Layered aerosol-generating materials

Abstract

To provide a laminate aerosol generating material.SOLUTION: The laminate aerosol generating material comprises a carrier layer 6, a layer of aerosol-forming amorphous solid 4 attached to the carrier layer 6, and a porous layer 2 attached to the amorphous solid layer 4. The carrier 6 functions as a support on which the amorphous solid layer 4 is formed. The porous layer 2 may provide rigidity to the amorphous solid layer 4 and also provides a non-tacky surface. That is, the carrier layer 6 abuts the amorphous solid layer 4, and in turn the amorphous solid layer 4 abuts the porous layer 2.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[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 a compound by heating but not burning a solid aerosolizable material. The solid aerosolizable material may, in some examples, 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 aerosolizable 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 by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosolizable 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. Summary of the Invention

[0005] A first aspect of the invention provides a layered aerosol-generating material comprising a layer of a carrier, a layer of an aerosol-forming amorphous solid attached to the layer of carrier, and a porous layer attached to the layer of amorphous solid.

[0006] In some examples, the porous layer comprises paper, polymeric fibers, open cell foam, ceramic, and / or zeolite.

[0007] In some examples, the carrier comprises or consists of one or more materials selected from metal foil, paper, carbon paper, ceramic, carbon allotropes, plastics, or combinations thereof.

[0008] A second aspect of the present invention provides an aerosol generating assembly comprising a layered aerosol-generating material according to the first aspect of the invention and a heater configured to heat but not combust the layered aerosol-generating material.

[0009] In some instances, the aerosol generating assembly may be a non-combustion heated device.

[0010] In some examples, the aerosol generating assembly may be an e-cigarette hybrid device.

[0011] A third aspect of the present invention provides an aerosol production article for use in an aerosol generating assembly, the article comprising a layered aerosol generating material according to the first aspect.

[0012] A fourth aspect of the invention provides a method of making a layered aerosol-generating material according to the first aspect, comprising the steps of (a) forming a slurry comprising components of an amorphous solid or precursors thereof, (b) applying the slurry to a carrier, (c) curing the gel, and (d) drying to form an amorphous solid.

[0013] The step (c) of hardening the gel may comprise adding a hardening agent to the slurry.

[0014] A further aspect of the invention described herein may provide for the use of the laminated aerosol-generating material, the aerosol product article, or the aerosol-generating assembly in the generation of an inhalable aerosol.

[0015] Further characteristics and advantages of the invention will become apparent from the following description, given by way of example only with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is an exploded schematic diagram of a layered aerosol-forming material. [Diagram 2] FIG. 1 is a cross-sectional view of an example of an aerosol product. [Diagram 3] FIG. 3 is a perspective view of the article of FIG. 2. [Figure 4] FIG. 2 is a cross-sectional elevation view of an example of an aerosol product. [Diagram 5] FIG. 5 is a perspective view of the article of FIG. [Figure 6] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 7] FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. [Figure 8] FIG. 1 is a perspective view of an example of an aerosol generation assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The aerosol-forming layer described herein comprises an "amorphous solid." An amorphous solid may also be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous solid is a solid material that may retain some fluid, e.g., liquid, within it. In some examples, the aerosol-forming layer comprises from 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight. In some examples, the aerosol-forming layer consists of an amorphous solid.

[0018] As mentioned above, the present invention provides a layered aerosol-generating material, which comprises a layer of a carrier, a layer of an aerosol-forming amorphous solid attached to the layer of the carrier, and a porous layer attached to the layer of the amorphous solid. Figure 1 is a schematic diagram of such a layered material. The layered structure (shown by the dotted lines) includes a carrier layer 6, an amorphous solid layer 4, and a porous layer 2.

[0019] The carrier acts as a support on which the amorphous solid layer is formed. The porous layer may provide rigidity to the amorphous solid and may provide a non-sticky surface. This allows the laminated structure to be wound onto a bobbin, facilitating handling of the aerosol-forming material. Additionally, porosity means that the aerosol-forming material can be easily volatilized and inhaled during use.

