Aerosol generating materials for use in aerosol delivery systems

Abstract

This disclosure relates to an aerosol-generating material for use in an aerosol delivery system, comprising one or more aerosolizable components bound to a matrix and one or more aerosolizable components not bound to the matrix. This disclosure also relates to articles comprising the aerosol-generating material for use in non-combustible aerosol supply devices, methods for manufacturing such materials and articles, and systems for supplying aerosols.

Claims

1. Aerosol generating material for use in an aerosol supply system, One or more aerosolizable components having a vapor pressure greater than 8 Pa and / or a boiling point less than 180°C, bound to a matrix containing one or more binders, wherein the one or more binders are selected to release the bound aerosolizable components when heated to a target temperature, One or more aerosolizable components having a vapor pressure of less than 8 Pa and / or a boiling point greater than 180°C, which are not bound to the matrix. Aerosol-generating materials, including those mentioned above.

2. The aerosol-generating material according to claim 1, wherein one or more aerosolizable components having a vapor pressure of less than 8 Pa and / or a boiling point greater than 180°C are not bound to any matrix.

3. The aerosol-generating material according to claim 1, wherein one or more aerosolizable components having a vapor pressure of less than 8 Pa and / or a boiling point greater than 180°C are bound in a second matrix, and the bound aerosolizable components are released when the second matrix is ​​heated to a temperature greater than about 50°C.

4. The aerosol-generating material according to claim 3, wherein the second matrix is ​​one or more forms selected from the group consisting of beads, tablets, granules, powders, or coatings.

5. The aerosol-generating material according to any one of claims 1 to 4, wherein one or more binders are selected to release the bound aerosolizable component when heated to a target temperature range of about 180 to about 300°C.

6. The aerosol generating material according to any one of claims 1 to 5, wherein the binder comprises sodium alginate or calcium alginate.

7. The aerosol-generating material according to any one of claims 1 to 6, further comprising a tobacco material or a tobacco extract.

8. The aerosol-generating material according to any one of claims 1 to 7, wherein the aerosolizable component is a flavor component selected to complement and / or enhance the tobacco flavor of the aerosol produced from the aerosol-generating material.

9. The aerosol-generating material according to claim 8, wherein the aerosolizable component is a flavor component that does not impart a characteristic non-tobacco flavor to the aerosol.

10. The aerosol-generating material according to claim 9, wherein the aerosolizable component does not contain menthol.

11. The aerosol-generating material according to any one of claims 1 to 10, wherein the matrix comprising one or more binders selected to release the bound aerosolizable components when heated to a target temperature range of about 180 to about 300°C is substantially in the form of spherical beads.

12. The aerosol generating material according to claim 11, wherein the beads have an average diameter of about 2 to about 5 mm.

13. The aerosol generating material according to any one of claims 1 to 12, wherein the binder is crosslinked.

14. The aerosol generating material according to any one of claims 1 to 13, further comprising an aerosol forming agent material.

15. The aerosol generating material according to claim 14, comprising approximately 0.1 to approximately 60 wt% of an aerosol-forming agent material.

16. The aerosol-forming material according to claim 14 or 15, wherein the aerosol-forming agent material comprises glycerol and / or propylene glycol.

17. The aerosol generating material according to any one of claims 14 to 16, wherein the matrix substantially does not contain an aerosol-forming agent material.

18. An aerosol generating material according to any one of claims 1 to 17, comprising less than approximately 10 wt% or less than approximately 7 wt% of water.

19. An article for use in an aerosol supply system, wherein a portion of the article comprises an aerosol generating material as described in any one of claims 1 to 18.

20. A non-combustible aerosol supply system comprising an aerosol generating material according to any one of claims 1 to 18 or an article according to claim 19.

21. The non-combustion aerosol supply system according to claim 20, configured to heat the aerosol generating material to form vapor and / or aerosol.

22. A method for preparing an aerosol generating material according to any one of claims 1 to 18, The steps include forming a slurry comprising one or more aerosolizable components having a vapor pressure greater than 8 Pa and / or a boiling point less than 180°C, and one or more binders, The steps include solidifying the slurry, The steps include freeze-drying the solidified slurry to form a matrix, The step of combining the matrix with one or more aerosolizable components having a vapor pressure of less than 8 Pa and / or a boiling point greater than 180°C. Methods that include...

23. The method according to claim 22, wherein the slurry is solidified to form a solid or semi-solid by crosslinking droplets or jets of the slurry.

24. The method according to claim 23, wherein the droplet or jet is crosslinked by being dispensed into a bath containing a crosslinking agent.

25. The method according to claim 23, wherein the slurry is solidified by rapidly freezing droplets or jets of the slurry.

26. The method according to claim 25, wherein the droplet or jet is frozen by being dispensed into liquid nitrogen.

27. The method according to any one of claims 22 to 26, wherein the solidified slurry is freeze-dried at a temperature of about -35 to about -50°C at a bar of about 30 to about 40 μbars.

28. The method according to any one of claims 22 to 27, wherein the solidified slurry is freeze-dried over a period of about 12 or about 24 hours to about 100 hours.

29. The method according to any one of claims 22 to 28, comprising a secondary drying step.

30. The method according to claim 29, wherein the secondary drying step includes raising the temperature of the freeze-dried solidified slurry to a secondary drying temperature of approximately +15°C to approximately +25°C.

31. The method according to claim 30, wherein the freeze-dried solidified slurry is held at the secondary drying temperature for a period of about 10 to about 25 hours.

32. The method according to any one of claims 22 to 31, wherein the solidified slurry is in the form of one or more beads and / or one or more strands.

33. The method according to claim 32, wherein the solidified slurry is in the form of one or more strands, and the one or more strands are cut before or after freeze-drying to form particles or segments.

34. Use of an aerosol-generating material according to any one of claims 1 to 18 to provide sustained release of flavor into an aerosol.

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