Aerosol generating element containing tobacco particles

Abstract

Aerosol generating elements (10, 20, 30, 40) for use in aerosol generating articles or systems are provided. The aerosol generating elements (10, 20, 30, 40) comprise an internal core (12) of an aerosol generating substrate, the internal core comprising a liquid solvent containing tobacco particles and one or more aerosol-forming bodies, and an external shell enclosing the internal core of the aerosol generating substrate, the external coating comprising at least one film-forming polymer. The aerosol generating substrate comprises at least 20 weight percent of tobacco particles and at least 30 weight percent of one or more aerosol-forming bodies on a dry weight basis. The weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 0.3.

Description

Technical Field

[0001] The present disclosure relates to an aerosol generating element of the type used in aerosol generating articles or systems.

Background Art

[0002] A number of aerosol generating articles have been proposed in the art in which an aerosol generating substrate, such as tobacco, is heated rather than burned. In these aerosol generating articles, the aerosol is typically generated by heating the aerosol generating substrate to a predetermined temperature. For example, smoking articles are disclosed in which an aerosol is generated by electrical heating or by transfer of heat from a combustible fuel element or heat source to a tobacco-containing aerosol generating substrate. During smoking, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in the air drawn through the smoking article. The released compounds condense as they cool to form an aerosol, which is inhaled by the consumer.

[0003] Typically, aerosol generating articles in which tobacco is heated rather than burned further comprise one or more elements that mate with the aerosol generating substrate. For example, an aerosol generating article has been proposed that includes one or more of a rod of a tobacco-containing substrate, a support element adapted to impart increased structure to the aerosol generating article, an aerosol cooling element configured to reduce the temperature of the aerosol before it reaches the mouth-end of the aerosol generating article, and a mouthpiece element.

Summary of the Invention

Problems to be Solved by the Invention

[0004] After an aerosol-generating article is smoked and discarded, it is generally desirable that its components decompose as quickly as possible. However, some of the materials most commonly used in aerosol-generating articles (such as cellulose acetate) are not easily biodegradable and can therefore persist in the environment for many years. As a result, elements contained in aerosol-generating articles combined with tobacco-containing rods may have the undesirable tendency to accumulate in the environment. For example, used cigarette filters made from cellulose acetate are one of the most commonly collected plastic items in beach cleanup activities. In addition, the manufacture of similar additional elements generally involves a considerable consumption of resources (water, energy, etc.). Therefore, there is a general sense of need to provide more sustainable alternatives to existing aerosol-generating articles that include multiple additional elements, particularly filter or mouthpiece components.

[0005] More recently, aerosol-generating elements have been described, which are actually individual aerosol-generating substrates in solid form, within which an aerosol-generating formulation is encapsulated. It has been proposed that multiple aerosol-generating elements of this type be provided within a cavity defined by a tubular element, thereby exposing the outer surface of the aerosol-generating element to the interior of a longitudinal airflow channel defined by the cavity. Upon heating, an aerosol is generated from the aerosol-generating element, released into the airflow channel, and drawn through the tubular element into the consumer's mouth.

[0006] It is desirable to provide aerosol generating elements that do not require combination with any additional elements for use in generating aerosols, as this will have less environmental impact, especially in terms of post-consumption waste management.

[0007] Furthermore, it is desirable to provide these aerosol-generating elements that can be manufactured in a more sustainable way, such as by reducing the overall consumption of resources and materials. [Means for solving the problem]

[0008] This disclosure relates to an aerosol generating element used in an aerosol generating article or system.

[0009] The aerosol generating element may include an internal core of the aerosol generating substrate.

[0010] The aerosol generating substrate may contain tobacco particles.

[0011] The aerosol generating substrate may contain a liquid solvent containing one or more aerosol-forming bodies.

[0012] The aerosol generating element may further include an outer shell that encloses an inner core of the aerosol generating substrate.

[0013] The external coating may include at least one film-forming polymer.

[0014] The aerosol generating substrate may contain at least 20 weight percent of tobacco particles on a dry weight basis.

[0015] The aerosol generating substrate may contain one or more aerosol-forming materials in an amount of at least 30% by dry weight.

[0016] The weight ratio of tobacco particles to the liquid solvent in the aerosol generating substrate may be at least 0.3.

[0017] This disclosure also relates to an aerosol generating article comprising the aerosol generating element described above.

[0018] According to a first aspect of the present invention, an aerosol generating element for use in an aerosol generating article or system is provided, the aerosol generating element comprising: an internal core of an aerosol generating substrate, the internal core comprising a liquid solvent containing tobacco particles and one or more aerosol forming bodies; and an external shell enclosing the internal core of the aerosol generating substrate, the external coating comprising at least one film-forming polymer, wherein the aerosol generating substrate contains at least 20 weight percent of tobacco particles and at least 30 weight percent of one or more aerosol forming bodies on a dry weight basis, and the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 0.3.

[0019] It has been found that combinations of tobacco particles in the relative proportions described herein with a solvent containing one or more aerosol-forming bodies provide an aerosol-generating substrate that can be stably and favorably formed into virtually any shape. While we do not wish to be bound by theory, this is understood to be a result of an aerosol-generating substrate having a paste-like consistency, which allows for, for example, the imparting of a predetermined shape to the aerosol-generating substrate by using a mold, and that the aerosol-generating substrate retains the imparted shape even when the formed aerosol-generating substrate is removed from the mold.

[0020] In particular, only a very small amount of water (if any at all) is required for the production of the aerosol generating element according to the present invention. As a result, the aerosol generating element according to the present invention is more sustainable than certain existing aerosol generating products.

[0021] In addition, the provision of an external shell that encapsulates the internal core simplifies the handling and transportation of the aerosol - generating substrate as part of the aerosol - generating element. At the same time, the external shell protects the aerosol - generating substrate from the external environment, at least until the aerosol - generating element is used. Therefore, the aerosol - generating substrate can be conveniently stored before use of the aerosol - generating element without the need for additional elements to establish a barrier between the aerosol - generating substrate and external agents that may undesirably affect its properties.

[0022] The aerosol - generating element according to the present invention can be directly heated within an aerosol - generating device without the need to combine it with any additional elements to form an aerosol - generating article. Thus, compared with existing aerosol - generating products, the manufacturing process is significantly simplified and generally more sustainable. The generation of waste before and after use is reduced, and as a result, waste management is significantly simplified.

[0023] Furthermore, the costs associated with storage and transportation may also be reduced compared to certain existing aerosol - generating products.

[0024] In any case, the aerosol - generating element according to the present invention may be incorporated into an aerosol - generating article for use in an aerosol - generating device, and thus it is worth noting that the present invention also offers various possibilities for article design.

[0025] Therefore, the present disclosure also relates to an aerosol - generating article comprising an aerosol - generating element as described above.

[0026] According to a second aspect of the present invention, there is provided an aerosol - generating article comprising an aerosol - generating element according to the first aspect of the present invention.

[0027] An aerosol - generating article incorporating one or more aerosol - generating elements according to the present invention may generally benefit from improved sustainability related to the manufacture of the aerosol - generating elements.

[0028] General definition As used herein in relation to the present invention, the term "aerosol-generating substrate" is used to describe a substrate comprising an aerosol-generating material having the ability to release a volatile compound capable of generating an aerosol upon heating.

[0029] As used herein in relation to the present invention, the term "aerosol" is used to describe the dispersion of solid particles, or droplets, or combinations of solid particles and droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include vapors of substances that are normally liquid or solid at room temperature, as well as solid particles, or droplets, or combinations of solid particles and droplets.

[0030] As used herein, the term "aerosol generating element" refers to an individual aerosol generating substrate in solid form, comprising an aerosol generating internal core enclosed within a shell. The structure and composition of the aerosol generating element are described in more detail below. Thus, the aerosol generating element can be heated to generate an inhalable aerosol for delivery to the user.