[0020] For the avoidance of doubt, the term "attached" as used herein refers to two layers attached in direct contact with each other. This excludes the presence of an intermediate layer. That is, the carrier layer 6 abuts the amorphous solid layer 4, which in turn abuts the porous layer 2.

[0021] In some examples, the porous layer comprises paper, polymeric fibers, open-cell foam, ceramic, and / or zeolite. The polymeric fibers may be woven or knitted in some examples. Suitable polymeric fibers include, but are not limited to, polypropylene, low density polyethylene, polyethylene terephthalate, polyurethane, polyvinyl acetate, polyvinyl alcohol, styrene, ethyl vinyl acetate, rayon, silk, cotton, polyester, cellulosic materials such as hydroxypropyl cellulose, and combinations thereof. In some examples, the polymeric fibers may include colored or dyed polymers. In some examples, reconstituted cellulose fibers (e.g., derived from tobacco plant tissue) may be used. In some examples, the porous layer is selected from the group consisting of open-cell foam, polymeric fibers, and paper.

[0022] In some instances, the carrier layer may also function as a flavor carrier, for example, the carrier may be impregnated with flavorants or tobacco extracts.

[0023] In some instances, the carrier may be magnetic, and this feature may be used to secure the carrier to an assembly during use, or to generate a particular amorphous solid shape.

[0024] In some instances, the layered aerosol-forming material may include one or more magnets that can be used to secure the material to an induction heater during use.

[0025] In some instances, the layered aerosol-forming material may include an embedded heating means, such as a resistive or inductive heating element, for example, the heating means may be embedded in the amorphous solid layer.

[0026] A bobbin wound with layered aerosol forming material according to the first aspect of the invention may form an additional aspect of the invention.

[0027] In some instances, the carrier layer of the laminated aerosol-generating material may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the carrier layer, thereby controlling the flow and ensuring delivery 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 assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

[0028] The carrier may be any suitable material that can be used to support an amorphous solid. In some examples, the carrier 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 carrier may comprise or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the carrier itself is a laminated structure comprising multiple layers of material selected from the aforementioned list.

[0029] In some instances, the surface of the carrier layer that abuts the amorphous solid may be porous. For example, in one instance, the carrier layer comprises paper. The inventors have found that porous carriers such as paper are particularly suitable for the present invention, with the 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 carrier layer (e.g., paper) such that the carrier is partially bonded to the gel when the gel cures and forms crosslinks. This results in a strong bond between the gel and the carrier (and between the dried gel and the carrier).

[0030] In addition, surface roughness may contribute to the strength of the bond between the amorphous material and the carrier. The inventors have found that the roughness of the paper (at the surface abutting the carrier) 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").

[0031] Conversely, the surface of the carrier 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 examples, the carrier is positioned to have a rougher side that abuts the amorphous material and a smoother side that does not face the amorphous material.

[0032] In one particular example, the carrier may be a paper-backed foil, where the paper layer abuts 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.

[0033] 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.

[0034] In some examples, the carrier is formed from or comprises a metal foil (such as aluminum foil). A metallic carrier 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 carrier 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.

[0035] In some instances, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials having a thickness of 0.2 mm are particularly suitable. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

[0036] The inventors have found that if the amorphous solid for aerosol formation is too thick, the heating efficiency is compromised, which negatively impacts the power consumption during use. Conversely, if the amorphous solid for aerosol formation is too thin, it is difficult to manufacture and handle. That is, very thin materials are more difficult to cast and are also more likely to break, which can impair the aerosol formation during use.

[0037] The inventors have found that the thickness of the amorphous solid defined herein optimizes the material properties taking into account these competing considerations.

[0038] The thicknesses specified herein are the average thickness of the material. In some instances, the thickness of the amorphous solid may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0039] Composition of the aerosol-forming material In some instances, the amorphous solid may comprise 1-60% by weight of gelling agent, where these weights are calculated on a dry weight basis.

[0040] 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%, 10-30%, or 15-27% by weight of gelling agent.

