Aerosol-forming material comprising an amorphous solid comprising menthol and calcium cross-linked alginate

Abstract

The present invention provides an aerosol-forming material comprising an amorphous solid, the amorphous solid comprising 0.1 to 80% by weight of menthol, 1 to 60% by weight of a gelling agent comprising calcium cross-linked alginate having α-(1-4)-linked L-guluronate (G) units, and 0.1 to 50% by weight of an aerosol-forming material, the calcium cross-linked alginate comprising α-(1-4)-linked L-guluronate (G) units. 2+ The molar ratio of cations to G units is 0.2:1 to 1:1.

Description

[Technical field]

[0001] The present invention relates to the generation of aerosols.

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

[0003] One example of such a product is a heating device that releases compounds by heating but not burning a solid aerosol-generating material, which in some examples may include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of a solid aerosol-generating material.

[0004] Another example is an e-cigarette / tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-forming material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Overview

[0005] According to a first aspect of the present invention there is provided an aerosol-forming material comprising an amorphous solid, the amorphous solid comprising: 0.1 to 80% by weight of menthol; 1-60% by weight of a gelling agent comprising calcium cross-linked alginate comprising α-(1-4)-linked L-guluronate (G) units; 0.1 to 50 weight percent of an aerosol-forming material; Equipped with Ca 2+ The molar ratio of cations to G units is 0.2-1.

[0006] According to a third aspect of the present invention, there is provided a substrate comprising an aerosol-generating material as described herein and a support on which the aerosol-generating material is disposed.

[0007] According to a further aspect of the invention, there is provided an article for use with a non-combustion aerosol delivery device, the article comprising an aerosol-generating material as described herein and / or a substrate as described herein.

[0008] According to a further aspect of the invention, there is provided a non-combustion aerosol delivery system comprising an article as described herein and a non-combustion aerosol delivery device configured to generate an aerosol from the article when the article is used with the non-combustion aerosol delivery device.

[0009] According to a further aspect of the present invention, there is provided a method of making the aerosol-forming material described herein.

[0010] According to a further aspect of the invention, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system described herein. The method comprises heating an aerosol-generating material. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of less than or equal to 350° C. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of about 220° C. to about 280° C.

[0011] According to a further aspect of the present invention there is provided a use of the non-combustion aerosol delivery system described herein.

[0012] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which description is given by way of example only with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a cross-sectional view of an example of an aerosol product. [Diagram 2] FIG. 2 is a perspective view of the article of FIG. [Diagram 3] FIG. 2 is a cross-sectional elevation view of an example of an aerosol product. [Figure 4] FIG. 4 is a perspective view of the article of FIG. [Diagram 5] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 6] FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. [Figure 7] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 8] FIG. 1 illustrates puff-by-puff sensory data for an example aerosol-generating material. Detailed Description

[0014] An aerosol-generating material as described herein is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or in any other manner. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine and / or flavorings. The aerosol-generating material comprises an "amorphous solid." An amorphous solid may also be referred to as 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 that may retain some fluid therein, e.g., liquid. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solid to about 90%, 95%, or 100% amorphous solid by weight. In some examples, the aerosol-generating material consists of an amorphous solid.

[0015] As described hereinabove, the present invention provides an aerosol-forming material comprising an amorphous solid, the amorphous solid comprising: 0.1 to 80% by weight of menthol; 1-60% by weight of a gelling agent comprising calcium cross-linked alginate comprising α-(1-4)-linked L-guluronate (G) units; 0.1 to 50 weight percent of an aerosol-forming material; Equipped with Ca 2+ The molar ratio of cations to G units is from 0.2:1 to 1:1.

[0016] The gelling agent of the present invention comprises alginate salts (also referred to as "alginates"). Alginates are derivatives of alginic acid, which are linear polysaccharides comprising G units and typically M units. When divalent cations are added to alginic acid, the alginates crosslink to form a gel.

[0017] As used herein, "G unit" refers to α-(1-4)-linked L-guluronate. α-L-guluronate is the conjugate base of α-L-guluronic acid. G units are sometimes referred to as guluronate monomers or G residues. As used herein, "M unit" refers to β-(1-4)-linked D-mannuronate. β-D-mannuronate is the conjugate base of β-D-mannuronic acid. M units are sometimes referred to as mannuronate monomers or M residues.

[0018] [ka]

[0019] Ca 2+ Divalent cations such as calcium cations interact with the carboxylate groups of alginate monomers to form ionic crosslinks. The amorphous solids of the present invention comprise calcium crosslinked alginate. The inventors have found that the physical properties of the amorphous solids comprising calcium crosslinked alginate are influenced by, in particular, the relative concentration of calcium cations (Ca 2+ ) molar ratio.

[0020] The amorphous solids of the present invention comprise menthol, which is present in the amorphous solid as an active agent, i.e., the menthol is contained in the amorphous solid, and when the amorphous solid is heated, the menthol can be aerosolized and delivered to the user to provide a physiological and / or olfactory response.

[0021] Due to the physical properties of menthol (e.g., its volatility, solubility, etc.), it is difficult to provide a menthol-containing amorphous solid that has an acceptable shelf life and delivers an acceptable inhalable aerosol to a user when heated in a non-combustion aerosol delivery system.On the one hand, the amorphous solid should retain a desired amount of menthol during storage until the time when the amorphous solid is heated in a non-combustion aerosol delivery system.On the other hand, the amorphous solid should be configured to release a desired amount of menthol as part of an inhalable aerosol when the amorphous solid is heated.