[0031] As used herein in relation to the present invention, the term “aerosol-generating article” is used to describe an article comprising one or more aerosol-generating elements that generate an inhalable aerosol that is heated and delivered to a user.

[0032] As used herein in relation to the present invention, the term “aerosol generator” is used to describe a device that generates an aerosol by interacting with an aerosol-generating substrate of an aerosol-generating element. The term “aerosol-generating system” may be used to describe a system comprising such an aerosol generator and an aerosol-generating element, or an aerosol-generating article containing one or more aerosol-generating elements.

[0033] Statement regarding dependent “element” claims As briefly described above, the aerosol generating element according to the present invention comprises an internal core of an aerosol generating substrate and an external shell enclosing the internal core of the aerosol generating substrate, wherein the aerosol generating substrate contains tobacco particles and a liquid solvent containing one or more aerosol-forming bodies.

[0034] The aerosol generating substrate may have a viscosity of up to 22,000 cp.

[0035] The term "viscosity" is used herein to indicate a measure of the internal resistance of a fluid to deformation under shear stress. More specifically, the term "viscosity" as used herein refers to the kinematic viscosity (μ) of a fluid. The physical unit for kinematic viscosity in the centigram-second system of units (cgs) is poise (P). 1 poise = 100 centipoise = 0.1 Pa·s.

[0036] More specifically, the term "viscosity" refers to the kinematic viscosity of the aerosol-generating substrate as measured at 23 degrees Celsius and with a shear rate of 100 per second (1 / s) on a linear ramp of 1 to 200 per second, using an MCR302 Anton Paar rheometer with PP25 geometric shape. The rheometer is equipped with a Peltier module P-PTD2000 with a VT2 cooling system.

[0037] Preferably, the viscosity of the aerosol generating substrate is 20,000 cp or less. More preferably, the viscosity of the aerosol generating substrate is 15,000 cp or less. Even more preferably, the viscosity of the aerosol generating substrate is 10,000 cp or less.

[0038] The aerosol generating substrate may have a viscosity of at least 5,000 cp. Preferably, the viscosity of the aerosol generating substrate is at least 6,000 cp. More preferably, the viscosity of the aerosol generating substrate is at least 7,000 cp. Even more preferably, the viscosity of the aerosol generating substrate is at least 8,000 cp.

[0039] In some embodiments, the viscosity of the aerosol-generating substrate is 5,000 cp to 22,000 cp, preferably 5,000 cp to 20,000 cp, more preferably 5,000 cp to 15,000 cp, and even more preferably 5,000 cp to 10,000 cp.

[0040] In a particular embodiment, the viscosity of the aerosol-generating substrate is 6,000 cp to 22,000 cp, preferably 6,000 cp to 20,000 cp, more preferably 6,000 cp to 15,000 cp, and even more preferably 6,000 cp to 10,000 cp.

[0041] In other embodiments, the viscosity of the aerosol-generating substrate is 7,000 cp to 22,000 cp, preferably 7,000 cp to 20,000 cp, more preferably 7,000 cp to 15,000 cp, and even more preferably 7,000 cp to 10,000 cp.

[0042] In a further embodiment, the viscosity of the aerosol generating substrate is 8,000 cp to 22,000 cp, preferably 8,000 cp to 20,000 cp, more preferably 8,000 cp to 15,000 cp, and even more preferably 8,000 cp to 10,000 cp.

[0043] While we do not wish to be constrained by theory, it has been observed that shaping an aerosol-generating element is particularly easy when the aerosol-generating substrate has a viscosity within the aforementioned range, because the paste-like consistency of the aerosol-generating substrate allows it to be formed into various shapes. In addition, it has been observed that aerosol-generating substrates having a viscosity within the aforementioned range can consistently maintain their shape during subsequent manufacturing processes. For example, as described in more detail below, removing the aerosol-generating substrate from the mold before immersing it in a film-forming polymer to form an outer shell does not significantly alter the shape imparted to the aerosol-generating substrate. Thus, when the outer shell is formed to enclose the inner core of the aerosol-generating substrate, the overall shape previously imparted to the aerosol-generating substrate is maintained and found to remain substantially unchanged in the formed aerosol-generating element.

[0044] The weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate may be 2 or less. Preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 1.5 or less. More preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 1.25 or less. Even more preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 1.2 or less.

[0045] Preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 0.5. More preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 0.75. Even more preferably, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 1.

[0046] In some embodiments, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 0.3 to 2, preferably 0.3 to 1.5, more preferably 0.3 to 1.25, and even more preferably 0.3 to 1.2.

[0047] In a particular embodiment, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 0.5 to 2, preferably 0.5 to 1.5, more preferably 0.5 to 1.25, and even more preferably 0.5 to 1.2.

[0048] In other embodiments, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 0.75 to 2, preferably 0.75 to 1.5, more preferably 0.75 to 1.25, and even more preferably 0.75 to 1.2.

[0049] In further embodiments, the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is 1 to 2, preferably 1 to 1.5, more preferably 1 to 1.25, and even more preferably 1 to 1.2.

[0050] The weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate within the above-mentioned range has the advantage of potentially maximizing the tobacco content within the aerosol generating substrate, while simultaneously contributing to maintaining the density and viscosity of the aerosol generating substrate at a value that ensures easy and reliable molding of the aerosol generating element during manufacturing and a paste-like consistency that is compatible with it.

[0051] Preferably, the aerosol-generating substrate is an aerosol-generating suspension of tobacco particles in a liquid solvent. As used herein, the term “aerosol-generating suspension” refers to a suspension having the ability to form aerosols and to be released upon heating of a volatile compound. The aerosol-generating suspension is a heterogeneous mixture in which tobacco particles are not dissolved but remain suspended and dispersed throughout the bulk of the solvent containing one or more aerosol-forming bodies. In other words, the tobacco particles may not substantially settle but remain uniformly distributed throughout the bulk of the solvent. This may be beneficially influencing the mass transfer mechanisms involved in the generation and release of aerosol particles upon heating of the aerosol-generating element.

[0052] Specifically, the aerosol-generating suspension is not a gel and does not contain a gelling agent.

[0053] The density of the aerosol generating substrate may be at least 0.75 grams per cubic centimeter. Preferably, the density of the aerosol generating substrate is at least 1 gram per cubic centimeter. More preferably, the density of the aerosol generating substrate is at least 1.1 grams per cubic centimeter. Even more preferably, the density of the aerosol generating substrate is at least 1.2 grams per cubic centimeter.

[0054] The density of the aerosol generating substrate may be 2.25 grams per cubic centimeter or less. Preferably, the density of the aerosol generating substrate is 2 grams per cubic centimeter or less. More preferably, the density of the aerosol generating substrate is 1.9 grams per cubic centimeter or less. Even more preferably, the density of the aerosol generating substrate is 1.8 grams per cubic centimeter or less.

[0055] In some embodiments, the density of the aerosol-generating substrate is 0.75 grams per cubic centimeter to 2.25 grams per cubic centimeter, preferably 1 gram per cubic centimeter to 2.25 grams per cubic centimeter, more preferably 1.1 grams per cubic centimeter to 2.25 grams per cubic centimeter, and even more preferably 1.2 grams per cubic centimeter to 2.25 grams per cubic centimeter.

[0056] In a particular embodiment, the density of the aerosol-generating substrate is 0.75 grams per cubic centimeter to 2 grams per cubic centimeter, preferably 1 gram per cubic centimeter to 2 grams per cubic centimeter, more preferably 1.1 grams per cubic centimeter to 2 grams per cubic centimeter, and even more preferably 1.2 grams per cubic centimeter to 2 grams per cubic centimeter.