[0041] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginate and / or pectin, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some examples, the amorphous solid may comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0042] In some embodiments, the gelling agent comprises alginate, which is present in the amorphous solid in an amount of 10-30% by weight of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0043] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0044] Suitably, the amorphous solid may comprise from about 5%, 10%, 15%, or 20% to about 80%, 70%, 60%, 55%, 50%, 45%, 40%, or 35% by weight of the aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise 5-60%, 10-50%, or 20-40% by weight of the aerosol generating agent. In some examples, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol generating agent comprises, consists essentially of, or consists of glycerol. The inventors have found that if the plasticizer content is too high, the amorphous solid may absorb water, resulting in a material that does not produce a suitable consumption experience when used. The inventors have found that if the plasticizer content is too low, the amorphous solid may become brittle and easily break. The plasticizer content specified herein provides the amorphous solid flexibility that allows the amorphous solid sheet to be wound onto a bobbin, which is useful for the manufacture of aerosol products.

[0045] In some examples, the amorphous solid may comprise a flavoring. Suitably, the amorphous solid may comprise up to about 60%, 50%, 40%, 30%, 20%, 10%, or 5% by weight of flavoring. In some examples, the amorphous solid may comprise at least about 0.5%, 1%, 2%, 5%, 10%, 20%, or 30% by weight of flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60%, 1-60%, 5-60%, 10-60%, 20-50%, or 30-40% by weight of flavoring. In some examples, the flavoring (if present) comprises, consists essentially of, or consists of menthol. In some examples, the amorphous solid is free of flavoring.

[0046] In some examples, the amorphous solid further comprises an active substance. For example, in some examples, the amorphous solid further comprises tobacco material and / or nicotine. For example, the amorphous solid may further comprise powdered tobacco and / or nicotine and / or tobacco extract. In some examples, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of an active substance. In some examples, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine.

[0047] In some examples, the amorphous solid comprises an active agent such as tobacco extract. In some examples, the amorphous solid may comprise 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the amorphous solid may comprise from about 5%, 10%, 15%, 20%, or 25% by weight to about 55%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 5-60%, 10-55%, or 25-55% by weight of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solid comprises 1%, 1.5%, 2%, or 2.5% by weight to about 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some instances, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0048] In some embodiments, the amorphous solid does not comprise tobacco material, but does comprise nicotine. In some such examples, the amorphous solid may comprise from about 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% nicotine by weight (calculated on a dry weight basis). For example, the amorphous solid may comprise 1-20% or 2-5% nicotine by weight.

[0049] In some instances, the total content of actives and fragrances may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, in some instances, the total content of actives and fragrances may be less than about 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0050] In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20% water by weight, calculated on a wet weight basis. In some instances, the hydrogel may comprise less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). In some instances, the hydrogel may comprise at least about 1%, 2%, or at least about 5% water by weight (WWB). In some instances, the amorphous solid comprises from about 1% to about 15% water, or from about 5% to about 15% water, calculated on a wet weight basis. Preferably, the water content of the amorphous solid may be from about 5%, 7%, or 9% to about 15%, 13%, or 11% by weight (WWB), and most preferably about 10% by weight.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] In certain embodiments that include 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 including a fibrous filler in an 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 aerosolizable material.

[0056] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0057] In some embodiments, the aerosol-forming material does not comprise tobacco fibers, hi certain embodiments, the aerosol-forming material does not comprise fibrous materials.

[0058] In some embodiments, the aerosol-generating substrate does not comprise tobacco fibers, hi certain embodiments, the aerosol-generating substrate does not comprise fibrous material.

[0059] In some embodiments, the aerosol product does not comprise tobacco fiber, hi certain embodiments, the aerosol product does not comprise fibrous material.

[0060] In some instances, the amorphous solid may consist essentially of or consist of a gelling agent, an aerosol forming agent, a tobacco material and / or a nicotine source, water, and optionally flavorings.

[0061] The amorphous solid may have a density of, for example, 30 g / m 2 ~120g / m 2 In some embodiments, the aerosol-forming material may have a suitable areal density of about 30 to 70 g / m 2 , or about 40 to 60 g / m 2 In some embodiments, the amorphous solids may have an areal density of about 80-120 g / m (so that the amorphous solids have a density similar to that of cut rag tobacco, such that a mixture of these two materials does not readily separate). 2 , or about 70 to 110 g / m 2 , 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).