[0022] The present inventors have 2+ It has been determined that forming an amorphous solid having a molar ratio of G units in the alginate of 0.2 to 1 provides a menthol-containing aerosol-forming material that has a good shelf life and releases a desired amount of menthol when the aerosol-forming material is heated in a non-combustion type aerosol delivery device. 2+ The ratio of G units in the alginate is 0.3:1 to 0.5:1. 2+ The ratio of G units in alginate is approximately 0.4:1 (approximately allowing for a 20% margin of error).

[0023] Without wishing to be bound by theory, the Ca 2+ Higher Ca content 2+ In amorphous solids having a Ca content, syneresis occurs and is therefore detrimental to the aerosol-forming material during storage. 2+ Ca content lower than 2+ Amorphous solids having such content are believed not to retain the desired amount of menthol after storage.

[0024] In examples, the calcium cross-linked alginate comprises a combination of G and M units. In some embodiments, the G and M units are present in a molar ratio of 1:2 to 10:1 (i.e., the number of α-(1-4)-linked L-guluronate units present compared to the number of β-(1-4)-linked D-mannuronate units). In some embodiments, the G and M units are present in a molar ratio of 1:3 to 3:1, or 1:2 to 2:1, or 1:1.5 to 1.5:1, or 1:1.2 to 1.2:1.

[0025] In some embodiments, when stored in a closed container under ambient conditions (22° C., 60% relative humidity, 1013 mbar) according to ISO 3402 for 30 days, the aerosol-forming material comprises at least 60%, 70%, 80%, or 90% menthol, by dry weight of the menthol present in the aerosol-forming material prior to storage.

[0026] In some embodiments, when stored in a closed container under ambient conditions (22° C., 60% relative humidity, 1013 mbar) according to ISO 3402 for 6 weeks (42 days), the aerosol-forming material comprises at least 60%, 70%, 80%, or 90% menthol, by dry weight of the menthol present in the aerosol-forming material prior to storage.

[0027] In some embodiments, when stored in a closed container under ambient conditions (22° C., 60% relative humidity, 1013 mbar) for 16 weeks (112 days) in accordance with ISO 3402, the aerosol-forming material contains at least 60%, 70%, 80%, or 90% menthol, by dry weight of the menthol present in the aerosol-forming material prior to storage.

[0028] In some embodiments, the alginate is included in the gelling agent in an amount of 15-40% by weight of the amorphous solid, i.e., the amorphous solid comprises alginate in an amount of 15-40% by weight based on the dry weight of the amorphous solid, hi some embodiments, the amorphous solid comprises alginate in an amount of 10-35% or 15%-30% by weight.

[0029] In some embodiments, the gelling agent further comprises pectin. In some embodiments, the alginate and pectin are present in an alginate to pectin ratio of 1:1 to 10:1. In some embodiments, the alginate to pectin ratio is 3:1 to 8:1, or 5:1 to 7:1. The alginate to pectin ratio is expressed as a dry weight ratio (w / w).

[0030] The inventors have found that providing a gelling agent with alginate and pectin in such a ratio can provide an improved amorphous solid. Without wishing to be bound by theory, it is believed that the combination of alginate and pectin can have a synergistic effect on binding in the amorphous solid. Furthermore, combining alginate and pectin in a specific ratio can affect the temperature at which menthol is released from the amorphous solid when heated.

[0031] Providing a gelling agent with more alginate than pectin can be advantageous due to lower material costs. However, a gelling agent with only alginate can have a high viscosity, which means that the gelling agent is difficult to process during the production of an amorphous solid. By combining alginate with pectin, which is present as a minority portion, the viscosity of the gelling agent can be easy to process during the production of an amorphous solid.

[0032] In some embodiments, pectin is included in the gelling agent in an amount of 3-10% by weight of the amorphous solids, i.e., the amorphous solids comprise 3-10% pectin by weight of the dry weight of the amorphous solids, hi some embodiments, the amorphous solids comprise pectin in an amount of 3-8%, or 4%-6% by weight.

[0033] Suitably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, 35%, 30%, or 27% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50%, 5-40%, or 25-35% by weight of gelling agent.

[0034] In some embodiments, the gelling agent further comprises a hydrocolloid other than those mentioned above. In some embodiments, the gelling agent further comprises one or more compounds selected from the group including starch (and derivatives), cellulose (and derivatives, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent further comprises one or more of hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

[0035] The gelling agent may further comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and combinations thereof.

[0036] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxylmethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0037] In some embodiments, the gelling agent further comprises one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0038] In some embodiments, the gelling agent further comprises one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, carrageenan, starch, and combinations thereof. In a preferred embodiment, the non-cellulosic gelling agent further comprises agar.

[0039] The aerosol-forming material comprises menthol in an amount of 0.1-80% by weight. In some embodiments, the aerosol-forming material comprises menthol in an amount of about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 50%, 45%, or 40% by weight (calculated on a dry weight basis). In certain embodiments, the amorphous solid comprises menthol in an amount of 10-60%, 40-60%, or 45-55% by weight.

[0040] The amorphous solid comprises 0.1 to 50% by weight of the aerosol-forming material, hi some embodiments, the amorphous solid comprises 10 to 30% by weight of the aerosol-forming material, or 15 to 25% by weight of the aerosol-forming material.

[0041] In some embodiments, the aerosol forming material may comprise one or more of 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 mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0042] In some embodiments, the aerosol forming agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0043] In embodiments, the amorphous solid is 20 to 35% by weight of a gelling agent; 15 to 25 weight percent of an aerosol-forming material; 45 to 55% by weight of menthol; where these weights are calculated on a dry weight basis.