[0057] In other embodiments, the density of the aerosol-generating substrate is 0.75 grams per cubic centimeter to 1.9 grams per cubic centimeter, preferably 1 gram per cubic centimeter to 1.9 grams per cubic centimeter, more preferably 1.1 grams per cubic centimeter to 1.9 grams per cubic centimeter, and even more preferably 1.2 grams per cubic centimeter to 1.9 grams per cubic centimeter.

[0058] In further embodiments, the density of the aerosol-generating substrate is 0.75 grams per cubic centimeter to 1.8 grams per cubic centimeter, preferably 1 gram per cubic centimeter to 1.8 grams per cubic centimeter, more preferably 1.1 grams per cubic centimeter to 1.8 grams per cubic centimeter, and even more preferably 1.2 grams per cubic centimeter to 1.8 grams per cubic centimeter.

[0059] Generally speaking, there is no direct correlation between the density and viscosity of a fluid. However, both density and viscosity are affected by temperature changes. For example, when the temperature of a fluid rises, particles in the fluid tend to move away from each other, which causes a decrease in both density and viscosity. Aerosol generating elements in which the aerosol generating substrate has a density within the aforementioned range have the advantage of easily maintaining their structure and shape, even after use. Therefore, adjusting the density of the aerosol generating substrate to be within the aforementioned range has the advantage that the aerosol generating elements, including the aerosol generating substrate, maintain their integrity even after exposure to heat under the normal operating conditions of the aerosol generator has altered their original density and viscosity, and even after some aerosol-forming material has been released during use.

[0060] Aerosol generating substrate composition - tobacco particles The aerosol generating substrate preferably contains at least 35 weight percent of tobacco particles on a dry weight basis, more preferably at least 40 weight percent of tobacco particles on a dry weight basis, and even more preferably 45 weight percent of tobacco particles on a dry weight basis. In a particularly preferred embodiment, the aerosol generating substrate contains at least 50 weight percent of tobacco particles on a dry weight basis.

[0061] The aerosol generating substrate may contain up to 70% by weight of tobacco particles on a dry weight basis. Preferably, the aerosol generating substrate contains 65% by weight or less of tobacco particles on a dry weight basis. More preferably, the aerosol generating substrate contains 60% by weight or less of tobacco particles on a dry weight basis.

[0062] In some embodiments, the aerosol generating substrate contains 35% to 70% by weight tobacco particles on a dry weight basis. Preferably, the aerosol generating substrate contains 40% to 70% by weight tobacco particles on a dry weight basis. More preferably, the aerosol generating substrate contains 45% to 70% by weight tobacco particles on a dry weight basis. Even more preferably, the aerosol generating substrate contains 50% to 70% by weight tobacco particles on a dry weight basis.

[0063] In a particular embodiment, the aerosol generating substrate contains 35% to 65% by weight tobacco particles on a dry weight basis. Preferably, the aerosol generating substrate contains 40% to 65% by weight tobacco particles on a dry weight basis. More preferably, the aerosol generating substrate contains 45% to 65% by weight tobacco particles on a dry weight basis. Even more preferably, the aerosol generating substrate contains 50% to 65% by weight tobacco particles on a dry weight basis.

[0064] In other embodiments, the aerosol generating substrate contains 35% to 60% by weight tobacco particles on a dry weight basis. Preferably, the aerosol generating substrate contains 40% to 60% by weight tobacco particles on a dry weight basis. More preferably, the aerosol generating substrate contains 45% to 60% by weight tobacco particles on a dry weight basis. Even more preferably, the aerosol generating substrate contains 50% to 60% by weight tobacco particles on a dry weight basis.

[0065] By adjusting the amount of tobacco particles in the aerosol-generating substrate, it may be advantageous to fine-tune the viscosity and density of the aerosol-generating substrate. This, in turn, affects the density and viscosity of the aerosol-generating substrate.

[0066] Furthermore, this may allow for beneficial control of the relative proportions of tobacco particles and one or more aerosol-forming agents in the solvent, which may affect the composition of the aerosols generated during use and delivered to the consumer. Therefore, by adjusting the tobacco particle content in the aerosol-generating substrate, it may be advantageously possible to fine-tune the delivery of certain aerosol species to the consumer during use.

[0067] The tobacco particles may have an average particle size of at least 25 micrometers. Preferably, the tobacco particles have an average particle size of at least 30 micrometers. More preferably, the tobacco particles have an average particle size of at least 35 micrometers. Even more preferably, the tobacco particles have an average particle size of at least 40 micrometers.

[0068] Using tobacco particles with an average particle size of 25 micrometers or larger can help control how easily the tobacco particles disperse in the solvent and how well they can be kept in a suspension state, which helps provide a homogeneous distribution of tobacco particles throughout the internal core of the aerosol generating element.

[0069] Tobacco particles may have an average size of up to 250 micrometers. Preferably, tobacco particles have an average size of 200 micrometers or less. More preferably, tobacco particles have an average size of 180 micrometers or less. Even more preferably, tobacco particles have an average size of 160 micrometers or less. Most preferably, tobacco particles have an average size of 140 micrometers or less.

[0070] In some embodiments, the tobacco particles have an average size of 30 to 200 micrometers, preferably 35 to 200 micrometers, and more preferably 40 to 200 micrometers. In other embodiments, the tobacco particles have an average size of 30 to 180 micrometers, preferably 35 to 180 micrometers, and more preferably 40 to 180 micrometers. In yet another embodiment, the tobacco particles have an average size of 30 to 160 micrometers, preferably 35 to 160 micrometers, and more preferably 40 to 160 micrometers. In yet another embodiment, the tobacco particles have an average size of 30 to 140 micrometers, preferably 35 to 140 micrometers, and more preferably 40 to 140 micrometers.

[0071] Advantageously, using tobacco particle sizes with an average size within the aforementioned range has a beneficial effect on the fluidity and malleability of the internal core material, and may also allow for some desirable control over the porosity of the formed aerosol-generating elements, which helps in the release of aerosol species during use.

[0072] Tobacco particles may have a D90 value of up to 140 micrometers. This expression means that 90 percent of tobacco particles in an aerosol-generating substrate have a size of 140 micrometers or less. In a population of particles, the D90 value may be determined by analyzing the particle size distribution. More specifically, by looking at the particle size distribution curve, the D90 value can be determined by identifying the point on the curve where 90 percent of the particles fall.

[0073] Preferably, the tobacco particles have a D90 value of 120 micrometers or less. More preferably, the tobacco particles have a D90 value of 100 micrometers or less. Even more preferably, the tobacco particles have a D90 value of 90 micrometers or less. In a particularly preferred embodiment, the tobacco particles have a D90 value of 80 micrometers or less or 70 micrometers or less.

[0074] Tobacco particles may have a D90 value of at least 35 micrometers. Preferably, tobacco particles have a D90 value of at least 40 micrometers. More preferably, tobacco particles have a D90 value of at least 45 micrometers. Even more preferably, tobacco particles have a D90 value of at least 50 micrometers.

[0075] The particle size distribution may be determined by laser diffraction. For example, the particle size distribution may be determined by laser diffraction using a Malvern Mastersizer 3000 laser diffraction particle size analyzer, according to the manufacturer's instructions.

[0076] Using tobacco particles with a D90 value that falls within the aforementioned range has the advantage of achieving a regular particle distribution within the aerosol generating element. This can facilitate the control of the porosity of the aerosol generating element, which helps in the release of aerosol species during use. In addition, this helps ensure that a consistent aerosol can be generated from the aerosol generating element as heating occurs.

[0077] Preferably, the tobacco particles are substantially uniformly dispersed through the aerosol-generating substrate.

[0078] Aerosol generating substrate composition - aerosol forming body Preferably, the aerosol generating substrate contains one or more aerosol-forming bodies at least 35% by weight on a dry weight basis. More preferably, the aerosol generating substrate contains one or more aerosol-forming bodies at least 40% by weight on a dry weight basis.