[0062] 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.

[0063] Aerosol Products and Assemblies A second aspect of the present invention provides an aerosol generating assembly comprising a layered aerosol-generating material according to the first aspect of the invention and a heater configured to heat but not combust the layered aerosol-generating material.

[0064] The heater is configured to heat but not combust the layered aerosol-generating material. The heater may be a thin-film electrical resistance heater in some examples. 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.

[0065] In some examples, the heater, in use, may heat the aerosolizable material to between 120°C and 350°C without burning the aerosolizable material. In some examples, the heater, in use, may heat the aerosolizable material to between 140°C and 250°C without burning the aerosolizable material. In some examples, 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 examples, 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 reflect the thickness of the carrier supporting the amorphous solid in some examples. In some examples, the surface of the amorphous solid may directly abut the heater.

[0066] The aerosol generation assembly 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 hot parts of the 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.

[0067] 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 aerosolizable 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.

[0068] In some examples, the aerosol generating assembly may be an e-cigarette hybrid device. That is, the aerosol generating assembly may include a solid aerosolizable material and a liquid aerosolizable material. In some examples, the amorphous solid may comprise nicotine. In some examples, the amorphous solid may comprise tobacco material. In some examples, the amorphous solid may comprise tobacco material and a separate nicotine source. These separate aerosolizable materials may be heated by separate heaters or may be heated by the same heater, and in some examples, the downstream aerosolizable material may be heated by a hot aerosol generated from the upstream aerosolizable material. An e-cigarette hybrid device is disclosed in WO2016 / 135331A1, the entirety of which is incorporated herein by reference.

[0069] The present invention also provides an aerosol product article for use in an aerosol generating assembly comprising an aerosol generating material according to the first aspect of the present invention. The article (which may also be referred to herein as an aerosol product article, cartridge or consumable) may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating product. 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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%.

[0074] In some examples, the layered aerosol-generating material may be included in the article / assembly in sheet form. In some examples, the layered aerosol-generating material may be included as a flat sheet. In some examples, the layered 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 aerosolizable material (such as tobacco). In other examples, the layered 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.

[0075] 2 and 3, 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 suitable for use with the device 51 shown in Figures 6-8, 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 6.

[0076] 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 a layered aerosol-generating material as described herein. In the illustrated embodiment, the layered aerosol-generating material is incorporated as a rolled sheet (i.e., in the form of a tube). In other embodiments, the layered aerosol-generating material may be incorporated in other forms as described above, including but not limited to, as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or in chopped form.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] In one example, the filter segment 109 is between 6 mm and 10 mm in length, preferably 8 mm.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 4 and 5, there are shown a partial cutaway cross-sectional view and a perspective view of an example of article 301. The reference numbers shown in Figures 4 and 5 correspond to the reference numbers shown in Figures 2 and 3, but are increased by 200.

[0098] In the example of article 301 shown in Figures 4 and 5, 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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 7 and 8. 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.

[0103] The length of cooling segment 307 is such that when item 301 is fully inserted into device 51 , cooling segment 307 is partially inserted into device 51 . This length of the cooling segment 307 serves two functions: first, to provide a physical gap between the heating device 51 and the heat sensitive filter device 309; and second, to allow the vent 317 to be located within the cooling segment when the item 301 is fully inserted into the device 51, while also being located outside the device 51. As can be seen in Figures 7 and 8, 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. It is in this portion of the cooling element 307 that extends outside the device 51 that the vent 317 is located.

[0104] 6-8 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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).

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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 .

[0118] 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.

[0119] 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.

[0120] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 6-8. Referring specifically to Figure 7, 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 functions as a mouthpiece assembly for the user.

[0121] 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.

[0122] 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, through the mouth end segment 111, 313 to the user. In the illustrated example, the flow path also passes through a tube formed by the rolled body of aerosol-generating material 103, 303. 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.

[0123] In the example of article 301 shown in Figures 4 and 5, 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.

