Method for Producing Amorphous Solids Comprising Aerosol-Forming Materials - Patent application

Abstract

The present invention provides a method for producing an amorphous solid, the method comprising the steps of: a) forming a slurry comprising a particulate plant matter material, a gelling agent, and an aerosol-forming material, b) forming a layer of the slurry, and c) drying the slurry to obtain an amorphous solid.

Description

[Technical field]

[0001] The present invention relates to a method of manufacturing a consumable for use in a non-combustion aerosol delivery system that comprises an amorphous solid and an aerosol-forming material that comprises an amorphous solid, and to a non-combustion aerosol delivery system.

[0002] Smoking consumables, such as cigarettes, cigars, and the like, burn tobacco to produce tobacco smoke during use. Alternatives to these types of consumables 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 consumables 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. The solid aerosol-generating material may, in some instances, include a plant matter 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 are hybrid devices. These 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 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 a method for producing an amorphous solid, the method comprising the steps of: a) forming a slurry comprising a particulate plant matter material, a gelling agent, and an aerosol forming agent; b) forming a layer of the slurry; c) drying the slurry to obtain an amorphous solid; Equipped with.

[0006] The present invention also provides an amorphous solid obtainable or obtained by the above process.

[0007] Also provided by the present invention is an aerosol-forming material comprising an amorphous solid, the amorphous solid comprising a particulate plant matter material, a gelling agent and an aerosol-forming agent, the amorphous solid being in the form of a sheet.

[0008] A further aspect of the invention is a consumable for use in a non-combustion aerosol delivery system, the consumable comprising an aerosol-generating material comprising an amorphous solid, the amorphous solid comprising a particulate plant matter material, a gelling agent, and an aerosol-forming agent.

[0009] The present invention also provides a non-combustion aerosol delivery system comprising the consumable described above and a non-combustion aerosol delivery device comprising an aerosol generation device for generating an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0010] The present invention also includes the use of the consumable described above in a non-combustion aerosol delivery device comprising an aerosol generation device for generating an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0011] 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]

[0012] [Figure 1] FIG. 2 is a cross-sectional view of an example of a consumable item. [Diagram 2] FIG. 2 is a perspective view of the consumable item of FIG. 1. [Diagram 3] FIG. 2 is a cross-sectional elevation view of an example consumable. [Figure 4] FIG. 4 is a perspective view of the consumable item of FIG. 3. [Diagram 5] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 6] FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. Detailed Description

[0013] As noted above, the present invention provides a method for producing an amorphous solid, the method comprising: a) forming a slurry comprising a particulate plant matter material, a gelling agent, and an aerosol forming agent; b) forming a layer of the slurry; c) drying the slurry to obtain an amorphous solid; Equipped with.

[0014] 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 hold some fluid, e.g., a liquid, within it. The amorphous solid forms part of an aerosol-forming material, the aerosol-forming material comprising from 50%, 60%, or 70% amorphous solid by weight to about 90%, 95%, or 100% amorphous solid by weight.

[0015] The amorphous solid is formed from the dried gel. The inventors have found that using these ingredient ratios, as the gel hardens, the flavor compounds are stabilized within the gel matrix, allowing for higher flavor loadings to be achieved than with non-gel compositions. The flavors are stabilized at high concentrations, and the product has good shelf life.

[0016] The amorphous solid is preferably formed by a type of casting process that generally comprises casting a slurry comprising particulate plant matter material and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a sheet of amorphous solid, and removing the sheet of amorphous solid from the support surface. In some examples, the method comprises casting the slurry of (a) onto a support movable along a transport direction. In some examples, the amorphous solid is formed into a continuous sheet.

[0017] In some embodiments, the method further comprises the step of d) slitting the sheet of amorphous solid along the transport direction while moving the sheet of amorphous solid along the transport direction to form separated sheets of amorphous solid.

[0018] In some examples, the method further comprises winding the sheet onto a bobbin. In examples where the sheet is slit, the sheet may be wound onto two or more bobbins of smaller size.