[0079] Preferably, the aerosol generating substrate contains one or more aerosol-forming bodies at a dry weight of 75% or less. More preferably, the aerosol generating substrate contains one or more aerosol-forming bodies at a dry weight of 70% or less. Even more preferably, the aerosol generating substrate contains one or more aerosol-forming bodies at a dry weight of 65% or less. In a particularly preferred embodiment, the aerosol generating substrate contains one or more aerosol-forming bodies at a dry weight of 60% or less.

[0080] In some embodiments, the aerosol generating substrate comprises one or more aerosol-forming materials at a dry weight of 35% to 75%. Preferably, the aerosol generating substrate comprises one or more aerosol-forming materials at a dry weight of 35% to 70%. More preferably, the aerosol generating substrate comprises one or more aerosol-forming materials at a dry weight of 35% to 65%. Even more preferably, the aerosol generating substrate comprises one or more aerosol-forming materials at a dry weight of 35% to 60%.

[0081] In a particular embodiment, the aerosol generating substrate comprises one or more aerosol-forming materials in an amount of 40% to 75% by weight on a dry weight basis. Preferably, the aerosol generating substrate comprises one or more aerosol-forming materials in an amount of 40% to 70% by weight on a dry weight basis. More preferably, the aerosol generating substrate comprises one or more aerosol-forming materials in an amount of 40% to 65% by weight on a dry weight basis. Even more preferably, the aerosol generating substrate comprises one or more aerosol-forming materials in an amount of 40% to 60% by weight on a dry weight basis.

[0082] By adjusting the amount of aerosol-forming material in the aerosol-generating substrate, it may be advantageous to fine-tune the viscosity and density of the aerosol-generating substrate. This, in turn, affects the density and viscosity of the aerosol-generating substrate.

[0083] Furthermore, this may allow for beneficial control of the relative proportions of tobacco particles and one or more aerosol-forming agents in the solvent, which may affect the composition of the aerosols generated during use and delivered to the consumer. Therefore, by adjusting the content of aerosol-forming agents in the aerosol-generating substrate, it may be advantageously possible to fine-tune the delivery of certain aerosol species to the consumer during use.

[0084] Suitable aerosol-forming materials for use in the manufacture of aerosol-generating elements according to this disclosure include, but are not limited to, glycerin, propylene glycol, and mixtures thereof.

[0085] In some embodiments, the aerosol generating substrate contains at least 35% by weight of glycerin on a dry weight basis. Preferably, the aerosol generating substrate contains at least 40% by weight of glycerin on a dry weight basis.

[0086] Preferably, the aerosol generating substrate contains 75% by weight or less of glycerin on a dry weight basis. More preferably, the aerosol generating substrate contains 70% by weight or less of glycerin on a dry weight basis. Even more preferably, the aerosol generating substrate contains 65% by weight or less of glycerin on a dry weight basis. In a particularly preferred embodiment, the aerosol generating substrate contains 60% by weight or less of glycerin on a dry weight basis.

[0087] In some embodiments, the aerosol generating substrate contains 35% to 75% by weight of glycerin on a dry weight basis. Preferably, the aerosol generating substrate contains 35% to 70% by weight of glycerin on a dry weight basis. More preferably, the aerosol generating substrate contains 35% to 65% by weight of glycerin on a dry weight basis. Even more preferably, the aerosol generating substrate contains 35% to 60% by weight of glycerin on a dry weight basis.

[0088] In other embodiments, the aerosol generating substrate contains 40% to 75% by weight of glycerin on a dry weight basis. Preferably, the aerosol generating substrate contains 40% to 70% by weight of glycerin on a dry weight basis. More preferably, the aerosol generating substrate contains 40% to 65% by weight of glycerin on a dry weight basis. Even more preferably, the aerosol generating substrate contains 40% to 60% by weight of glycerin on a dry weight basis.

[0089] Preferably, the combined total amount of tobacco particles in the aerosol generating substrate and one or more aerosol forming bodies is at least 95% by dry weight. More preferably, the combined total amount of tobacco particles in the aerosol generating substrate and one or more aerosol forming bodies is at least 96% by dry weight. Even more preferably, the combined total amount of tobacco particles in the aerosol generating substrate and one or more aerosol forming bodies is at least 97% by dry weight.

[0090] Therefore, the majority of aerosol-generating substrates essentially consist of tobacco particles and a solvent containing one or more aerosols. This maximizes the ability of the aerosol-generating element to generate and release aerosol species and provides more efficient use of the volume of the aerosol-generating element compared to certain existing aerosol-generating products. This is also desirable from the standpoint of overall efficiency and sustainability, where energy and other resources are actually consumed primarily to provide the aerosol-generating material to consumers, both during the manufacture of the aerosol-generating element and during storage and transportation.

[0091] Preferably, the aerosol generating substrate contains less than 5% by weight of water. More preferably, the aerosol generating substrate contains less than 4% by weight of water. Even more preferably, the aerosol generating substrate contains less than 3% by weight of water.

[0092] Reducing water consumption during the manufacturing process is desirable from a sustainability perspective. In addition, limiting the water content in aerosol-generating elements has the advantage that only a negligible amount of electricity is consumed during use to heat the water to over 100 degrees Celsius (including providing the latent heat of vaporization required to form steam), while the majority of the electricity is used more efficiently to heat the aerosol-generating material.

[0093] In some embodiments, the combined total amount of tobacco particles and one or more aerosol-forming materials in the aerosol-generating substrate is substantially 100 percent by weight on a dry weight basis. In other words, the aerosol-generating substrate exclusively contains tobacco particles and aerosol-forming materials, preferably exclusively containing tobacco particles and glycerin.

[0094] Aerosol-generating substrate composition - Others In some embodiments, the aerosol generating substrate further comprises a hydrophilic colloid.

[0095] Including hydrophilic colloids in the aerosol generating substrate means that the mechanical properties of the internal core of the aerosol generating element are such that the internal core contains divalent cations (for example, Ca in aqueous solution). ++ It has the advantage that it can be adjusted, for example, by exposure to ions. Crosslinking of hydrophilic colloids may cause some degree of hardening of the inner core, along with some decrease in the elasticity of the inner core. By adjusting the amount of hydrophilic colloid in the aerosol-generating substrate, the degree of crosslinking achieved by exposing the inner core to divalent cations can be favorably fine-tuned.

[0096] The aerosol generating substrate may contain at least 0.5 weight percent of hydrophilic colloid. Preferably, the aerosol generating substrate contains at least 1 weight percent of hydrophilic colloid. More preferably, the aerosol generating substrate contains at least 1.5 weight percent of hydrophilic colloid. Even more preferably, the aerosol generating substrate contains at least 2 weight percent of hydrophilic colloid.

[0097] The aerosol generating substrate preferably contains 7% by weight or less of hydrophilic colloid. More preferably, the aerosol generating substrate contains 6% by weight or less of hydrophilic colloid. Even more preferably, the aerosol generating substrate contains 5% by weight or less of hydrophilic colloid.

[0098] In some embodiments, the aerosol generating substrate contains 0.5% to 7% by weight of hydrophilic colloid, preferably 1% to 7% by weight of hydrophilic colloid, and more preferably 2% to 7% by weight of hydrophilic colloid.

[0099] In a particular embodiment, the aerosol generating substrate comprises 0.5% to 6% by weight of hydrophilic colloid, preferably 1% to 6% by weight of hydrophilic colloid, and more preferably 2% to 6% by weight of hydrophilic colloid.

[0100] In other embodiments, the aerosol generating substrate comprises 0.5% to 5% by weight of hydrophilic colloid, preferably 1% to 5% by weight of hydrophilic colloid, and more preferably 2% to 5% by weight of hydrophilic colloid.

[0101] Preferably, the hydrophilic colloid is selected from the group consisting of starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gum, and combinations thereof.