[0124] Manufacturing method A fourth aspect of the invention provides a method of making a layered aerosol-forming material according to the first aspect.

[0125] The method comprises the steps of (a) forming a slurry comprising components of an amorphous solid or precursors thereof, (b) applying the slurry to a carrier, (c) hardening the gel, and (d) drying to form an amorphous solid.

[0126] The step (b) of applying the slurry to the carrier may include, for example, spraying, casting, or extruding the slurry. In some examples, the slurry is applied by electrostatically spraying the slurry. In some examples, the slurry is applied by casting the slurry.

[0127] In some instances, steps (b) and / or (c) and / or (d) may occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, these steps may occur sequentially.

[0128] In some examples, a porous layer may be placed on the surface of the slurry prior to step (c) of curing the gel, allowing the slurry to partially impregnate the porous layer, such that the porous layer is partially bonded to the gel when the gel cures and forms crosslinks. This results in a strong bond between the gel and the porous layer. In other examples, the porous layer may be secured to the gel after the gel has cured.

[0129] 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.

[0130] The step (c) of hardening the gel may include adding a hardening agent to the slurry. For example, the slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a hardening agent comprising a calcium source (e.g., calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0131] The total amount of hardening agent, e.g. calcium source, may be 0.5-5% by weight (calculated on a dry weight basis). The inventors have found that adding too little hardening agent may result in an amorphous solid that does not stabilize the amorphous solid components, leading to these components falling off the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

[0132] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. When calcium cations are added, alginates crosslink to form a gel. The inventors have determined that alginates having a high G monomer content form gels more readily upon addition of a calcium source. Thus, in some examples, the gel precursor may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0133] 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).

[0134] 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.

[0135] Example Embodiments In some embodiments, the amorphous solid comprises menthol.

[0136] Certain embodiments comprising menthol-containing amorphous solids may be particularly suitable for inclusion as shredded sheets in an aerosol product / assembly. In these embodiments, the amorphous solids may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 20% to about 40%, or about 25% to 35% by weight (DWB), menthol in an amount of about 35% to about 60%, or about 40% to 55% by weight, and aerosol generating agent (preferably comprising glycerol) in an amount of about 10% to about 30%, or about 15% to about 25% by weight.

[0137] In one embodiment, the amorphous solid comprises (by weight DWB) about 32-33% alginate / pectin gelling agent blend, about 47-48% menthol flavoring, and about 19-20% glycerol aerosol generating agent.

[0138] The amorphous solids of these embodiments may have any suitable water content, for example, the amorphous solids may have a water content of about 2% to about 10% by weight, or about 5% to about 8% by weight, or about 6% by weight.

[0139] As noted above, the laminate material of these embodiments containing such amorphous solids may be included in the aerosol product article / assembly as a shredded sheet. The shredded sheet may be blended with cut tobacco and provided in the article / assembly. Alternatively, the laminate may be provided as an unshredded sheet. Suitably, the shredded or unshredded sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0140] Certain embodiments of the menthol-containing amorphous solids may be particularly suitable for inclusion in an aerosol product / assembly as a sheet, for example a sheet surrounding a rod of aerosolizable material (such as tobacco). In these embodiments, the amorphous solids may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 5% to about 40% by weight (DWB), or about 10% to 30% by weight, menthol in an amount of about 10% to about 50% by weight, or about 15% to 40% by weight, aerosol generating agent (preferably comprising glycerol) in an amount of about 5% to about 40% by weight, or about 10% to about 35% by weight, and optionally a filler in an amount up to 60% by weight (e.g., in an amount of 5% to 20% by weight, or 40% to 60% by weight).

[0141] In one of these embodiments, the amorphous solids comprise (by weight) about 11% alginate / pectin gelling agent blend, about 56% wood pulp filler, about 18% menthol flavoring, and about 15% glycerol.

[0142] In another of these embodiments, the amorphous solids comprise (by weight) about 22% alginate / pectin gelling agent blend, about 12% wood pulp filler, about 36% menthol flavoring, and about 30% glycerol.

[0143] As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is disposed on a carrier comprising paper. In one embodiment, the sheet is disposed on a carrier comprising a metal foil, preferably an aluminum metal foil. In this embodiment, the amorphous solid may abut against the metal foil.

