar cut widths can be blended to provide a more homogeneous aerosol-generating composition (e.g., a better distribution of each component throughout the aerosol-generating composition).

[0047] In the example, the amorphous solid has a surface density of approximately 90-110% of the tobacco material's surface density. That is, the amorphous solid and the tobacco material have similar surface densities. The inventors have identified that by configuring the amorphous solid and the tobacco material to have similar surface densities, a better blend of the amorphous solid and the tobacco material is possible, typically when provided as shredded sheets. For example, shredded amorphous solid sheets and shredded rag tobacco having similar surface densities can be blended to provide a more homogeneous aerosol-generating composition (e.g., a better distribution of each component throughout the aerosol-generating composition).

[0048] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet, then shredded, and incorporated into an aerosol-generating consumable.

[0049] In some examples, the amorphous solid consists essentially of, or may consist of, a gelling agent, water, an aerosol-forming material, a fragrance, and optionally, an active substance.

[0050] In some examples, the amorphous solid is essentially composed of, or may be composed of, a gelling agent, water, an aerosol-forming material, a flavoring, and optionally, tobacco material and / or a nicotine source.

[0051] In some embodiments of the method, the slurry layer has a thickness of about 0.015 mm to about 2.0 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. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable.

[0052] The inventors have found that if the amorphous solid is too thick, heating efficiency is impaired. This negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. Very thin materials are more difficult to cast, are brittle, and may impair aerosol formation during use. The inventors have found that the amorphous solid thickness specified herein optimizes the material properties considering these competing considerations.

[0053] The thickness defined in this specification is the average value for the thickness in question. In some examples, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0054] An aerosol-generating material comprising an amorphous solid may have any suitable surface density, for example, 30 g / m 2 ~120 g / m 2 It may have. In some examples, the sheet is 80 - 120 g / m 2 or about 70 - 110 g / m 2 or particularly about 90 - 110 g / m 2 or preferably about 100 g / m 2 per unit area (so that the sheet has a density similar to cut - lag tobacco and mixtures of these substances do not separate easily). Such a surface density can be particularly suitable when the aerosol - generating material is included as a shredded sheet in a consumable / assembly (further described below). In some examples, the sheet may have a mass per unit area of about 30 - 70 g / m 2 40 - 60 g / m 2 or 25 - 60 g / m 2 per unit area.

[0055] Consumables and non - combustible aerosol supply systems As used herein, the term "delivery system" is intended to encompass systems that deliver a substance to a user, combustion - type aerosol supply systems, such as cigarettes, cigars, cigarillos, and pipes or tobacco for hand - rolled or handmade cigarettes (regardless of whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials), non - combustible aerosol supply systems that release compounds from an aerosol - generating material without burning the aerosol - generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol - generating materials, consumables that contain an aerosol - generating material and are configured to be used within one of these non - combustible aerosol supply systems, and Aerosol-free delivery systems that deliver one or more substances (which may or may not contain nicotine) to a user orally, nasally, transdermally, or by other means without forming an aerosol (including, but not limited to, consumables such as lozenges, gums, patches, inhalation powders, and oral products such as oral tobacco, which includes snus or wet snuff). Includes.

[0056] According to this disclosure, a "combustible" aerosol supply system is one in which the aerosol-generating material (or its components) of the aerosol supply system is combusted or burned during use to facilitate delivery to the user.

[0057] According to this disclosure, a “non-combustible” aerosol supply system is one in which the aerosol-generating material (or its components) of the aerosol supply system is not combusted or burned during use in order to facilitate delivery to the user.

[0058] In some embodiments, the delivery system is a combustion-type aerosol delivery system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0059] In some embodiments, the disclosure relates to components used in combustion-type aerosol supply systems, such as additive-releasing components including filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or to papers such as plug wraps, tip paper, or cigarette paper.

[0060] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powdered non-combustible aerosol supply system.

[0061] In some embodiments, the non-combustion aerosol supply system is an e-cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0062] In some embodiments, the non-combustion aerosol supply system is a tobacco heating system also known as a non-combustion heating system.

[0063] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, contain tobacco or non-tobacco products.

[0064] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables used in conjunction with the non-combustible aerosol supply device. However, it is conceivable that a consumable having means for supplying power to an aerosol generating component itself may constitute a non-combustible aerosol supply system.