[0044] The amorphous solid may have any suitable water content, for example, from 1% to 15% by weight (on a wet weight basis - "WWB"). Suitably, the water content of the amorphous solid may be from about 5%, 7%, or 9% by weight to about 15%, 13%, or 11% by weight (on a WWB).

[0045] The aerosolizable or non-aerosol-forming material may be present on or in a support to form a substrate. The support acts as a support on which the amorphous solid layer is formed to facilitate manufacturing. The support may also provide rigidity to the amorphous solid layer to facilitate handling.

[0046] The support may be any suitable material that can be used to support an amorphous solid. In some examples, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some examples, the support may comprise or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the support comprises paper. In some examples, the support itself is a laminated structure comprising multiple layers of materials selected from the aforementioned list. In some examples, the support may also function as a flavor support. For example, the support may be impregnated with flavorings or tobacco extracts.

[0047] Suitably, the thickness of the support layer may range from about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The support may comprise two or more layers and the thicknesses mentioned herein refer to the combined thicknesses of these layers.

[0048] In some examples, the support may be magnetic. This feature may be used to secure the support to an assembly during use or to generate a particular amorphous solid form. In some examples, the aerosol-generating substrate may include one or more magnets that may be used to secure the substrate to an induction heater during use.

[0049] In some instances, the support may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the support layer, thereby controlling the flow and ensuring that the aerosol or gas is delivered to the user. This may also be utilized to prevent the gas / aerosol from condensing or otherwise depositing during use, for example on the surface of a heater provided in the aerosol generating assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

[0050] In some instances, the surface of the support that abuts the amorphous solid may be porous. For example, in one instance, the support comprises paper. The inventors have found that porous supports such as paper are particularly suitable for the present invention, with a porous (e.g., paper) layer abutting the amorphous solid layer and forming a strong bond. The amorphous solid is formed by drying a gel, and, without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous support (e.g., paper) such that the support is partially bonded to the gel as the gel cures and forms crosslinks. This results in a strong bond between the gel and the support (and between the dried gel and the support).

[0051] In addition, surface roughness may contribute to the strength of the bond between the amorphous material and the support. The inventors have found that the roughness of the paper (at the surface abutting the support) may preferably be in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of a paper surface. In this tester, air at a specific pressure is inserted between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

[0052] Conversely, the surface of the support that does not face the amorphous solid may be placed in contact with the heater, and the smoother surface may provide more efficient heat transfer. Thus, in some instances, the support is positioned to have a rougher side that abuts the amorphous material and a smoother side that does not face the amorphous material.

[0053] In one particular example, the support may be a paper-backed foil, where the paper layer abuts against the amorphous solid layer, providing the properties discussed in the previous paragraphs. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also act to transfer heat to the amorphous solid.

[0054] In another example, a foil layer of a paper-backed foil abuts the amorphous solid, the foil being substantially impermeable to prevent moisture provided in the amorphous solid from being absorbed into the paper, which could weaken the structural integrity of the paper.

[0055] In some examples, the support is formed from or comprises a metal foil (such as aluminum foil). A metallic support may allow for better transfer of thermal energy to the amorphous solid. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the support comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0056] In some examples, the support may have a thickness of from about 0.017 mm to about 2.0 mm, preferably from about 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0057] In some instances, the aerosol-generating substrate may comprise an embedded heating means, such as a resistive or inductive heating element. For example, the heating means may be embedded in the amorphous solid.

[0058] The amorphous solid may be made of a gel, and the gel may further comprise a solvent contained in an amount of 0.1 to 50% by weight. However, the present inventors have found that the inclusion of a solvent in which the fragrance can dissolve reduces gel stability, and the fragrance may leave the gel and crystallize. Therefore, in some examples, the gel does not include a solvent in which the fragrance can dissolve.

[0059] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, for example, between 1% and 60% by weight, or between 5% and 50% by weight, or between 5% and 30% by weight, or between 10% and 20% by weight of filler.

[0060] In other embodiments, the amorphous solid comprises less than 20% by weight of filler, preferably less than 10% by weight or less than 5% by weight. In some instances, the amorphous solid comprises less than 1% by weight of filler, and in some instances, no filler.

[0061] Aspects of the invention relate to articles. A consumable is an article that is intended to be consumed in part or in whole during use by a user. The consumable may comprise or consist of an aerosol-generating material. The consumable may comprise one or more other elements, e.g., a filter or an aerosol modifying substance. The consumable may comprise a heating element that generates heat during use to cause aerosol generation from the aerosol-generating material. The heating element may comprise, for example, a combustible material or may comprise a susceptor that can be heated by passing it through a varying magnetic field.

[0062] The article of the present invention may be provided in any suitable shape. In some examples, the article is provided as a rod (e.g., substantially cylindrical). The article provided as a rod may include the aerosol-generating material as a shredded sheet, optionally blended with cut tobacco. Alternatively or additionally, the article provided as a rod may include the aerosol-generating material as a sheet, e.g., a sheet surrounding a rod of aerosol-generating material (e.g., tobacco). In some embodiments, the article comprises a layer portion of the aerosol-generating material disposed on a carrier. In examples, the article may have at least one substantially flat surface.

[0063] The susceptor is a material that can be heated by passing it through a varying magnetic field, such as an alternating magnetic field. The heating material can be an electrically conductive material, in which case passing it through a varying magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material, in which case passing it through a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material can be both electrically conductive and magnetic, in which case the heating material can be heated by both heating mechanisms.