[0144] The laminate material has a carrier layer and a porous layer disposed on either side of a sheet of amorphous solid material. Preferably, both the carrier and porous layers comprise paper attached to the top and bottom surfaces of the sheet. Suitably, the sheet of amorphous solid has a thickness of about 0.015 mm to about 1 mm.

[0145] In some embodiments, the amorphous solid comprises a flavoring that does not comprise menthol. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of about 5 to about 40%, or about 10 to about 35%, or about 20 to about 35% by weight (DWB); flavoring agent in an amount of about 0.1 to about 40%, about 1 to about 30%, about 1 to about 20%, or about 5 to about 20% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of 15 to 75%, about 30 to about 70%, or about 50 to about 65% by weight; and optionally a filler (suitably wood pulp) in an amount of about 60%, about 20%, about 10%, or less than about 5% by weight (preferably the amorphous solid is no filler).

[0146] In one of these embodiments, the amorphous solid comprises (by weight DWB) about 27% alginate gelling agent, about 14% flavoring, and about 57% glycerol aerosol generating agent.

[0147] In another of these embodiments, the amorphous solid comprises (by weight in DWB) about 29% alginate gelling agent, about 9% flavoring, and about 60% glycerol.

[0148] Laminates of these embodiments containing such amorphous solids may be included in an aerosol product / assembly as shredded sheets, optionally blended with cut tobacco, or may be included in an aerosol product / assembly as a sheet, such as a sheet surrounding a rod of aerosolizable material (such as tobacco).

[0149] In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of about 5% to about 40%, about 10% to 30%, or about 15% to about 25% by weight (DWB), tobacco extract in an amount of about 30% to about 60%, about 40% to 55%, or about 45% to about 50% by weight, and aerosol generating agent (preferably comprising glycerol) in an amount of about 10% to about 50%, about 20% to about 40%, or about 25% to about 35% by weight.

[0150] In one embodiment, the amorphous solid comprises (by weight in DWB) about 20% alginate gelling agent, about 48% Virginia tobacco extract, and about 32% glycerol.

[0151] The amorphous solids of these embodiments may have any suitable water content, for example, the amorphous solids may have a water content of about 5% to about 15% by weight, or about 7% to about 13% by weight, or about 10% by weight.

[0152] Laminates of these embodiments containing such amorphous solids may be included in an aerosol product / assembly as shredded sheets, optionally blended with cut tobacco. Alternatively, laminates of these embodiments containing such amorphous solids may be included in an aerosol product / assembly as a sheet, such as a sheet surrounding a rod of aerosolizable material (such as tobacco). Preferably, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0153] The slurry for forming the amorphous solid may also form part of the present invention. In some examples, the slurry may have an elastic modulus (also called storage modulus) of about 5 to 1200 Pa, and in some examples, the slurry may have a viscous modulus (also called loss modulus) of about 5 to 600 Pa.

[0154] definition As used herein, an active agent is a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active agent may be selected from, for example, functional foods, nootropics, and psychoactive substances. The active agent may be naturally occurring or synthetically obtained. The active agent may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active agent may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other botanical materials.

[0155] In some embodiments, the active agent comprises nicotine.

[0156] In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0157] As described herein, the active substance may comprise one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0158] Cannabinoids are a class of natural or synthetic compounds that act on cannabinoid receptors (i.e., CB1 and CB2) in cells that inhibit neurotransmitter release in the brain. Cannabinoids can be found naturally in plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis species exhibit at least 85 different phytocannabinoids, divided into several subclasses. These subclasses include cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol and cannabinodiol, and other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0159] As described herein, the active substance may comprise or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, skins, etc. Alternatively, the material may comprise an active compound that is naturally present in the botanical material or is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical materials include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo leaf extract, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Menthapiperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Menthapulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0160] In some embodiments, the botanical material is selected from eucalyptus, star anise, cocoa, and hemp.

[0161] In some embodiments, the plant material is selected from rooibos and fennel.