[0065] In some embodiments, the non-combustible aerosol supply device may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source comprises a carbon substrate that may be energized to distribute power in the form of heat to the aerosol-generating material, or a heat transfer material adjacent to the heat source. In some embodiments, the power source, such as the heat source, is provided in a consumable to form a non-combustible aerosol supply.

[0066] In some embodiments, consumables used with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating component, an aerosol generating area, a mouthpiece, and / or an area for receiving the aerosol generating material.

[0067] In some embodiments, the aerosol-generating component is a heater capable of interacting with an aerosol-generating material to cause the material to release one or more volatile substances and form an aerosol. In some embodiments, the aerosol-generating component is capable of generating an aerosol from an aerosol-generating material without heating. For example, the aerosol-generating component may be capable of generating an aerosol from an aerosol-generating material without applying heat, for example, via one or more means such as vibration, mechanical, pressurized, or electrostatic means.

[0068] This consumable may also be referred to as a cartridge in this specification. This consumable may be adapted for use in a THP, hybrid device, or other aerosol generating device. In some examples, the consumable may further comprise a filter and / or cooling element as already described. In some examples, the consumable may be enclosed in packaging material such as paper.

[0069] The consumables may further include vents. These may be provided on the side walls of the consumables. In some examples, the vents may be provided on the filter and / or cooling element. These vents allow cold air to be drawn into the consumables during use, and this cold air can mix with the heated volatile components, thereby cooling the aerosol.

[0070] Ventilation facilitates the generation of visible thermal volatile components from consumables when they are heated during use. These thermal volatile components are made visible by a process of cooling them to the point where supersaturation occurs. The thermal volatile components then undergo droplet formation (also known as nucleation), and ultimately, the size of the thermal volatile component aerosol particles increases due to further condensation of the thermal volatile components and the aggregation of newly formed droplets from the thermal volatile components.

[0071] In some cases, the ratio of cold air to the total amount of heated volatile components (known as the permeability ratio) is at least 15%. A permeability ratio of 15% makes it possible to visualize the heated volatile components in the manner described above. The visibility of heated volatile components allows the user to identify that volatile components have been generated, enhancing the perceptual experience of the smoking experience.

[0072] In another example, the permeability ratio is 50% to 85% to further cool the heated volatile components. In some examples, the permeability ratio may be at least 60% or 65%.

[0073] Referring to Figures 1 and 2, a partial cross-sectional view and a perspective view of an example of an aerosol generating consumable 101 are shown. The consumable 101 is adapted for use with a device having a power supply and a heater. The consumable 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 5 to 7, which are described below. When in use, the consumable 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 5.

[0074] One example of a consumable 101 is in the form of a substantially cylindrical rod, comprising an aerosol-generating material body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material includes an amorphous solid material as described herein. In some embodiments, it may be included in the form of a sheet. In some embodiments, it may be included in the form of a shredded sheet. In some embodiments, the aerosol-generating material described herein may be incorporated in both sheet and shredded forms.

[0075] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouth-end segment 111. The consumable 101 has a first end 113, also known as the mouth-end or proximal end, and a second end 115, also known as the distal end. The aerosol-generating material 103 is located on the distal end 115 side of the consumable 101. In one example, the cooling segment 107 is positioned adjacent to the aerosol-generating material 103 between the aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in contact with the aerosol-generating material 103 and the filter segment 109. In other examples, there may be separations between the aerosol-generating material 103 and the cooling segment 107, and between the aerosol-generating material 103 and the filter segment 109. The filter segment 109 is positioned between the cooling segment 107 and the mouth-end segment 111. The mouth end segment 111 is positioned on the proximal end 113 side of the consumable 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in contact with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is 37 mm to 45 mm, and more preferably, the total length of the filter assembly 105 is 41 mm.

[0076] In one example, the rod of the aerosol generating material 103 has a length of 34 mm to 50 mm, preferably 38 mm to 46 mm, and preferably 42 mm.

[0077] For example, the total length of consumable 101 is 71mm to 95mm, preferably 79mm to 87mm, and preferably 83mm.

[0078] One axial end of the aerosol-generating material 103 is visible at the distal end 115 of the consumable 101. However, in other embodiments, the distal end 115 of the consumable 101 may include an end member (not shown) that covers one axial end of the aerosol-generating material 103.