[0064] Induction heating is a process in which an electrically conductive object is heated by passing the object through a varying magnetic field. This process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electric current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another so that the resulting varying magnetic field generated by the electromagnet passes through the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to heat up. This process is called Joule, Ohmic or resistive heating.

[0065] In some embodiments, the susceptor is in the form of a closed circuit. When the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in stronger or improved Joule heating.

[0066] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by passing the object through a varying magnetic field. The magnetic material can be thought of as comprising many atomic-scale magnets or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align along the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field produced by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes with the variation of the applied magnetic field. This reorientation of the magnetic dipoles causes the generation of heat in the magnetic material.

[0067] When an object is both electrically conductive and magnetic, passing the object through a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Additionally, the use of magnetic materials can strengthen the magnetic field, which can intensify Joule heating.

[0068] In each of the above processes, when heat is generated within the object itself rather than by an external heat source via thermal conduction, a more rapid temperature rise and more uniform heat distribution in the object can be achieved, especially by selection of the appropriate object material and geometry, and appropriate varying magnetic field strength and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require physical contact between the source of the varying magnetic field and the object, allowing for greater design freedom and control over the heating profile and reducing costs.

[0069] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0070] In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in the amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in instances where the amorphous solid is provided as a sheet, for example, when the amorphous solid sheet surrounds a rod of aerosol-forming material.

[0071] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0072] In some embodiments, the aerosol-forming material does not comprise tobacco fibers, hi certain embodiments, the aerosol-forming material does not comprise fibrous materials.

[0073] In some embodiments, the aerosol-forming material does not comprise tobacco fibers, hi certain embodiments, the aerosol-forming material does not comprise fibrous materials.

[0074] In some embodiments, the aerosol product does not comprise tobacco fiber, hi certain embodiments, the aerosol product does not comprise fibrous material.

[0075] In some instances, the amorphous solid may consist essentially of or consist of the gelling agent, the aerosol forming agent, water, and menthol.

[0076] In some embodiments, the aerosol-generating material or amorphous solid comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabiersoin (CBE), cannabicitran (CBT).

[0077] The aerosol-forming material or amorphous solid may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0078] The aerosol-forming material or amorphous solid may comprise cannabidiol (CBD).

[0079] The aerosol-forming material or amorphous solid may comprise nicotine and cannabidiol (CBD).

[0080] The aerosol-forming material or amorphous solid may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0081] The aerosol-forming material comprising an amorphous solid may have any suitable areal density, for example 30 g / m 2 ~120g / m 2 In some embodiments, the aerosol-forming material may have a density of about 30 to 70 g / m 2 , or about 40 to 60 g / m 2 In some embodiments, the amorphous solid may have an areal density of about 80-120 g / m 2 , or about 70 to 110 g / m2 , or in particular about 90 to 110 g / m 2 Such areal densities may be particularly suitable when the aerosol-forming material is included in the aerosol product article / assembly in sheet form or as chopped sheets (discussed further below).

[0082] Aspects of the invention provide a non-combustion aerosol delivery system comprising an article according to that described herein and a non-combustion aerosol delivery device comprising a heater configured to heat but not combust the aerosol product article. The non-combustion aerosol delivery system may also be referred to as an aerosol generation assembly. The non-combustion aerosol delivery device may also be referred to as an aerosol generation apparatus.

[0083] In some cases, in use, the heater may heat the aerosol-forming material to 350° C. or less, for example, 120° C. to 350° C., without burning the aerosol-forming material. In some cases, the heater may heat the aerosol-forming material to 140° C. to 250° C., or 220° C. to 280° C., without burning the aerosol-forming material. In some cases, in use, substantially the entirety of the amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the solid is located about 0.010 mm to 2.0 mm, preferably about 0.02 mm to 1.0 mm, preferably about 0.1 mm to 0.5 mm, from the heater. These minimum distances may in some cases reflect the thickness of the support supporting the amorphous solid. In some cases, the surface of the amorphous solid may be in direct contact with the heater.

[0084] The heater is configured to heat but not combust the aerosol product, and thus the aerosol generating material. The heater may in some examples be a thin film electrical resistance heater. In other examples, the heater may comprise an inductive heater or other heater. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol generating assembly may comprise multiple heaters. The heaters may be powered by a battery.

[0085] The aerosol product may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components so that they condense to form the aerosol. The cooling element may also act to move a hot portion of the non-combustion aerosol delivery device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0086] In some examples, the aerosol generating assembly may be a heat-not-burn device. That is, the aerosol generating assembly may include a solid tobacco-containing material (and no liquid aerosol-generating material). In some examples, the amorphous solid may comprise a tobacco material. A heat-not-burn device is disclosed in WO2015 / 062983A2, the entirety of which is incorporated herein by reference.

[0087] In some examples, the aerosol generating assembly may be an e-cigarette hybrid device. That is, the aerosol generating assembly may include a solid aerosol generating material and a liquid aerosol generating material. In some examples, the amorphous solid may include nicotine. In some examples, the amorphous solid may include tobacco material. In some examples, the amorphous solid may include tobacco material and a separate nicotine source. These separate aerosol generating materials may be heated by separate heaters or may be heated by the same heater, and in some examples, the downstream aerosol generating material may be heated by a hot aerosol generated from the upstream aerosol generating material. An e-cigarette hybrid device is disclosed in WO2016 / 135331A1, the entirety of which is incorporated herein by reference.