[0102] In a preferred embodiment, the hydrophilic colloid comprises one or more polysaccharides. In a particularly preferred embodiment, the hydrophilic colloid comprises an alginate.

[0103] In a particular embodiment, the hydrophilic colloid in the aerosol-generating substrate and the film-forming polymer in the outer shell contain the same compound.

[0104] This has advantages from a manufacturing standpoint, as it allows for the addition of hydrophilic colloids both on the surface of the inner core and within the inner core using a single operation. Furthermore, the crosslinking process induced by exposing the hydrophilic colloids to divalent cations may strengthen the bond between the outer shell and the more inward portion of the inner core.

[0105] In some embodiments, the aerosol generating substrate further comprises one or more flavoring agents.

[0106] Suitable flavorings for inclusion in the aerosol generating elements according to the present invention will be well known to those skilled in the art. The flavorings may include one or more natural flavorings, one or more synthetic flavorings, or a combination of natural and synthetic flavorings. Suitable flavorings include, but are not limited to, natural or synthetic menthol, mint flavors such as peppermint or spearmint, coffee flavor, spice flavor (cinnamon, clove, ginger, etc.), cocoa flavor, vanilla flavor, fruit flavor, chocolate flavor, licorice flavor, citrus flavor, gamma octamer, vanillin, ethyl vanillin, breath freshener flavor, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, ginger oil, tobacco flavor, tea flavor, wine flavor, berry flavor, rosemary, star anise, chamomile, sage, lavender, eucalyptus, geranium, eugenol, agave, juniper, anethole, and linalool.

[0107] In some embodiments, the aerosol generating substrate further comprises a pH adjusting agent.

[0108] pH adjusters may be included in the aerosol generating element according to the present invention for the purpose of utilizing their antioxidant properties. pH adjusters can help maintain the stability of the aerosol generating substrate and can also act as preservatives.

[0109] In certain embodiments, the aerosol-generating substrate further comprises a viscosity modifier. This may help increase the viscosity of the inner core without requiring an increase in the tobacco particle content beyond a certain threshold. Very high tobacco particle content may lead to an increase in viscosity, yet may nevertheless provide only a slight increase in terms of aerosol delivery; therefore, it may be preferable to control the viscosity of the inner core without necessarily changing the tobacco particle content.

[0110] External shell At least one film-forming polymer of the outer shell preferably comprises a hydrophilic colloid, preferably a hydrophilic colloid selected from the group consisting of starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gum, and combinations thereof.

[0111] Preferably, the hydrophilic colloid comprises one or more polysaccharides. More preferably, the one or more polysaccharides comprises alginates. One reason why alginates are preferred hydrophilic colloids is their ability to form networks in the presence of divalent cations, mainly Ca2+ ions.

[0112] In some embodiments, one or more polysaccharides include an alginate composite material comprising an alginate and further hydrophilic colloids or proteins or starches.

[0113] Suitable alginate composite materials containing alginates and further hydrophilic colloids include alginate-chitosan, alginate-gelatin, alginate-pectin, alginate-carrageenan, alginate-guar gum, and alginate-carboxymethylcellulose (CMC).

[0114] Suitable alginate composite materials containing alginates and proteins include alginate-casein, alginate-whey protein, and alginate-soy protein.

[0115] Suitable alginate composite materials containing alginate and starch include alginate-natural starch, alginate-resistant starch, and alginate-gelatinized starch. Resistant starch consists of only a small amount that is not digested in the human small intestine.

[0116] The use of alginate composite materials may be beneficial because it may provide improved protection and control over the release of the material encapsulated within the shell. While we do not wish to be bound by theory, it is understood that this may be due to the improved physical and mechanical properties of the encapsulated shell obtained when additional hydrophilic colloids or proteins or starches are added to the alginate. Preferably, the hydrophilic colloids in the outer shell are crosslinked.

[0117] The outer shell may contain at least 70 weight percent of at least one film-forming polymer on a dry weight basis. Preferably, the outer shell contains at least 80 weight percent of at least one film-forming polymer on a dry weight basis. More preferably, the outer shell contains at least 85 weight percent of at least one film-forming polymer on a dry weight basis. Even more preferably, the outer shell contains at least 90 weight percent of at least one film-forming polymer on a dry weight basis. Most preferably, the outer shell contains at least 95 weight percent of at least one film-forming polymer on a dry weight basis.

[0118] In some embodiments, the outer shell further contains a plasticizer. Preferably, the outer shell contains at least 1 weight percent of plasticizer on a dry weight basis. More preferably, the outer shell contains at least 2 weight percent of plasticizer on a dry weight basis. Even more preferably, the outer shell contains at least 3 weight percent of plasticizer on a dry weight basis.

[0119] Preferably, the outer shell contains 6% by weight or less of plasticizer on a dry weight basis. More preferably, the outer shell contains 5% by weight or less of plasticizer on a dry weight basis.

[0120] The outer shell may have a thickness of at least 60 micrometers. Preferably, the outer shell has a thickness of at least 80 micrometers. More preferably, the outer shell has a thickness of at least 100 micrometers. Even more preferably, the outer shell has a thickness of at least 110 micrometers. In a particularly preferred embodiment, the outer shell has a thickness of at least 120 micrometers.

[0121] The outer shell preferably has a thickness of 2 mm or less. More preferably, the outer shell has a thickness of 1.5 mm or less. Even more preferably, the outer shell has a thickness of 1 mm or less.

[0122] The average thickness of the outer shell may correspond to 15 percent or less of the maximum dimensions of the aerosol-generating element.

[0123] In this specification, the expression “maximum dimensions of the aerosol generating element” is used to indicate the largest dimensions of an aerosol generating element consistent with this disclosure. Depending on the shape of the aerosol generating element, which will be discussed in more detail below, the term “dimensions” may refer to different geometric parameters of the aerosol generating element. For example, in the case of a substantially spherical aerosol generating element, the maximum dimension corresponds to the diameter of the aerosol generating element. In another embodiment, in the case of a parallelepiped aerosol generating element, the term maximum dimension may refer to the largest of the length, width, and thickness of the parallelepiped.

[0124] Preferably, the average thickness of the outer shell corresponds to 10 percent or less of the maximum dimensions of the aerosol generating element. More preferably, the average thickness of the outer shell corresponds to 8 percent or less of the maximum dimensions of the aerosol generating element. Even more preferably, the average thickness of the outer shell corresponds to 6 percent or less of the maximum dimensions of the aerosol generating element.

[0125] The average thickness of the outer shell preferably corresponds to at least 1 percent of the maximum dimensions of the aerosol generating element. More preferably, the average thickness of the outer shell preferably corresponds to at least 2 percent of the maximum dimensions of the aerosol generating element. Even more preferably, the average thickness of the outer shell preferably corresponds to at least 3 percent of the maximum dimensions of the aerosol generating element.

[0126] In some embodiments, the average thickness of the outer shell corresponds to 1 to 10 percent of the maximum dimensions of the aerosol generating element, preferably 2 to 10 percent, and more preferably 3 to 10 percent.

[0127] In a particular embodiment, the average thickness of the outer shell corresponds to 1 to 8 percent of the maximum dimensions of the aerosol generating element, preferably 2 to 8 percent, and more preferably 3 to 8 percent.

[0128] In some embodiments, the average thickness of the outer shell corresponds to 1 to 6 percent of the maximum dimensions of the aerosol generating element, preferably 2 to 6 percent, and more preferably 3 to 6 percent.

[0129] The weight of the outer shell may correspond to 50 percent or less of the weight of the aerosol generating element. Preferably, the weight of the outer shell corresponds to 45 percent or less of the weight of the aerosol generating element. More preferably, the weight of the outer shell corresponds to 40 percent or less of the weight of the aerosol generating element. Even more preferably, the weight of the outer shell corresponds to 35 percent or less of the weight of the aerosol generating element.