[0079] The aerosol-generating material 103 is bonded to the filter assembly 105 by annular tip paper (not shown), which is positioned substantially around the filter assembly 105 so as to surround it and partially extends along the length of the aerosol-generating material 103. In one example, the tip paper is made from 58GSM standard tip base paper. In one example, the tip paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0080] In one example, the cooling segment 107 is an annular tube positioned around a void within the cooling segment, defining the void. This void provides a chamber through which heated volatile components generated from the aerosol-generating material 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the consumable 101 is being used during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

[0081] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient between the two ends of the cooling segment 107 in the longitudinal direction. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In another example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference between the two ends of the cooling element 107 in the longitudinal direction protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol-generating material 103 when the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the aerosol-generating material 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and may not effectively perform its required function.

[0082] In one example, the length of the cooling segment 107 is at least 15 mm. In another example, the length of the cooling segment 107 is 20 mm to 30 mm, more specifically 23 mm to 27 mm, more specifically 25 mm to 27 mm, preferably 25 mm.

[0083] The cooling segment 107 is made of paper, meaning that the cooling segment 107 is composed of a material that does not generate compounds of concern (e.g., toxic compounds) when it is adjacent to the heater of the device 51 during use. In one example, the cooling segment 107 is manufactured from a spiral-wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spiral-wound paper tube can meet the stringent dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and straightness of the tube.

[0084] In another example, the cooling segment 107 is a recess made from rigid plug wrap or tip paper. The rigid plug wrap or tip paper is manufactured to be rigid enough to withstand the axial compressive forces and bending moments that may occur during manufacturing and while the consumable 101 is being used during insertion into the device 51.

[0085] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heat-volatile components of the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material such as cellulose acetate. The filter segment 109 provides cooling and irritation reduction of the heat-volatile components without depleting the amount of heat-volatile components to an unsatisfactory level for the user.

[0086] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. This capsule may be positioned substantially at the center of the filter segment 109 in both the radial and longitudinal directions. In other examples, the capsule may be offset from the center in one or more dimensions. In some examples, if a capsule is present, it may contain volatile components such as flavorings or aerosol-generating agents.

[0087] The density of the cellulose acetate tow material in the filter segment 109 controls the pressure drop between the ends of the filter segment 109, and consequently controls the suction resistance of the consumable 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the suction resistance of the consumable 101. Furthermore, the filter segment performs a filtration function in the consumable 101.

[0088] In one example, filter segment 109 is made of 8Y15 grade filter tow material. This filter tow material provides a filtering effect against heated volatile materials while reducing the size of condensed aerosol droplets generated from the heated volatile materials.

[0089] The presence of the filter segment 109 provides an insulating effect by further cooling the heated volatile components that exit the cooling segment 107. This further cooling effect lowers the contact temperature of the user's lips with the surface of the filter segment 109.

[0090] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0091] The mouth end segment 111 is an annular tube positioned around a void within the mouth end segment 111, defining the void. This void provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the consumables during manufacturing and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is 6 mm to 10 mm, preferably 8 mm.

[0092] The mouth end segment 111 may be manufactured from a helical paper tube that provides a hollow internal chamber while maintaining important mechanical rigidity. The helical paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0093] The mouth end segment 111 provides a function to prevent liquid condensation accumulating at the outlet of the filter segment 109 from coming into direct contact with the user.

[0094] In one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, and the filter segment 109 may be placed inside that tube to separate the mouth end segment 111 and the cooling segment 107.

[0095] Referring to Figures 3 and 4, a partial fractured section view and perspective view of an example of consumable part 301 are shown. The reference numerals shown in Figures 3 and 4 correspond to the reference numerals shown in Figures 1 and 2, but the numbers are increased by 200.

[0096] In the example of the consumable 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the consumable 301 to allow air to flow from the outside of the consumable 301 into the inside of the consumable 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the consumable 301. These ventilation holes may be located in a cooling segment 307 to help cool the consumable 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes arranged along the outer circumference of the consumable 301 in a cross section substantially perpendicular to the longitudinal axis of the consumable 301.

[0097] In one example, the consumable 301 has 1 to 4 rows of vents to provide ventilation. Each row of vents may have 12 to 36 vents 317. The diameter of the vents 317 can be, for example, 100 to 500 μm. In one example, the axial spacing between rows of vents 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0098] In one example, the vents 317 have a uniform size. In another example, the vents 317 have varying sizes. The vents can be fabricated using one or more of any suitable techniques, such as laser technology, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before it is formed in the consumable 301. The vents 317 are positioned to effectively cool the consumable 301.