[0019] In some instances, the method of manufacturing includes corrugating the amorphous solid. Subsequently, in some instances, the corrugated amorphous solid is gathered to form a rod, which is then surrounded by a paper wrapper to form the consumable article.

[0020] Thus, in an exemplary embodiment, the present invention provides a method of manufacturing a consumable for use with a non-combustion aerosol delivery system configured to heat but not combust the consumable. This method is a) forming a slurry comprising a particulate plant matter material, a gelling agent, and an aerosol forming agent; b) forming a layer of the slurry; c) drying the slurry to obtain an amorphous solid; d) corrugating the sheet to form a corrugated sheet; e) gathering the corrugated sheet to form a rod; Equipped with.

[0021] In some embodiments, the slurry of a) is 1 to 60% by weight of a gelling agent; 0.1 to 50% by weight of an aerosol forming agent; an active substance comprising 0.1 to 80% by weight of particulate plant matter material; and weights are calculated on a dry weight basis.

[0022] In some embodiments, the slurry of a) comprises 1-80% by weight of flavoring, calculated on a dry weight basis (herein DWB), the flavoring comprising particulate plant matter material. In some embodiments, the slurry comprises a solvent.

[0023] In some embodiments, the slurry is 1 to 50% by weight of a gelling agent; 0.1 to 50% by weight of an aerosol forming agent; 30-60% by weight of an active substance comprising particulate plant material; (Weights are calculated on a dry basis). A solvent; Equipped with.

[0024] The present invention also provides a consumable for use in a non-combustion aerosol delivery system. The consumable comprises an aerosol-generating material including an amorphous solid, the amorphous solid comprising a particulate plant matter material, a gelling agent, and an aerosol-forming agent. In certain embodiments, the amorphous solid is in the form of a sheet. In some such embodiments, the sheet is a corrugated sheet.

[0025] In some embodiments, the aerosol-generating material is provided on a support to form a substrate. In such embodiments, the support may be a carrier sheet. Preferably, both the carrier sheet and the sheet of aerosol-generating material are corrugated. However, it is also envisaged that only one sheet may be corrugated. Preferably, the carrier sheet and the amorphous solid form a laminated structure. In some instances, the carrier sheet and the amorphous solid may be corrugated in a single step, for example, by passing the laminated structure through a crimper. In some instances, the carrier sheet and the amorphous solid sheet are not laminated together.

[0026] In some examples, at least one of the carrier sheets is a sheet of homogenized plant matter material. In some examples, at least one of the carrier sheets is a sheet of susceptor material. In other examples, additional carrier sheets may be present. For example, one carrier sheet may comprise homogenized plant matter material and another carrier sheet may comprise a different support material as described herein, e.g., paper, or a susceptor material such as aluminum foil. In such embodiments, a tri-laminate structure may be formed, which is then corrugated and gathered to form a rod surrounded by a wrapping paper.

[0027] In certain embodiments, the sheet of amorphous solid and at least one carrier sheet are provided on a bobbin, which are rewound together into a layer of the sheet of amorphous solid and the sheet of carrier material.

[0028] In certain embodiments, both the sheet of amorphous solid and the carrier sheet are corrugated. However, it is also envisioned that only one sheet may be corrugated. Preferably, the carrier sheet and the amorphous solid form a laminated structure. In some instances, the carrier sheet and the amorphous solid sheet may be corrugated in a single step, for example, by passing the laminated structure through a crimper. In some instances, the carrier sheet and the amorphous solid sheet are not laminated together.

[0029] In certain embodiments, the amorphous solid is 1 to 60% by weight of a gelling agent; 0.1 to 50% by weight of an aerosol forming agent; an active substance comprising 0.1 to 80% by weight of particulate plant matter material; where these weights are calculated on a dry weight basis.

[0030] In some embodiments, the amorphous solid is 1 to 50% by weight of a gelling agent; 0.1 to 50% by weight of an aerosol forming agent; an active substance comprising 30-60% by weight of particulate plant matter material; where these weights are calculated on a dry weight basis.

[0031] In some embodiments, the active substances comprise particulate botanical matter material and a flavoring. In some embodiments, the flavoring is menthol. In some embodiments, the particulate botanical matter material is particulate tobacco.