[0088] The aerosol-generating material or the amorphous solid may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0089] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0090] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0091] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material or amorphous solid comprises nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry in which the aerosol-forming material or amorphous solid is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

[0092] The amorphous solid may comprise a colorant. The addition of a colorant can change the visual appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the visual appearance of the amorphous solid and the aerosol-forming material. By adding a colorant to the amorphous solid, the amorphous solid can match the color of other components of the aerosol-forming material or other components of an article comprising the amorphous solid.

[0093] Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) in the aerosol-forming material that comprises the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid renders the amorphous solid visually indistinguishable from other components in the aerosol-forming material.

[0094] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry with the materials that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0095] The aerosol product article (sometimes referred to herein as an article, cartridge, or consumable) may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some examples, the article may further comprise a filter and / or a cooling element (as described above). In some examples, the aerosol product article may be surrounded by a packaging material, such as paper.

[0096] The aerosol product article may further comprise vent holes. These may be provided in the sidewalls of the article. In some instances, the vent holes may be provided in the filter and / or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0097] The ventilation facilitates the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by a process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation) and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of newly formed droplets from the heated volatiles.

[0098] In some instances, the ratio of cold air to the sum of heated volatiles and cold air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0099] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0100] In some examples, the aerosol-generating material may be included in the article / assembly in sheet form. In some examples, the aerosol-generating material may be included as a flat sheet. In some examples, the aerosol-generating material may be included as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some such examples, the amorphous solid of these embodiments may be included in the aerosol product article / assembly as a sheet, for example, as a sheet surrounding a rod of aerosol-generating material (such as tobacco). In some other examples, the aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article. In some examples, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

[0101] 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, such as examples where the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments where the aerosol-generating material is formed as a sheet and then chopped and incorporated into an aerosol product. In some examples, such as examples where the amorphous solid includes a filler, 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 where the aerosol-generating material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0102] The assembly may comprise an integrated aerosol production article and heater, or may comprise a heating device into which the article is inserted during use.

[0103] 1 and 2, there is shown a partially cut-away cross-sectional view and a perspective view of an example of an aerosol production article 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suited for use with the device 51 shown in Figures 5-7, described below. In use, the article 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 5.

[0104] The example article 101 is in the form of a generally cylindrical rod including a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol-generating material as described herein may be incorporated in both sheet form and chopped form.

[0105] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The body of aerosol-generating material 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the body of aerosol-generating material 103 between the body of aerosol-generating material 103 and the filter segment 109 such that the cooling segment 107 is in an abutting relationship with the aerosol-generating material 103 and the filter segment 109. In another example, there may be a separation between the body of aerosol-generating material 103 and the cooling segment 107 and between the body of aerosol-generating material 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed toward proximal end 113 of article 101 and is adjacent filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0106] In one example, the rod of aerosol-generating material 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably has a length of 42 mm.

[0107] In one example, the overall length of the article 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0108] One axial end of the body of aerosol-generating material 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) that covers one axial end of the body of aerosol-generating material 103.

[0109] The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0110] In one example, the cooling segment 107 is an annular tube that is disposed around and defines a cavity within the cooling segment that provides a chamber through which heated volatile components generated from the body of aerosol-generating material 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 101 during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0111] 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 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures 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 body 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may become damaged during use and no longer effectively perform its required function.

[0112] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0113] The cooling segment 107 is made from paper, meaning that it is constructed from a material that does not generate compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 51 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness and straightness.

[0114] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 101 during insertion into device 51.

[0115] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatiles from 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 reduced irritation of the heated volatiles without depleting the amount of the heated volatiles to an unsatisfactory level for the user.

[0116] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be substantially centered within the filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, the capsule, if present, may contain a volatile component, such as a flavoring or an aerosol generating agent.

[0117] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to draw of the article 101. Thus, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the article 101. Additionally, the filter segment performs a filtration function in the article 101.

[0118] In one example, the filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0119] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the temperature of the contact of the user's lips with the surface of filter segment 109.

[0120] In one example, the filter segment 109 is between 6 mm and 10 mm in length, preferably 8 mm.

[0121] The mouth end segment 111 is an annular tube that is disposed around and defines a cavity within the mouth end segment 111. The cavity 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 article during manufacture and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0122] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outside diameter, roundness and straightness.

[0123] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0124] It should be appreciated that in one example, the oral end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 disposed within the tube to separate the oral end segment 111 and the cooling segment 107.

[0125] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0126] In the example of article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in article 301 to allow air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of article 301. The vent holes may be located in cooling segment 307 to aid in cooling article 301. In one example, ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

[0127] In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

[0128] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

[0129] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is such that the vent holes 317 are not blocked by a user when the article 301 is in use.

[0130] By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 51 when the article 301 is fully inserted into the device 51, as seen in Figures 6 and 7. By locating the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 51 through the vent holes to help cool the article 301.

[0131] The length of the cooling segment 307 is such that when the item 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 serves a first function of providing a physical gap between the heating device and the heat-sensitive filter device 309 of the device 51, and a second function of allowing the vent hole 317 to be located within the cooling segment while also being located outside the device 51 when the item 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 within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 51.

[0132] 5-7 in more detail, an example of a device 51 is shown that is configured to heat an aerosol-forming material to volatilize at least one component of said aerosol-forming material, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, but not combusting, the aerosol-forming material.

[0133] The first end 53 may be referred to herein as the oral 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, allowing the entire device 51 to be activated / deactivated as desired by the user.

[0134] 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 includes a unitary sleeve 11 that surrounds the outer periphery of the device 51 and is capped with a top panel 17 that generally forms the "top" of the device 51 and a bottom panel 19 that generally forms the "bottom" of the device 51. In another example, the housing includes, in addition to the top panel 17 and bottom panel 19, a front panel, a rear panel, and a pair of opposing side panels.