[0099] In one example, the row of vents 317 is located at least 11 mm from the proximal end 313 of the consumable, preferably 17 mm to 20 mm from the proximal end 313 of the consumable 301. The position of the vents 317 is determined so that the user does not block the vents 317 when using the consumable 301.

[0100] By providing a row of vents 17mm to 20mm from the proximal end 313 of the consumable 301, the vents 317 can be positioned outside the device 51 when the consumable 301 is fully inserted into the device 51, as shown in Figures 6 and 7. Positioning the vents outside the device allows unheated air to enter the consumable 301 from outside the device 51 through the vents, helping to cool the consumable 301.

[0101] The length of the cooling segment 307 is such that when the consumable 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 has two functions: firstly, it provides a physical gap between the heating device and the heat-sensitive filter device 309 of the device 51, and secondly, it allows the vents 317 to be located within the cooling segment while also being located outside the device 51 when the consumable 301 is fully inserted into the device 51. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located inside the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vents 317 are located in this portion of the cooling element 307 that extends outside the device 51.

[0102] Referring more closely to Figures 5 to 7, an example of a device 51 is shown which is configured to heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby typically forming an inhalable aerosol. Device 51 is a heating device that releases compounds by heating the aerosol-generating material but not burning it.

[0103] The first end 53 may be referred to herein as the oral end or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on / off button 57 that allows the user to start / stop the entire device 51 as desired.

[0104] The device 51 includes a housing 59 for arranging and protecting various internal components of the device 51. In the illustrated example, the housing 59 comprises a single sleeve 11 surrounding the outer edge of the device 51, which is covered by a top panel 17 that generally forms the “upper” part of the device 51 and a bottom panel 19 that generally forms the “bottom” part of the device 51. In another example, the housing comprises a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and the bottom panel 19.

[0105] The top panel 17 and / or bottom panel 19 may be detachably fixed to the single-piece sleeve 11 to allow easy access to the interior of the device 51, or they may be "permanently" fixed to the single-piece sleeve 11 to prevent, for example, a user from accessing the interior of the device 51. In one example, the panels 17 and 19 are made of plastic material (including glass-filled nylon formed by injection molding, etc.) and the single-piece sleeve 11 is made of aluminum, but other materials and other manufacturing processes may be used.

[0106] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, so that during use, the user can insert consumables 101, 301 containing aerosol generating material into and out of the device 51 through this opening 20.

[0107] The housing 59 houses or secures the heating device 23, the control circuit 25, and the power supply 27. In this example, the heating device 23, the control circuit 25, and the power supply 27 are located close together laterally (i.e., close together when viewed from one end), and the control circuit 25 is generally located between the heating device 23 and the power supply 27, although other arrangements are possible.

[0108] The control circuit 25 may include a controller, such as a microprocessor, configured and positioned to control the heating of the aerosol-generating material in the consumables 101 and 301, as will be discussed further below.

[0109] The power source 27 may be, for example, a battery, which may be rechargeable or non-rechargeable. Suitable battery examples include lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery 27 is electrically coupled to the heating device 23 and supplies power under the control of the control circuit 25 when needed to heat the aerosol-generating material in the consumables (volatilizing the aerosol-generating material without burning it, as described above).

[0110] The advantage of positioning the power supply 27 laterally close to the heating device 23 is that a physically larger power supply 25 can be used without making the entire device 51 excessively long. Naturally, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.) and therefore can extend the battery life of the device 51.

[0111] In one example, the heating device 23 generally takes the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which consumables 101, 301 containing aerosol-generating material are inserted for heating during use. Various configurations are possible for the heating device 23. For example, the heating device 23 may have a single heating element, or it may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The heating element or each heating element may be annular or tubular, or at least partially annular or at least partially tubular along its outer circumference. In one example, the heating element or each heating element may be a thin-film heater. In another example, the heating element or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramics, aluminum nitride ceramics, and silicon nitride ceramics, which may be laminated and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by emitting infrared radiation), and resistance heating elements formed by resistive electric windings.

[0112] In one particular example, the heating device 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heating device 23 is sized such that when the consumables 101, 301 are inserted into the device 51, substantially the entire body of the consumables 101, 301, consisting of the aerosol-generating material 103, 303, is inserted into the heating device 23.