[0032] Suitably, the amorphous solid may comprise up to about 80%, 70%, 60%, 55%, 50%, or 45% by weight of flavoring. In some examples, the amorphous solid may comprise at least about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-80%, 10-80%, 20-70%, 30-60%, 35-55%, or 30-45% by weight of flavoring. In some examples, the flavoring comprises, consists essentially of, or consists of menthol.

[0033] Preferably, the flavoring is added to the slurry during the method of manufacture. In some embodiments, the flavoring added to the slurry comprises molten menthol. The molten menthol and particulate botanical matter material may be present in a ratio ranging from 10:1 to 1:10, the ratio representing the dry weight of the molten menthol and particulate botanical matter material added to the slurry, for example, the molten menthol and particulate botanical matter material may be added in a ratio of 9:1, 8:1, 7:1, 6:1, 5:1, 4:1, 2:1, 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, or 1:10. In some examples, the molten menthol is omitted.

[0034] In some instances, the amorphous solids may further comprise an emulsifier, which emulsifies the molten flavor during manufacture. For example, the amorphous solids may comprise about 5% to about 15% by weight of an emulsifier (calculated on a dry weight basis), preferably about 10% by weight. The emulsifier may comprise gum acacia.

[0035] 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 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).

[0036] Suitably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, or 35% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise from 1 to 50%, 5 to 45%, 10 to 40%, or 20 to 35% by weight of gelling agent.

[0037] 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, e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), 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, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, 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.

[0038] In examples, the hardener comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the hardener comprises or consists of calcium formate and / or calcium lactate. In certain examples, the hardener comprises or consists of calcium formate. The inventors have determined that the use of calcium formate as a hardener typically results in an amorphous solid having higher tensile strength and higher resistance to elongation.

[0039] The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and combinations thereof.

[0040] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxypropyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0041] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0042] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof, In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0043] 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.

[0044] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0045] The inclusion of a gelling agent in the slurry results in the formation of the aerosol-forming material from a dry gel. The inventors have found that the inclusion of a gelling agent in the amorphous solid stabilizes flavor compounds, such as menthol and particulate tobacco, within the gel matrix, allowing for higher flavor loadings to be achieved than with non-gel compositions. The flavorings (e.g., menthol or particulate tobacco) are stabilized at high concentrations, and the product has good shelf life.

[0046] Suitably, the amorphous solid may comprise from about 0.1%, 0.5%, 1%, 3%, 5%, 7%, or 10% to about 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol former (all calculated on a dry weight basis). The aerosol former may act as a plasticizer. For example, the amorphous solid may comprise from 0.5 to 40%, 3 to 35%, or 10 to 25% by weight of the aerosol former. In some examples, the aerosol former comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol former 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 consumer experience when used. The inventors have found that if the plasticizer content is too low, the amorphous solid may become brittle and break easily. The plasticizer content specified herein provides the amorphous solid flexibility that allows the sheet to be wound onto a bobbin, which is useful in the manufacture of the consumables of the present invention.

[0047] 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.

[0048] 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. In some instances, the hydrogel may comprise at least about 1%, 2%, or at least about 5% water by weight (WWB).

[0049] In some embodiments, the amorphous solid further comprises an active substance. For example, in some embodiments, the amorphous solid further comprises nicotine. In some embodiments, the amorphous solid may comprise 5 to 60% by weight (calculated on a dry weight basis) of the active substance. In some embodiments, the amorphous solid may comprise about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active substance. In some embodiments, the amorphous solid may comprise about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20% by weight, 2-18% by weight, or 3-12% by weight nicotine.

[0050] 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 about 5%, 10%, 15%, 20%, or 25% by weight to about 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 10-50%, 15-40%, or 20-35% by weight of tobacco extract. The tobacco extract may include 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 originating from the tobacco extract may be present in the amorphous solid.

[0051] In some embodiments, the active agent 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).

[0052] The active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0053] The active substance may comprise cannabidiol (CBD).

[0054] The active substances may include nicotine and cannabidiol (CBD).