[0135] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 51, or may be "permanently" secured to unitary sleeve 11, for example to prevent a user from accessing the interior of device 51. In one example, panels 17 and 19 are made of a plastic material (including glass-filled nylon formed by injection molding, etc.) and unitary sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

[0136] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51 through which a user can insert and remove an article 101, 301 containing an aerosol-generating material into and from the device 51 during use.

[0137] Housing 59 has disposed therein or secured thereto heating device 23, control circuitry 25, and power source 27. In this example, heating device 23, control circuitry 25, and power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuitry 25 generally located between heating device 23 and power source 27, although other arrangements are possible.

[0138] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol-generating material within the article 101, 301, as discussed further below.

[0139] Power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and provides power under the control of control circuitry 25 when needed to heat the aerosol-forming material within the article (to volatilize the aerosol-forming material without burning it, as discussed above).

[0140] An advantage of locating the power source 27 laterally adjacent to the heating apparatus 23 is that a physically larger power source 25 can be used without making the overall device 51 excessively long. Of course, a physically larger power source 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore may provide a longer battery life for the device 51.

[0141] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride ceramics, as well as silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), resistive heating elements formed by resistive electrical windings, and the like.

[0142] In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the article 101, 301 is inserted into the device 51, substantially the entire body of the aerosol-generating material 103, 303 of the article 101, 301 is inserted into the heating device 23.

[0143] The, or each, heating element may be arranged so as to heat selected zones (areas) of the aerosol-forming material independently, for example sequentially (over time as described above) or together (simultaneously) as desired.

[0144] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heating device 23 to the exterior of the device 51. This generally reduces heat loss and therefore helps to keep the power requirements of the heating device 23 low. The insulation 31 also helps to keep the exterior of the device 51 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (including, for example, a suitable foam-type material) in addition to or in place of the double-walled sleeve.

[0145] The housing 59 may further include various internal support structures 37 for supporting all of the internal components as well as the heating device 23 .

[0146] The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 disposed 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 plurality of cooling fins 35f spaced along an outer surface of the chamber 35, each fin being disposed to circumscribe the outer surface of the chamber 35. When the article 101, 301 is 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 article 101, 301. The gap 36 circumscribes the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

[0147] The collar 33 includes a number of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage an article 101, 301 inserted within the device to help secure it within the device 51. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the article 101, 301 form ventilation paths around the outer surface of the article 101, 301. These ventilation paths allow hot steam escaping from the article 101, 301 to exit the device 51, and allow cooling air to flow within the gap 36 around the article 101, 301 into the device 51.

[0148] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. Referring specifically to Figure 6, in one example, the body of aerosol-generating material 103, 303 (which is disposed at the distal end 115, 315 of the article 101, 301) is completely contained within the heating arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

[0149] During operation, the heating device 23 heats the article 101 , 301 to volatilize at least one component of the aerosol-forming material from the body 103 , 303 of aerosol-forming material.

[0150] The primary flow path for heated volatiles from the body of aerosol-generating material 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the temperature of heated volatiles generated from the body of aerosol-generating material is between 60° C. and 250° C., which may be above an acceptable inhalation temperature for a user. The heated volatiles cool as they travel through the cooling segment 107, 307, and some of the volatiles condense on the inner surface of the cooling segment 107, 307.

[0151] In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0152] Another aspect of the invention provides a method of making an aerosol-forming material according to the first aspect.

[0153] The method comprises the steps of (a) forming a slurry comprising components of an amorphous solid or precursors thereof, (b) casting a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form an amorphous solid.

[0154] Step (b) of forming the layer of the slurry may include, for example, spraying, casting, or extruding the slurry. In some examples, the slurry layer is formed by electrostatically spraying the slurry. In some examples, the slurry layer is formed by casting the slurry.

[0155] In some instances, (b) and / or (c) and / or (d) may be performed at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (b), (c) and (d) may be performed sequentially.

[0156] In some instances, the slurry is applied to a substrate. A layer of the slurry may be formed on the substrate.

[0157] In an example, the slurry comprises a gelling agent, an aerosol-forming material, and menthol. The slurry may comprise these components in any of the proportions set forth herein for the composition of the aerosol-generating material. For example, the slurry may comprise: 0.1 to 80% by weight of menthol; 1 to 60% by weight of a gelling agent / gelling agent precursor; 0.1 to 50 weight percent of an aerosol-forming material; Equipped with.

[0158] The slurry may comprise a gelling agent precursor. For example, the slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as the gelling agent precursor. In some embodiments, the G and M units are present in the gelling agent precursor in a molar ratio of 1:2 to 10:1 (i.e., the number of α-(1-4)-linked L-guluronate units present compared to the number of β-(1-4)-linked D-mannuronate units). In some embodiments, the G and M units are present in a molar ratio of 1:3 to 3:1, or 1:2 to 2:1, or 1:1.5 to 1.5:1, or 1:1.2 to 1.2:1.

[0159] The step (c) of hardening the gel may include adding a hardening agent to the slurry. For example, (c) may include adding Ca 2+ Adding a cation such as Ca 2+The cations may be provided as part of a calcium source. For example, a slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a hardener comprising a calcium source (such as a calcium salt, e.g., calcium chloride) may be added to the slurry to form a calcium cross-linked alginate gel. 2+ The calcium source is Ca in the slurry. 2+ They are provided to the slurry in an amount such that the molar ratio of cations to G units is from 0.2:1 to 1:1, or from 0.3:1 to 0.5:1, or approximately 0.4:1 ("approximately" allows for a 20% margin of error).