[0113] The heating elements, or each heating element, may be arranged to independently heat multiple selected zones (areas) of the aerosol-generating material, for example, sequentially (over time as described above) or together (simultaneously), as desired.

[0114] In this example, the heating device 23 is surrounded by an insulating material 31 along at least a portion of its length. The insulating material 31 helps reduce the heat that passes from the heating device 23 to the outside of the device 51. This generally reduces heat loss and thus helps keep the power requirements of the heating device 23 low. The insulating material 31 also helps keep the outside of the device 51 cool while the heating device 23 is operating. In one example, the insulating material 31 may be a double-walled sleeve that provides a low-pressure region between the two walls of the sleeve. That is, the insulating material 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially vacuum-evacuated to minimize heat transfer by conduction and / or convection. Other configurations of the insulating material 31 are also possible, including the use of insulating material (including, for example, a suitable foam type material) in addition to, or instead of, a double-walled sleeve.

[0115] The housing 59, like the heating device 23, may further comprise various internal support structures 37 for supporting all internal components.

[0116] The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the housing 59, and a substantially tubular chamber 35 positioned between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a number of spaced-apart cooling fins 35f along the outer surface of the chamber 35, each cooling fin arranged to surround the outer surface of the chamber 35. When the consumables 101, 301 are inserted into the device 51 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the consumables 101, 301. The gap 36 surrounds the entire outer circumference of the consumables 101, 301 over at least a portion of the cooling segment 307.

[0117] The collar 33 is provided with a plurality of protrusions 60 arranged to surround the outer periphery of the opening 20, and these protrusions project into the opening 20. The protrusions 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the protrusions 60 is smaller than the opening distance of the opening 20 at the location without the protrusions 60. The protrusions 60 are configured to engage with the consumables 101, 301 inserted into the device and help to secure them within the device 51. The open space (not shown) defined by adjacent pairs of protrusions 60 and the consumables 101, 301 forms a ventilation path around the outer surface of the consumables 101, 301. These ventilation paths allow hot vapor escaping from the consumables 101, 301 to exit the device 51, and also allow cooling air to flow into the device 51 around the consumables 101, 301 within the void 36.

[0118] During operation, consumables 101 and 301 are removably inserted into the insertion points 20 of the device 51, as shown in Figures 5-7. Referring particularly to Figure 6, in one example, the aerosol-generating material bodies 103 and 303 (located on the distal ends 115 and 315 of consumables 101 and 301) are fully housed within the heating element 23 of the device 51. The proximal ends 113 and 313 of consumables 101 and 301 extend from the device 51 and function as a mouthpiece assembly for the user.

[0119] During operation, the heating device 23 heats the consumables 101 and 301 to volatilize at least one component of the aerosol-generating material from the aerosol-generating material bodies 103 and 303.

[0120] The primary channel for heated volatile components from the aerosol-generating materials 103, 303 passes axially through consumables 101, 301, through the inner chambers of the cooling segments 107, 307, through filter segments 109, 309, and through mouth-end segments 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating materials is 60°C to 250°C, which may exceed the user's acceptable inhalation temperature. As the heated volatile components move through the cooling segments 107, 307, they are cooled, and some of the volatile components condense on the inner surfaces of the cooling segments 107, 307.

[0121] In the example of the consumable 301 shown in Figures 3 and 4, cold air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cold air mixes with the heated volatile components to further cool them.

[0122] Example method Referring to Figure 8, the exemplary method 800 of the present invention includes a step 801 of forming a slurry layer. The layering step 801 includes preparing a slurry by mixing 26 wt% alginate, 16 wt% glycerol, 38 wt% menthol, and 20 wt% wood pulp (these weights are calculated on a dry weight basis) with water. The layering step 801 further includes casting the slurry as a layer approximately 2 mm thick. The slurry layer is sprayed with a calcium lactate solution to accelerate the hardening of the alginate, which forms a gel.

[0123] The method further comprises step 802, which involves drying a layer of slurry to form a sheet of amorphous solid. In some examples of method 800, the method includes step 803, which involves cutting the sheet of amorphous solid into flags for storage and / or transport, or winding the amorphous solid onto bobbins for storage and / or transport. In other examples of method 800, method 800 does not include step 803, which involves cutting or winding, after step 802, which involves drying.