[0055] The active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0056] In some embodiments, the amorphous solid does not comprise tobacco extract, but does comprise nicotine. In some such examples, the amorphous solid may comprise from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the amorphous solid comprises from 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0057] In some instances, the total content of actives and / or flavorings 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 / or flavorings may be less than about 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0058] In some examples, the total content of particulate plant matter material, nicotine and flavorings may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight. In some examples, the total content of particulate plant matter material, nicotine and flavorings may be less than about 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0059] The amorphous solid may be made of a gel, which may further comprise a solvent present at 0.1-50% by weight. However, the present inventors have found that the inclusion of a solvent in which the flavoring agent can dissolve reduces gel stability and may cause the flavoring agent to leave the gel and crystallize. Thus, in some instances, the gel does not include a solvent in which the flavoring agent can dissolve.

[0060] Surprisingly, the inventors have found that the use of molten menthol in the manufacturing process (as opposed to menthol in powder form) can reduce contamination of other machinery at the manufacturing site with menthol. In particular, by putting menthol into molten form before combining at least some or all of the other components of the slurry, contamination of other machinery can be reduced (i.e., menthol is melted before all of the components in the slurry are combined). The use of molten menthol can also improve the distribution of menthol throughout the resulting amorphous solid and / or provide a material in which more of the starting menthol present in the slurry is retained in the amorphous solid. Thus, in some embodiments, the flavoring comprises molten menthol.

[0061] The inventors have also found that the addition of particulate plant matter material to an amorphous solid (gel) results in a uniform suspension of plant matter particles. When particulate tobacco material is included, the particulate tobacco material contributes a natural tobacco taste to the aerosol generated by the resulting consumable. In some instances, the particulate tobacco is of the same size as or less than the tobacco cell structure for at least a fraction of the total tobacco powder amount. Without wishing to be bound by theory, it is believed that pulverizing tobacco to about 0.05 millimeters may advantageously open up the tobacco cell structure to improve aerosolization of, for example, tobacco flavorings and nicotine. Examples of substances whose aerosolization may be improved by providing a tobacco powder having an average powder size of about 0.03 millimeters to about 0.12 millimeters are pectin, nicotine, essential oils, and other tobacco flavorings. As used herein, the term "tobacco powder" refers to tobacco having an average size of about 0.03 millimeters to about 0.12 millimeters. The slurry comprises several components that produce a homogenized tobacco containing an aerosol-generating material. In some embodiments, a component of the slurry is particulate tobacco, which may also be referred to as "tobacco powder." Preferably, the particulate tobacco represents the majority of the tobacco present in the slurry and provides the natural tobacco flavors.

[0062] Water may be added to the slurry to achieve a particular viscosity and moisture content of the slurry that is optimal for casting a web of homogenized amorphous solid.

[0063] The use of finely ground particulate plant matter material results in a very homogenous slurry and then a very homogenous amorphous solid. However, the tensile strength of the amorphous solid obtained from this slurry is relatively low and may be insufficient to withstand the forces acting on the amorphous solid during processing. Advantageously, the inclusion of a gelling agent improves the tensile strength of the amorphous solid. In some instances, this means that it is not necessary to add fibers to increase the tensile strength of the amorphous solid. Furthermore, in some instances, the use of a support is not necessary because the tensile strength is increased by the gel. Without wishing to be bound by theory, it is believed that the dispersion of particulate plant matter material such as tobacco in the gel promotes the release of aroma components of the plant matter material when the final aerosol generating material is used in a non-combustion type aerosol delivery system.

[0064] A consistent average size of particulate plant material between about 0.03 millimeters and about 0.12 millimeters may also improve the homogeneity of the slurry. Plant material particles that are too large, for example, greater than about 0.15 millimeters, may result in defects and weak areas in the amorphous solid formed from the slurry. Defects in the amorphous solid may reduce the tensile strength of the amorphous solid. Reduced tensile strength may make subsequent handling of the amorphous solid in the manufacture of consumables difficult, for example, causing machine stoppages. Additionally, non-homogeneous amorphous solids may result in unintended differences in aerosol delivery between consumables manufactured from the same amorphous solid.