[0130] The weight of the outer shell may correspond to at least 1 percent of the weight of the aerosol generating element. Preferably, the weight of the outer shell corresponds to at least 2 percent of the weight of the aerosol generating element. More preferably, the weight of the outer shell corresponds to at least 5 percent of the weight of the aerosol generating element.

[0131] In some embodiments, the weight of the outer shell corresponds to 1 to 45 percent of the weight of the aerosol generating element, preferably 1 to 40 percent, and more preferably 1 to 35 percent.

[0132] In a particular embodiment, the weight of the outer shell corresponds to 2 to 45 percent of the weight of the aerosol generating element, preferably 2 to 40 percent, and more preferably 2 to 35 percent.

[0133] In other embodiments, the weight of the outer shell corresponds to 5 to 45 percent of the weight of the aerosol generating element, preferably 5 to 40 percent, and more preferably 5 to 35 percent.

[0134] In some embodiments, the outer shell comprises a combination of two or more different film-forming polymers.

[0135] As discussed above, since the internal core has a paste-like consistency, it is easy to form aerosol generating elements into various different shapes according to the previously described method. This may be achieved, for example, by introducing a predetermined amount of a formulation containing tobacco particles and a liquid solvent containing one or more aerosol-forming bodies into a mold having a shape to be applied to the aerosol generating element.

[0136] In some preferred embodiments, the aerosol generating element is substantially spherical.

[0137] In another preferred embodiment, the aerosol generating element is ring-shaped (toroidal).

[0138] In a further notable embodiment, the aerosol generating element is parallelepiped. One dimension of the parallelepiped may be significantly smaller than the other two dimensions, so that the aerosol generating element may be substantially in the form of a sheet. The three dimensions of the parallelepiped may all be substantially the same, so that the aerosol generating element may be substantially cubic.

[0139] The maximum dimension of the aerosol generating element may be at least 0.25 millimeters. Preferably, the maximum dimension of the aerosol generating element is at least 0.5 millimeters. More preferably, the maximum dimension of the aerosol generating element is at least 0.75 millimeters. Even more preferably, the maximum dimension of the aerosol generating element is at least 1 millimeter.

[0140] The maximum dimensions of the aerosol generating element may be 5 millimeters or less. Preferably, the maximum dimensions of the aerosol generating element are 4 millimeters or less. More preferably, the maximum dimensions of the aerosol generating element are 3 millimeters or less.

[0141] In some embodiments, the maximum dimensions of the aerosol generating element are 0.5 mm to 5 mm, preferably 0.75 mm to 5 mm, and more preferably 1 mm to 5 mm.

[0142] In a particular embodiment, the maximum dimensions of the aerosol generating element are 0.5 mm to 4 mm, preferably 0.75 mm to 4 mm, and more preferably 1 mm to 4 mm.

[0143] In other embodiments, the maximum dimensions of the aerosol generating element are 0.5 mm to 3 mm, preferably 0.75 mm to 3 mm, and more preferably 1 mm to 3 mm.

[0144] The total weight of the aerosol generating element may be at least 0.05 grams. Preferably, the total weight of the aerosol generating element is at least 0.1 grams. More preferably, the total weight of the aerosol generating element is at least 0.25 grams. Even more preferably, the total weight of the aerosol generating element is at least 0.5 grams.

[0145] The total weight of the aerosol generating elements may be 1.5 grams or less. Preferably, the total weight of the aerosol generating elements is 1.25 grams or less. More preferably, the total weight of the aerosol generating elements is 1 gram or less. Even more preferably, the total weight of the aerosol generating elements is 0.8 grams or less.

[0146] In some embodiments, the total weight of the aerosol generating element is 0.1 grams to 1.5 grams, preferably 0.1 grams to 1.25 grams, more preferably 0.1 grams to 1 gram, and even more preferably 0.1 grams to 0.8 grams.

[0147] In a particular embodiment, the total weight of the aerosol generating element is 0.25 grams to 1.5 grams, preferably 0.25 grams to 1.25 grams, more preferably 0.25 grams to 1 gram, and even more preferably 0.25 grams to 0.8 grams.

[0148] In other embodiments, the total weight of the aerosol generating element is 0.5 grams to 1.5 grams, preferably 0.5 grams to 1.25 grams, more preferably 0.5 grams to 1 gram, and even more preferably 0.5 grams to 0.8 grams.

[0149] The total water content of the aerosol generating elements may be less than 5 percent. Preferably, the total water content of the aerosol generating elements is less than 4 percent. More preferably, the total water content of the aerosol generating elements is less than 3 percent. Even more preferably, the total water content of the aerosol generating elements is less than 2.5 percent. In a particularly preferred embodiment, the total water content of the aerosol generating elements is less than 2 percent.

[0150] Similarly, lower moisture content allows the manufacturing process to be more sustainable, as the overall consumption of natural resources is favorably minimized.

[0151] As briefly stated above, an aerosol generating element consistent with the above description may be used on its own in conjunction with an aerosol generating device adapted to supply heat to an aerosol generating substrate contained within the aerosol generating element to generate an inhalable aerosol that can be delivered to a consumer. Specifically, the aerosol generating device is preferably an electrically operated aerosol generating device comprising a heater element configured to heat the aerosol generating element.

[0152] However, one or more of the aerosol generating elements described above may also be included in the aerosol generating article used in the aerosol generating device. The aerosol generating device is preferably an electrically operated aerosol generating device that includes a heater element configured to heat the aerosol generating article.

[0153] This disclosure also relates to a method for producing an aerosol generating element as described above.

[0154] The method may include a step of forming a core composition comprising tobacco particles and one or more aerosol-forming bodies.

[0155] The method may further include the step of forming individual parts of the core composition to provide an internal core.

[0156] The method may additionally include a step of coating the internal core with a coating composition comprising at least one film-forming polymer.

[0157] The method may also include the step of drying the coated inner core to form an aerosol generating element having an inner core and an outer shell.

[0158] A third aspect of the present invention provides a method for producing an aerosol generating element according to a first aspect of the present invention, the method comprising the steps of: forming a core composition comprising tobacco particles and one or more aerosol forming bodies; forming separate parts of the core composition to provide an internal core; coating the internal core with a coating composition comprising at least one film-forming polymer; and drying the coated internal core to form an aerosol generating element having an internal core and an external shell.

[0159] Advantageously, due to the paste-like consistency of the core composition, the size and shape of the internal core can be adjusted and controlled during the process of forming individual parts of the core composition. The internal core can then be easily encapsulated using a coating composition containing a film-forming polymer in a subsequent step of coating the internal core, which may further stabilize the size and shape of the internal core, and more generally, the size and shape of the entire aerosol-generating element.

[0160] Preferably, the method further includes a step of adding the coated inner core to a crosslinking solution of polyvalent cations before the drying step to crosslink the film-forming polymer. This enables the production of an aerosol-generating element in which a stronger bond may be established between the outer shell and the inner core.

[0161] In some embodiments, the core composition further comprises a hydrophilic colloid.

[0162] Preferably, the method further includes the step of adding individual portions of the core composition to a crosslinking solution of polyvalent cations prior to the coating step. The crosslinking reaction between the hydrophilic colloid and the polyvalent cation advantageously provides hardening and general strengthening of the outer shell, and more broadly, hardening and general strengthening of the entire aerosol generating element. In those embodiments in which the (same) hydrophilic colloid is present in both the core composition and the coating composition, a particularly strong bond may be established between the inner core and the outer shell, which may impart a particularly desirable structural strength to the aerosol generating element.

[0163] Preferably, the core composition contains less than 5% by weight of water. More preferably, the core composition is substantially water-free. This has the advantage of making the overall manufacturing process particularly sustainable.

[0164] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, forms, or aspects described herein.