[0124] In an example where method 800 includes the step 803 of winding an amorphous solid sheet onto a bobbin, the method further includes the step 804 of unwinding the amorphous solid sheet from the bobbin.

[0125] Method 800 further includes step 805 of shredding an amorphous solid sheet. In an example of Method 800, which includes step 804 of unwinding the amorphous solid sheet from a bobbin, the bobbin is unwound by step 805 of shredding the amorphous solid sheet (for example, the bobbin is unwound as the sheet is fed into the shredding device). Step 805 of shredding the amorphous solid sheet is carried out as described elsewhere herein.

[0126] Following step 805 of shredding, in some examples, method 800 includes step 806 of mixing the shredded amorphous solid with the shredded tobacco material and incorporating the mixture into a rod consumable.

[0127] definition active substance In some embodiments, the delivered substance includes an active substance.

[0128] The active substances used herein are physiologically active materials, i.e., materials for achieving or enhancing physiological reactions. Active substances may be selected from, for example, functional foods, nootropics, and psychoactive substances. Active substances may be naturally occurring or obtained by synthesis. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, and C), melatonin, cannabinoids, or their components, derivatives, or combinations. Active substances may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

[0129] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0130] plant matter As described herein, the active substance may include or be derived from one or more plant materials or components, derivatives, or extracts thereof. As used herein, the term “plant material” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the material may include active compounds that are naturally present in the plant material or obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, shards, sheets, etc. Examples of plant-based ingredients include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, 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 arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0131] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, wherein the plant substance is tobacco.

[0132] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0133] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, the plant substances being selected from rooibos and fennel.

[0134] fragrance In some embodiments, the delivered substance includes a fragrance.

[0135] As used herein, the terms “flavoring” and “flavoring” refer to materials that can be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where local regulations permit. These include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango). Clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, citrus Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any variety of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, laurel, mate, orange peel, rose, tea (green tea, black tea, etc.), Thai (Lumin, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators, or stimulants, sugars and / or sugar substitutes (e.g., sucralose,It may contain acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives, such as charcoal, chlorophyll, minerals, plant materials, or breath fresheners. These may be imitation ingredients, synthetic ingredients, natural ingredients, or blends thereof. They may be in any suitable form, such as liquid (e.g., oil), solid (e.g., powder), or gas.

[0136] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus fruit, and / or red berry flavorings. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavorings extracted from tobacco. In some embodiments, the flavoring includes flavorings extracted from cannabis.

[0137] In some embodiments, the fragrance may include sensory agents intended to achieve somatosensory effects that are normally chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory nerve or gustatory nerve, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0138] Aerosol generating materials Aerosol-generating materials are materials capable of generating aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of, for example, a solid, a liquid, or a gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may include an "amorphous solid," which may also be called a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid to about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0139] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0140] Aerosol-forming materials The aerosol-forming material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0141] consumables Consumables are articles containing or consisting of aerosol-generating material, which is intended to be consumed in whole or in part during use by the user. Consumables may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a rolled paper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater that generates heat to cause aerosol generation from the aerosol-generating material during use. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0142] aerosol generator An aerosol generator is a device configured to induce the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy, thereby causing one or more volatile substances to be released from the aerosol-generating material and forming an aerosol. In some embodiments, the aerosol generator is configured to induce the generation of an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of the following: vibration, high pressure, or electrostatic energy.

[0143] example Example 1 Two amorphous solids (A and B) were prepared by forming slurries of menthol, glycerol, and alginate according to Table 1 below. 20% by weight of fibers was added to slurry B, while no fibers were added to slurry A. Both slurries were formed into layers and sprayed with a calcium lactate solution. The slurry layers were dried to form sheets of amorphous solid A and amorphous solid B. The only difference between amorphous solids A and B was that amorphous solid B contained 20% by weight of fibers. The sheets were cut into flags (6 × 6 cm square) for transport.

[0144] [Table 1]

[0145] Once the amorphous solid A flags reached their destination, they were compressed / compacted. As a result, they had to be broken apart for shredding. When shredding the amorphous solid A flags, the sheets were sticky and adhered to the shredding equipment, causing clogging of the machinery. Once the amorphous solid A sheets were shredded, they were blended with the shredded tobacco material and added to consumables in the form of rods. However, the amorphous solid A fragments tended to aggregate (clump together), which meant that there was a very high variability in the menthol in the rods, with some rods containing lumps of amorphous solid and others not.