[0065] Thus, particulate plant matter material having a relatively small average particle size is desirable as a starting material for forming a slurry to obtain an amorphous solid acceptable for the consumable of the present invention. If the plant matter particles are too small, the energy consumption required for the process to reduce their size increases without the added benefit of this further reduction. A reduction in particulate plant matter average size is also beneficial because it reduces the viscosity of the slurry, thereby allowing for better homogeneity.

[0066] 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.

[0067] 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 in the aerosol-forming material that comprises the amorphous solid, such as the tobacco material. 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.

[0068] 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).

[0069] In some instances, the amorphous solid comprises 1-60% by weight of filler, e.g., 5-50%, 10-40%, or 15-30% by weight of filler. In some such instances, the amorphous solid comprises at least 1% by weight of filler, e.g., at least 5%, at least 10%, at least 20% at least 30%, at least 40%, or at least 50% by weight of filler.

[0070] 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.

[0071] 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.

[0072] 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, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC). In certain instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0073] 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, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC). Without wishing to be bound by theory, it is believed that including 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, such as when a sheet of amorphous solid surrounds a rod of aerosol-generating material, or in instances where a sheet of amorphous solid is corrugated and gathered to form a rod.

[0074] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0075] In some embodiments, the aerosol-forming material does not comprise tobacco fibers, hi certain embodiments, the aerosol-forming material does not comprise fibrous materials.

[0076] In some embodiments, the consumable does not comprise tobacco fiber, hi certain embodiments, the consumable does not comprise fibrous material.

[0077] In some instances, the aerosol-generating material 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 aerosol-generating material may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

[0078] 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.

[0079] The inventors have found that if the aerosol-generating material or amorphous solid is too thick, the heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it is difficult to manufacture and handle, and very thin materials are more difficult to cast and prone to breaking, which can impair aerosol formation during use.

[0080] The inventors have found that the thickness of the aerosol-forming material or amorphous solid defined herein optimizes the material properties taking into account these competing considerations.

[0081] 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.

[0082] 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 generating consumable. 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 generating consumable / assembly as a rolled sheet, preferably in the form of a tube.

[0083] In some embodiments, the amorphous solid is formed as a sheet. In some instances, the amorphous solid sheet may be incorporated into the consumable in sheet form. The amorphous solid sheet may be incorporated as a flat sheet, as a gathered or pleated sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some such instances, the amorphous solid of these embodiments may be included in the consumable as a sheet, for example, as a sheet surrounding a rod of aerosol-generating material (such as tobacco). For example, the amorphous solid sheet may be formed on a wrapping paper that surrounds an aerosol-generating material such as tobacco. In other instances, the sheet may be shredded and then incorporated into an assembly, preferably mixed into an aerosol-generating material such as cut rag tobacco. In some instances, the amorphous solid may be incorporated into a pod or cartridge.

[0084] The amorphous solid may have any suitable areal density, for example 30 g / m2 ~120g / m 2 In some examples, the sheet may have a density of 80 to 120 g / m 2 , or about 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 or preferably about 100 g / m 2 (so that the sheet has a density similar to shredded rag tobacco and mixtures of these materials do not easily separate). Such areal densities may be particularly suitable when the aerosol-generating material is included in the aerosol-generating consumable / assembly in sheet form or as shredded sheets (discussed further below). In some examples, the sheet has a mass per unit area of ​​about 30-70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be used to surround an aerosol-forming material such as a cigarette.

[0085] A support may be provided to support the aerosol-generating material. The support acts as a support on which the amorphous solid layer is formed, facilitating manufacturing. The support may provide tensile strength to the amorphous solid, facilitating handling.

[0086] 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 a plant material (such as a sheet of reconstituted tobacco). In some examples, the support may be formed from a susceptor material. In other 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 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 carrier. For example, the carrier support may be impregnated with flavors or tobacco extracts.

[0087] In some instances, the support may be non-magnetic.

[0088] 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 material may include one or more magnets that can be used to secure the material to an induction heater during use.