[0165] Example 1: An aerosol generating element for use in an aerosol generating article or system, comprising: an internal core of an aerosol generating substrate, the internal core comprising a liquid solvent containing tobacco particles and one or more aerosol-forming bodies; and an external shell enclosing the internal core of the aerosol generating substrate, the external coating comprising at least one film-forming polymer, wherein the aerosol generating substrate comprises at least 20 weight percent of tobacco particles and at least 30 weight percent of one or more aerosol-forming bodies on a dry weight basis. Example 2: The aerosol generating element according to Example 1, wherein the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is at least 0.3. Example 3: An aerosol generating element according to Example 1 or Example 2, wherein the viscosity of the aerosol generating substrate is less than 20,000 cp. Example 4: An aerosol generating element according to any one of Examples 1 to 3, wherein the viscosity of the aerosol generating substrate is at least 6,000 cp. Example 5: An aerosol generating element according to any one of Examples 1 to 4, wherein the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is less than 1.5. Example 6: An aerosol generating element according to any one of Examples 1 to 5, wherein the aerosol generating substrate is an aerosol-generating suspension of tobacco particles in a liquid solvent. Example 7: An aerosol generating element according to any one of Examples 1 to 6, wherein the density of the aerosol generating substrate is at least 1 gram per cubic centimeter. Example 8: An aerosol generating element according to any one of Examples 1 to 7, wherein the density of the aerosol generating substrate is less than 2 grams per cubic centimeter. Example 9: An aerosol generating element according to any one of Examples 1 to 8, wherein the aerosol generating substrate contains at least 35 weight percent of tobacco particles on a dry weight basis. Example 10: An aerosol generating element according to any one of Examples 1 to 9, wherein the aerosol generating substrate contains less than 65% by weight of tobacco particles on a dry weight basis. Example 11: An aerosol generating element according to any one of Examples 1 to 10, wherein the tobacco particles have an average particle size of at least 30 micrometers. Example 12: An aerosol generating element according to any one of Examples 1 to 11, wherein the tobacco particles have a D90 value of less than 120 micrometers. Example 13: An aerosol generating element according to any one of Examples 1 to 12, wherein the tobacco particles have a D90 value of 50 micrometers to 70 micrometers. Example 14: An aerosol generating element according to any one of Examples 1 to 13, wherein tobacco particles are substantially homogeneously dispersed through an aerosol generating substrate. Example 15: An aerosol generating element according to any one of Examples 1 to 14, wherein the aerosol generating substrate comprises one or more aerosol forming bodies in a dry weight basis of at least 40 weight percent. Example 16: An aerosol generating element according to any one of Examples 1 to 15, wherein the aerosol generating substrate comprises one or more aerosol forming bodies in a dry weight basis of less than 60 weight percent. Example 17: An aerosol generating element according to any one of Examples 1 to 16, wherein the aerosol generating substrate contains at least 40% by weight of glycerin on a dry weight basis. Example 18: An aerosol generating element according to any one of Examples 1 to 17, wherein the total amount of tobacco particles and one or more aerosol forming bodies combined in the aerosol generating substrate is at least 95 percent by dry weight. Example 19: An aerosol generating element according to any one of Examples 1 to 18, wherein the aerosol generating substrate contains less than 5% by weight of water. Example 20: An aerosol generating element according to any one of Examples 1 to 19, wherein the aerosol generating substrate further comprises a hydrophilic colloid. Example 21: The aerosol generating element according to Example 20, wherein the aerosol generating substrate contains at least 1 weight percent of hydrophilic colloid. Example 22: An aerosol generating element according to Example 20 or Example 21, wherein the aerosol generating substrate contains less than 5% by weight of hydrophilic colloid. Example 23: An aerosol generating element according to any one of Examples 20 to 22, wherein the hydrophilic colloid is selected from the group consisting of starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gum, and combinations thereof. Example 24: An aerosol generating element according to any one of Examples 20 to 23, wherein the hydrophilic colloid contains one or more polysaccharides. Example 25: An aerosol generating element according to Example 23 or Example 24, wherein the hydrophilic colloid contains alginate. Example 26: An aerosol generating element according to any one of Examples 20 to 25, wherein the hydrophilic colloid in the aerosol generating substrate and the film-forming polymer in the outer shell contain the same compound. Example 27: An aerosol generating element according to any one of Examples 1 to 26, wherein the aerosol generating substrate further comprises one or more flavoring agents. Example 28: An aerosol generating element according to any one of Examples 1 to 27, wherein at least one film-forming polymer of the outer shell contains a hydrophilic colloid. Example 29: The aerosol generating element according to Example 28, wherein the hydrophilic colloid is selected from the group consisting of starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, agar, carrageenan, gelatin, natural gum, and combinations thereof. Example 30: An aerosol generating element according to Example 28 or Example 29, wherein the hydrophilic colloid comprises one or more cross-linked polysaccharides. Example 31: The aerosol generating element according to Example 30, wherein one or more [crosslinked] polysaccharides contain alginate. Example 32: An aerosol generating element according to any one of Examples 1 to 31, wherein the outer shell comprises at least 80 weight percent by dry weight of at least one film-forming polymer. Example 33: The aerosol generating element according to Example 32, wherein the outer shell comprises at least 90 percent by weight of at least one film-forming polymer on a dry weight basis. Example 34: An aerosol generating element according to any one of Examples 1 to 33, wherein the outer shell further comprises a plasticizer. Example 35: The aerosol generating element according to Example 34, wherein the outer shell contains at least 2 weight percent of plasticizer on a dry weight basis. Example 36: An aerosol generating element according to any one of Examples 1 to 35, wherein the outer shell has an average thickness of at least 100 micrometers. Example 37: An aerosol generating element according to any of Examples 1 to 36, wherein the outer shell has an average thickness of less than 2 millimeters. Example 38: An aerosol generating element according to any of Examples 1 to 37, wherein the average thickness of the outer shell corresponds to less than 10 percent of the maximum dimensions of the aerosol generating element. Example 39: An aerosol generating element according to any of Examples 1 to 38, wherein the weight of the outer shell corresponds to less than 10 percent of the weight of the aerosol generating element. Example 40: An aerosol generating element according to any one of Examples 1 to 39, wherein the outer shell comprises a combination of two or more different film-forming polymers. Example 41: An aerosol generating element according to any of Examples 1 to 40, wherein the maximum dimension of the aerosol generating element is at least 0.5 millimeters. Example 42: An aerosol generating element according to any one of Examples 1 to 41, wherein the maximum dimension of the aerosol generating element is at least 1 millimeter. Example 43: An aerosol generating element according to any of Examples 1 to 42, wherein the maximum dimension of the aerosol generating element is less than 3 millimeters. Example 44: An aerosol generating element according to any one of Examples 1 to 43, wherein the total weight of the aerosol generating element is at least 0.1 grams. Example 45: An aerosol generating element according to any of Examples 1 to 44, wherein the total weight of the aerosol generating element is less than 1 gram. Example 46: An aerosol generating element according to any of Examples 1 to 45, wherein the total water content of the aerosol generating element is less than 5 percent. Example 47: An aerosol generating element according to any one of Examples 1 to 46, wherein the aerosol generating element is substantially spherical. Example 48: An aerosol generating element according to any one of Examples 1 to 47, wherein the aerosol generating element is ring-shaped. Example 49: An aerosol generating element according to any of Examples 1 to 48, wherein the aerosol generating element is in the form of a sheet. Example 50: An aerosol generating article comprising an aerosol generating element described in any of Examples 1 to 49. Example 51: An aerosol generating system comprising an aerosol generating element described in any one of Examples 1 to 49 and an electrically operated aerosol generating device having a heater element configured to heat the aerosol generating element. Example 52: A method for producing an aerosol generating element described in any one of Examples 1 to 49, A step of forming a core composition comprising tobacco particles and one or more aerosol-forming bodies, A step of forming individual parts of a core composition to provide an internal core, A step of coating the internal core with a coating composition containing at least one film-forming polymer, A method comprising the steps of drying a coated inner core to form an aerosol generating element having an inner core and an outer shell. Example 53: The method according to Example 52, further comprising the step of adding a coated inner core to a crosslinking solution of polyvalent cations to crosslink the film-forming polymer before the drying step. Example 54: The method according to Example 52 or Example 53, wherein the core composition further comprises a hydrophilic colloid. Example 55: The method according to Example 54, further comprising the step of adding individual parts of the core composition to a crosslinking solution of polyvalent cations before the coating step. Example 56: The method according to Example 52, wherein the core composition contains less than 5% by weight of water. Example 57: The method according to Example 56, wherein the core composition is substantially water-free.