[0160] In some embodiments, the hardening agent or calcium source comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the hardening agent or calcium source comprises or consists of calcium formate and / or calcium lactate. In certain examples, the hardening agent or calcium source comprises or consists of calcium formate. The inventors have determined that the use of calcium formate as the hardening agent or calcium source typically results in amorphous solids with higher tensile strength and higher elongation resistance.

[0161] In the example, Ca 2+ The cations are provided to the slurry as part of a fluid system comprising a calcium source and an aqueous carrier. The calcium source may comprise a combination of calcium-containing compounds. In some embodiments, the calcium source comprises one or more calcium salts, such as calcium chloride, calcium lactate, calcium citrate, calcium acetate, or calcium citrate.

[0162] In some instances, the calcium source is dissolved and optionally suspended in the aqueous carrier. In some instances, the calcium source is present in the fluid system in an amount greater than is soluble in the aqueous carrier at ambient temperature and pressure, as defined by the National Institute of Standards and Technology, and refers to a temperature of 20° C. and an absolute pressure of 1 atmosphere.

[0163] In some embodiments, the fluid source is a supersaturated solution of the calcium source(s), e.g., a supersaturated solution of a calcium salt. In some embodiments, the fluid source comprises a dissolved and suspended (particulate) calcium source, e.g., a dissolved and suspended (particulate) calcium salt. Providing the calcium source in a slurry in a small amount of aqueous carrier may reduce the amount of evaporation during drying step (d), thereby allowing for faster and less energy intensive production of the aerosol-generating material.

[0164] The drying step (d) may, in some instances, remove from about 50%, 60%, 70%, 80%, or 90% to about 80%, 90%, or 95% of the water in the slurry (WWB).

[0165] The drying step (d) may in some instances reduce the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry may be cast to a thickness of 2 mm and the resulting dried amorphous solid material may have a thickness of 0.2 mm.

[0166] The slurry itself may also form part of the present invention. In some instances, the slurry solvent may consist essentially of or consist of water. In some instances, the slurry may comprise about 50%, 60%, 70%, 80%, or 90% or more solvent by weight (WWB).

[0167] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, such as a viscosity of about 14 to about 16 Pa·s at 46.5°C.

[0168] In instances where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the amorphous solids. Thus, any discussion herein regarding the composition of solids is expressly disclosed in conjunction with the slurry aspects of the invention.

[0169] According to aspects of the invention, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system described herein. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of 350° C. or less. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of about 220° C. to about 280° C. In some embodiments, the method comprises heating at least a portion of the aerosol-generating material to a temperature of about 220° C. to about 280° C. over a use session.

[0170] As used herein, a "use session" refers to a single period of use of a non-combustion aerosol delivery system by a user. A use session begins when at least one heating unit present in the heating assembly is first powered. The device is ready for use after a period of time has elapsed since the start of the use session. A use session ends when no power is supplied to any of the heating elements of the aerosol delivery device. The end of a use session may coincide with the point at which the smoking article is depleted (the point at which the user considers the total particulate matter yield (mg) per puff to be unacceptably low). A session has a duration of multiple puffs. The session may have a duration of 7 minutes, or 6 minutes, or 5 minutes, or 4 minutes 30 seconds, or less than 4 minutes, or 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, or 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or preferably 4 minutes. A session may be initiated by a user activating a button or switch on the device, initiating an increase in temperature of at least one heating element.

[0171] In some embodiments, at least 20% by weight, or at least 30%, 40%, or 50% by weight of the menthol present in the amorphous solid is aerosolized during a use session. That is, after a use session, the amount of menthol in the amorphous solid is depleted by 20%, 30%, 40%, or 50% by weight. 2+ The molar ratio of G units can allow for efficient delivery of menthol to the user (e.g., a high percentage of the active is aerosolized from the amorphous solid), while maintaining a long shelf life before the amorphous solid is heated by the non-combustion aerosol delivery device.

[0172] According to an aspect of the present invention, there is provided a use of the non-combustion aerosol delivery system described herein. The use of the non-combustion aerosol delivery system may comprise interacting with the non-combustion aerosol delivery device (e.g., actuating an actuator) to initiate a smoking session.

[0173] Working Example A first aerosol-generating material and a second aerosol-generating material were prepared according to the methods described herein. Both aerosol-generating materials were prepared from slurries having the following compositions (w / w dry weight basis): 50% menthol 20% glycerol 26% sodium alginate 4% pectin

[0174] Calcium lactate was provided to the slurry as a hardening agent. The aerosol-generating materials differed only in the amount of calcium lactate provided to the slurry to crosslink the alginate. The first aerosol-generating material contained Ca 2+ The second aerosol-generating material was prepared by providing calcium lactate in an amount such that the molar ratio of cation to G units in the sodium alginate was 0.4:1. 2+ The slurry was prepared by providing calcium lactate in an amount such that the molar ratio of cation to G units in the sodium alginate was 0.2:1.

[0175] The dry material was formed into a sheet which was subsequently shredded and combined with tobacco to obtain a blend. Each blend of aerosol-generating material and tobacco was formed into a rod consumable and provided with a filter as described herein to obtain a first consumable comprising a first aerosol-generating material and a second consumable comprising a second aerosol-generating material.