[0162] As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They can be naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sheesh Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the mint genus, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai tea citron, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose,They may contain saccharides such as acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanical materials, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid (such as an oil), a solid (such as a powder), or a gas.

[0163] The flavouring may suitably comprise one or more mint flavours, suitably mint oil from any species of the mint genus. The flavouring may suitably comprise, consist essentially of or consist of menthol.

[0164] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint.

[0165] In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components.

[0166] In some embodiments, the flavoring comprises eugenol.

[0167] In some embodiments, the flavoring comprises flavor components extracted from tobacco.

[0168] In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0169] In some embodiments, the flavoring may comprise a sensory agent intended to achieve somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0170] As used herein, the term "aerosol generating agent" refers to an agent that facilitates the generation of an aerosol. An aerosol generating agent may facilitate the generation of an aerosol by facilitating the initial volatilization and / or condensation of a gas into an inhalable solid and / or liquid aerosol.

[0171] Suitable aerosol generating agents include, but are not limited to, polyols, such as sorbitol, glycerol, and glycols, such as propylene glycol and triethylene glycol, as well as non-polyols, such as monohydric alcohols, high boiling point hydrocarbons, acids (such as lactic acid), glycerol derivatives, esters (such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates (including ethyl myristate and isopropyl myristate) and aliphatic carboxylic acid esters (such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate). The aerosol generating agent may preferably have a composition that does not dissolve menthol. The aerosol generating agent may preferably comprise, consist essentially of, or consist of glycerol.

[0172] As used herein, the term "tobacco material" refers to any material comprising tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract.

[0173] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. It may also be "fines" or dust of tobacco particles, expanded tobacco, stems, expanded stems, and other processed stem materials (such as rolled cut stems). The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibers and may be formed by casting, a Fourdrinier type approach with back addition of tobacco extract, or extrusion.

[0174] All weight percentages (indicated as wt.%) described herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights indicated on a dry weight basis refer to the totality of the extract, slurry or material other than water, and may include ingredients that are liquid by themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages indicated on a wet weight basis refer to all ingredients, including water.

[0175] For the avoidance of doubt, where the term "comprising" is used herein in defining the invention or features of the invention, there are also disclosed embodiments in which the invention or features may be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material "comprising" certain features means that those features are contained in, contained in, or retained within the material.

[0176] The above-described embodiments should be understood as illustrative of the present invention. 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. A layered aerosol-generating material comprising a layer of a carrier, a layer of an aerosol-forming amorphous solid attached to the layer of carrier, and a porous layer attached to the layer of amorphous solid, the layer of carrier and the porous layer being disposed on either side of the layer of amorphous solid.

2. 2. The layered aerosol generating material of claim 1, wherein the layer of carrier abuts the layer of amorphous solid which in turn abuts the porous layer.

3. 3. The layered aerosol-generating material of claim 1 or 2, wherein the porous layer comprises paper, polymeric fibers, open-cell foam, ceramic, and / or zeolite.

4. 4. The layered aerosol-generating material of claim 1, wherein the carrier comprises one or more materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes, plastic, cardboard, wood, or combinations thereof.

5. 5. An aerosol generating assembly comprising the layered aerosol generating material according to any one of claims 1 to 4 and a heater configured to heat but not combust the layered aerosol generating material.

6. 6. The aerosol generating assembly of claim 5, which is a non-combustion heated device.

7. 6. The aerosol generating assembly of claim 5, which is an e-cigarette hybrid device.

8. An aerosol product article for use in an aerosol generating assembly, the aerosol product article comprising the layered aerosol generating material according to any one of claims 1 to 4.

9. A method of making the layered aerosol-forming material of any one of claims 1 to 4.

10. 10. The method of claim 9, comprising the steps of: (a) forming a slurry comprising components of an amorphous solid or precursors thereof; (b) applying the slurry to a carrier; (c) curing the gel; and (d) drying the gel to form an amorphous solid.

11. The method of claim 10, wherein the porous layer is disposed on a surface of the slurry prior to (c) hardening the gel.

12. 12. The method of claim 10 or 11, wherein (c) comprises adding a hardening agent to the slurry.

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