[0146] In contrast, the amorphous solid B (containing fibers) did not need to be separated. Furthermore, the sheets could be easily shredded without causing clogging of the shredding equipment. No clump formation was observed in the shredded amorphous solid B, and it was possible to blend it homogeneously with the shredded tobacco material to form a rod consumable with a uniform distribution of amorphous solid fragments. The only difference between formulations A and B was the addition of 20% fibers to the amorphous solid formulation, and it was demonstrated that the use of fibers improved the handling of the amorphous solid, resulting in these improved distributions when the amorphous solid fragments were added to the rod consumable.

[0147] All weight percentages (indicated as wt%) used herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights expressed on a dry weight basis refer to the entirety of the extract, slurry, or material other than water, and may include components that are liquid by themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages expressed on a wet weight basis refer to all components, including water.

[0148] To avoid misunderstanding, while the term “contains” is used herein to define the invention or its features, embodiments are also disclosed in which the terms “essentially consist of” or “consist of” may be used instead of “contains.” References to materials that “contain” certain features mean that those features are included in, contained in, or retained within the material.

[0149] The embodiments described above should be understood as illustrative examples of the present invention. Further embodiments of the present invention are conceivable. Any feature described in relation to any one embodiment may be used alone or in combination with other features described, or in combination with one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may also be used without departing from the scope of the present invention as defined in the appended claims.

Claims

1. A method for producing an aerosol-generating material containing shredded amorphous solid, a) 1 to 60% by weight of gelling agent, 0.1 to 50% by weight of aerosol-forming material, 5-50% of fibrous fillers, and 0.1 to 80% by weight of flavorings and / or active substances, A step of forming a slurry layer containing, wherein the weights of these are calculated on a dry weight basis, b) A step of drying the slurry to obtain an amorphous solid, c) The step of shredding the amorphous solid to obtain shredded amorphous solid, Methods that include...

2. The method according to claim 1, wherein the fiber includes wood fiber.

3. The method according to claim 1 or 2, wherein the flavoring is menthol.

4. The method according to any one of claims 1 to 3, wherein the gelling agent comprises a hydrophilic colloid.

5. The method according to any one of claims 1 to 3, wherein the gelling agent comprises one or more compounds selected from the group consisting of alginates, cellulose derivatives, gums, silica or silicone compounds, clays, and combinations thereof.

6. The method according to any one of claims 1 to 5, wherein the gelling agent comprises calcium cross-linked alginate and / or calcium cross-linked pectin.

7. an aerosol generating material containing an amorphous solid, wherein the amorphous solid is 1 to 60% by weight of a gelling agent, 0.1 to 50% by weight of an aerosol-forming material, 5-50% of the filler is in the form of fibers, 0.1 to 80% by weight of flavorings and / or active substances, These weights are calculated on a dry weight basis, The amorphous solid is in the form of fine fragments, and is an aerosol-generating material.

8. The aerosol generating material according to claim 7, wherein the amorphous solid is in the form of a shredded sheet.

9. The aerosol generating material according to claim 7 or 8, wherein the aforementioned fibers include wood fibers.

10. The aerosol generating material according to any one of claims 7 to 9, wherein the flavoring agent is menthol.

11. The aerosol generating material according to any one of claims 7 to 10, wherein the gelling agent includes a hydrophilic colloid.

12. The aerosol generating material according to any one of claims 7 to 10, wherein the gelling agent comprises one or more compounds selected from the group including alginates, cellulose derivatives, gums, silica or silicone compounds, clay, and combinations thereof.

13. The aerosol generating material according to any one of claims 7 to 12, wherein the gelling agent comprises calcium cross-linked alginate and / or calcium cross-linked pectin.

14. An aerosol-generating material according to any one of claims 7 to 13, comprising shredded tobacco material blended with an amorphous solid in the form of fine fragments.

15. An aerosol-generating material that can be obtained by using the method described in any one of claims 1 to 6.

16. A consumable used in conjunction with a non-combustible aerosol supply system, comprising an aerosol generating material according to any one of claims 7 to 15.

17. A non-combustible aerosol supply system comprising a consumable product according to claim 16 and a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device arranged to generate an aerosol from the consumable product when the consumable product is used together with the non-combustible aerosol supply device.

18. Use of an aerosol generating material according to any one of claims 7 to 15 in a consumable used with a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustible aerosol supply device.

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