[0166] Here, we will further describe the examples with reference to the figures. [Brief explanation of the drawing]

[0167] [Figure 1] Figure 1 shows a schematic side view of the aerosol generating element according to the present invention. [Figure 2] Figure 2 shows a schematic cross-sectional view of the aerosol generating element shown in Figure 1. [Figure 3] Figure 3 is a photograph showing the aerosol generating elements schematically illustrated in Figures 1 and 2. [Figure 4] Figure 4 shows a schematic side view of another aerosol generating element according to the present invention. [Figure 5]Figure 5 shows a schematic side view of a further aerosol generating element according to the present invention. [Figure 6] Figure 6 shows a schematic perspective view of yet another aerosol generating element according to the present invention. [Modes for carrying out the invention]

[0168] The aerosol generating element 10 according to the present invention is schematically illustrated in Figure 1. The aerosol generating element 10 is substantially spherical and has a maximum dimension D of 10.8 mm, corresponding to the diameter of the aerosol generating element 10. MAX It has.

[0169] As shown in Figure 2, the aerosol generating element comprises an internal core 12 of an aerosol generating substrate and an external shell 14 that encloses the internal core 12 of the aerosol generating substrate.

[0170] The aerosol generating substrate comprises tobacco particles and a liquid solvent containing glycerin.

[0171] More specifically, the inner core is formed from a paste prepared by mixing 17 grams of tobacco particles with 20 grams of glycerin. The inner core is shaped using a mold and then immersed in a 2% by weight alginate aqueous solution. The inner core with the alginate coating is then immersed for a few seconds in a 2% by weight calcium lactate solution, which almost immediately produces an alginate coating that solidifies around the inner core, thus forming an outer shell that encloses the inner core.

[0172] The thickness of the outer shell 14 is 0.8 millimeters, i.e., the maximum dimension D MAX That is 7.4 percent.

[0173] The structure of the aerosol generating element in Figures 1 and 2 is also shown in the photograph in Figure 3. Both the inner core and the outer shell can be easily identified.

[0174] Figures 4, 5, and 6 illustrate other embodiments of the aerosol generating element according to the present invention. The internal core and external shell of the aerosol generating elements 20, 30, and 40 in Figures 4, 5, and 6 have the same composition as the internal core 12 and external shell 14 of the aerosol generating element 10 in Figures 1, 2, and 3. However, the aerosol generating elements 20, 30, and 40 have different shapes and therefore different maximum dimensions D MAX It differs from the aerosol generating element 10 in that it has [a certain characteristic].

[0175] The aerosol generating element 20 in Figure 4 has an elongated pill shape, and its maximum dimension D MAX This corresponds to the length of the aerosol generating element 20 measured along the longitudinal axis of the aerosol generating element 20.

[0176] The aerosol generating element 30 in Figure 5 has a toroidal shape, and its maximum dimension D MAX This corresponds to the outer diameter of the aerosol generating element 30.

[0177] The aerosol generating element 40 in Figure 6 has a parallelepiped shape, and its maximum dimension D MAX In the parallelepiped shown in Figure 6, the depth and height are smaller than the width, and therefore correspond to the width of the aerosol generating element 40.

[0178] In another embodiment, the inner core is formed from a paste prepared by mixing 10 grams of tobacco particles with 20 grams of glycerin and 40 grams of a 2 wt% alginate aqueous solution. The inner core is shaped using a mold and then immersed for several seconds in a 2 wt% calcium lactate solution. Subsequently, the resulting inner core is immersed for several more seconds in the 2 wt% alginate aqueous solution, and then again for several seconds in the 2 wt% calcium lactate solution. This almost immediately causes the formation of a solid alginate coating around the inner core, thus forming an outer shell that encloses the inner core. In the previous immersion step, at least some of the alginate contained within the inner core also reacts with calcium cations, thus establishing a bond between the inner core and the outer shell.

[0179] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., should be understood in all cases as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the number A is understood as A ± 10 percent. In this context, the number A may be considered to include a number that falls within the general standard error to the measurement of the characteristic that the number A modifies. In some cases as used in the appended claims, the number “A” may deviate by the percentage listed above, provided that the amount of deviation of “A” does not substantially affect the basic and novel characteristics(s) of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. Aerosol generating element used in an aerosol generating article or system, An internal core of an aerosol generating substrate, wherein the aerosol generating substrate contains a liquid solvent containing tobacco particles and one or more aerosol forming bodies, An outer shell enclosing the inner core of an aerosol generating substrate, wherein the outer coating comprises at least one film-forming polymer, The aerosol generating substrate comprises at least 20 weight percent of tobacco particles and at least 30 weight percent of one or more aerosol forming bodies, on a dry weight basis. An aerosol generating element in which the weight ratio of tobacco particles to the liquid solvent in the aerosol generating substrate is at least 0.

3.

2. The aerosol generating element according to claim 1, wherein the weight ratio of tobacco particles to liquid solvent in the aerosol generating substrate is less than 1.

5.

3. The aerosol generating element according to any one of claims 1 to 2, wherein the aerosol generating substrate is an aerosol generating suspension of tobacco particles in a liquid solvent.

4. The aerosol generating element according to any one of claims 1 to 3, wherein the density of the aerosol generating substrate is at least 1 gram per cubic centimeter.

5. The aerosol generating element according to any one of claims 1 to 4, wherein the density of the aerosol generating substrate is less than 2 grams per cubic centimeter.

6. The aerosol generating element according to any one of claims 1 to 5, wherein the aerosol generating substrate contains at least 35 weight percent of tobacco particles on a dry weight basis.

7. The aerosol generating element according to any one of claims 1 to 6, wherein the aerosol generating substrate contains less than 65% by weight of tobacco particles on a dry weight basis.

8. The aerosol generating element according to any one of claims 1 to 7, wherein the tobacco particles have a D90 value of less than 120 micrometers.

9. The aerosol generating element according to any one of claims 1 to 8, wherein the aerosol generating substrate comprises one or more aerosol forming bodies in an amount of at least 40% by weight on a dry weight basis.

10. The aerosol generating element according to any one of claims 1 to 9, wherein the total amount of the tobacco particles and one or more aerosol forming bodies combined in the aerosol generating substrate is at least 95 percent by weight on a dry weight basis.

11. The aerosol generating element according to any one of claims 1 to 10, wherein the outer shell comprises at least one film-forming polymer containing a hydrophilic colloid.

12. An aerosol generating article comprising an aerosol generating element according to any one of claims 1 to 11.

13. An aerosol generating system comprising an aerosol generating element according to any one of claims 1 to 11, and an electrically operated aerosol generating device having a heater element configured to heat the aerosol generating element.

14. A method for producing an aerosol generating element according to any one of claims 1 to 11, A step of forming a core composition comprising tobacco particles and one or more aerosol-forming bodies, A step of forming individual parts of the core composition to provide an internal core, A step of coating the internal core with a coating composition comprising at least one film-forming polymer, A method comprising the step of drying the coated inner core to form an aerosol generating element having an inner core and an outer shell.

15. The method according to claim 14, further comprising the step of adding the coated inner core to a crosslinking solution of polyvalent cations to crosslink the film-forming polymer before the drying step.

Images