[0176] Each consumable was subjected to a puff-by-puff sensory analysis. Puff-by-puff analysis was performed according to the Health Canada Intense (HCI) puff regime: no air block, 55 mL puff for 2 seconds every 30 seconds. Each puff was captured with a gas-tight syringe attached to a smoking engine. The captured samples were extracted with a solvent and analyzed by gas chromatography with flame ionization detection (GC-FID) to quantify menthol against a calibration range.

[0177] Figure 8 shows the results of this analysis. As can be seen, both materials show acceptable puff-by-puff menthol perception performance. 2+ The first material having a molar ratio of cations to G units has been found to provide a particularly desirable per-puff menthol sensory performance.

[0178] The above-described embodiments should be understood as illustrative of the present invention. Further embodiments of the present invention are envisioned. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other embodiment, or any combination of any other embodiment. Moreover, 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. 1. An aerosol-forming material comprising an amorphous solid, the amorphous solid comprising: 0.1 to 80% by weight of menthol; 1-60% by weight of a gelling agent, the gelling agent comprising calcium cross-linked alginate comprising α-(1-4)-linked L-guluronate (G) units; 0.1 to 50% by weight of an aerosol forming material; Ca ２＋ An aerosol-forming material having a molar ratio of cations to G units of from 0.2:1 to 1:

1.

2. 2. The aerosol forming material of claim 1, wherein the molar ratio of calcium to G units is from 0.3:1 to 0.5:

1.

3. 3. The aerosol-forming material of claim 1 or claim 2, wherein the calcium cross-linked alginate also comprises β-(1-4)-linked D-mannuronic acid (M) units.

4. 4. The aerosol forming material of claim 3, wherein the molar ratio of G units to M units is from 1:2 to 10:

1.

5. 5. The aerosol-forming material of claim 1, which when stored in a closed container under ambient conditions (22° C., 60% relative humidity, 1013 mbar) for 30 days contains at least 60% of the menthol, by dry weight of the menthol present in the aerosol-forming material before storage.

6. 6. The aerosol-forming material of claim 1, wherein the amorphous solid comprises 10 to 30% by weight of the aerosol-forming material.

7. 7. The aerosol forming material of claim 1, wherein the amorphous solid comprises the menthol in an amount of 40 to 60% by weight.

8. The amorphous solid is 20 to 35% by weight of said gelling agent; 15 to 25% by weight of the aerosol forming material; 45 to 55% by weight of said menthol; 8. The aerosol-forming material of claim 1 , wherein the weights are calculated on a dry weight basis.

9. 9. The aerosol-forming material according to claim 1, wherein the calcium cross-linked alginate contained in the gelling agent is present in the amorphous solid in an amount of 15 to 40% by weight of the amorphous solid on a dry weight basis.

10. The aerosol forming material of any one of claims 1 to 9, wherein the gelling agent further comprises pectin.

11. 11. The aerosol forming material of claim 10, wherein the dry weight ratio of the calcium cross-linked alginate to the pectin is from 1:1 to 10:

1.

12. 12. The aerosol-forming material of claim 10 or 11, wherein the pectin contained in the gelling agent is present in the amorphous solid in an amount of 3 to 10% by weight of the amorphous solid on a dry weight basis.

13. An aerosol-generating material as claimed in any one of claims 1 to 12, comprising 1% to 15% by weight (wet weight basis) water.

14. The aerosol-forming material according to any one of claims 1 to 13, wherein the aerosol-forming material is selected from erythritol, propylene glycol, glycerol, and mixtures thereof.

15. A substrate comprising the aerosol-forming material of any one of claims 1 to 14 and a support on which the aerosol-forming material is disposed.

16. 17. An article for use with a non-combustion aerosol delivery device, comprising an aerosol-forming material according to any one of claims 1 to 14 and / or a substrate according to claim 15.

17. 17. A non-combustion aerosol delivery system comprising the article of claim 16 and a non-combustion aerosol delivery device configured to generate an aerosol from the article when the article is used with the non-combustion aerosol delivery device.

18. 20. The system of claim 17, wherein the non-combustion aerosol delivery device comprises a heater configured to heat but not combust the item.

19. 20. The system of claim 18, wherein the heater is configured, in use, to heat the article to a temperature of less than 350°C.

20. 20. The system of claim 19, wherein the heater is configured, in use, to heat the article to a temperature of between 220°C and 280°C.

21. The system of any one of claims 17 to 19, wherein the article is provided as a rod.

22. A method of making the aerosol-forming material of any one of claims 1 to 14.

23. providing a slurry comprising a gelling agent, an aerosol forming material, and menthol; forming a layer of the slurry; curing the slurry to form a gel; drying the gel to form the amorphous solid; 23. The method of claim 22 comprising:

24. The step of hardening the slurry comprises: ２＋ 24. The method of claim 23, comprising adding a calcium source comprising a cation to the slurry.

25. 25. The method of claim 24, wherein the calcium source is provided as part of a fluid system comprising the calcium source and an aqueous carrier.

26. 26. The method of claim 25, wherein the calcium source is dissolved and optionally suspended in the aqueous carrier.

27. 27. The method of claim 25 or 26, wherein the calcium source is present in the fluid system in an amount greater than is soluble in the aqueous carrier at ambient temperature and pressure.

28. 22. A method of generating an aerosol using the non-combustion aerosol delivery system of any one of claims 17 to 21, comprising heating the aerosol-forming material to a temperature of less than 350°C.

29. 29. The method of claim 28, wherein the temperature is from 220°C to 280°C.

30. 30. The method of claim 28 or 29, wherein at least 20% by weight of the menthol present in the amorphous solid is aerosolized during a session of use.

31. Use of a non-combustion aerosol delivery system according to any one of claims 17 to 21.

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