[0089] 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 carrier 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.

[0090] 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 carrier 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 carrier).

[0091] In addition, surface roughness may contribute to the strength of the bond between the amorphous solid and the support. The inventors have found that the roughness of the paper (at the surface abutting the carrier) may preferably be in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure interval of 50.66 to 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").

[0092] 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 solid and a smoother side that does not face the amorphous solid.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] In some examples, the support may have a thickness of from about 0.010 mm to about 2.0 mm, preferably from about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0097] A sheet of homogenized plant matter material may be used as a support. The sheet of homogenized plant matter material is preferably formed by a type of casting process that includes casting a slurry comprising particulate plant matter material and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a sheet of homogenized plant matter material, and removing the sheet of homogenized plant matter material from the support surface. In certain embodiments, the sheet of homogenized plant matter material is wound onto a bobbin.

[0098] In certain embodiments, sheets of homogenized plant material may be formed from a slurry comprising particulate plant material, guar gum, cellulose fibers, and glycerol by a casting process. Such sheets of homogenized plant material may be textured using known machinery suitable for texturing filter tow, paper, and other materials. For example, sheets of homogenized plant material to form rods as described herein may be corrugated using a crimping unit of the type described in CH-A-691156, which comprises a pair of rotating crimp rollers. Sheets of homogenized plant material may be textured using other suitable machinery and processes that deform or perforate the sheets of homogenized plant material.

[0099] As used herein, the term "corrugated sheet" is intended to be synonymous with the term "creped sheet" and refers to a sheet having a plurality of substantially parallel ridges or pleats. Preferably, the corrugated sheet of aerosol-generating material has a plurality of ridges or pleats that are substantially parallel to the cylindrical axis of the rod. This advantageously facilitates gathering the corrugated sheet of aerosol-generating material to form a rod. However, it is recognized that the corrugated sheet of aerosol-generating material or the corrugated sheet of amorphous solid used in a rod as described herein may alternatively or additionally have a plurality of substantially parallel ridges or pleats that are arranged at an acute or obtuse angle relative to the cylindrical axis of the rod.

[0100] In certain embodiments, a sheet of aerosol-generating material used in a consumable product as described herein may be textured substantially uniformly across substantially its entire surface. For example, a corrugated sheet of aerosol-generating material or a corrugated sheet of amorphous solid used in a rod as described herein may comprise a plurality of substantially parallel ridges or corrugations that are substantially uniformly spaced across the width of the sheet.

[0101] The amorphous solid or sheet of aerosol-generating material may be textured using known machinery suitable for texturing filter tow, paper, and other materials. For example, a sheet of aerosol-generating material to form a rod as described herein may be corrugated using a crimping unit of the type described in CH-A-691156, which comprises a pair of rotating crimp rollers. However, the amorphous solid or sheet of aerosol-generating material may be textured using other suitable machinery and processes that deform or perforate the amorphous solid or sheet of aerosol-generating material.

[0102] In some embodiments, the amorphous solid may be formed by casting the slurry onto a support movable along a transport direction. In some embodiments, the slurry is cast by a casting device across the width of the moving transport support. For example, casting may be performed by a casting blade. The transport support moves along the length or transport direction to remove the slurry from the casting device. The support may include, for example, a stainless steel moving belt. The casting device is preferably designed and constructed to form a cast having a substantially uniform thickness on the moving support.

[0103] The cast homogenized tobacco sheet has a width, defined as its dimension substantially perpendicular to the transport direction of the moving support, which is preferably determined by a compromise between production speed and drying speed. Preferably, the moisture of the sheet must be maintained substantially uniform and controlled to obtain a final product with a limited number of defects, in addition to obtaining the fastest possible production speed. A relatively "small width" allows for a higher uniformity of the moisture content, especially during the drying step, however, the production speed may increase when the sheet is relatively wide, so that with proper moisture control the selection value for the width of the sheet is reduced. Thus, preferably, the width of the sheet is as wide as possible to allow for proper control of its moisture content.

[0104] Consumables and non-combustion aerosol delivery systems As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user;

[0105] Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials; a consumable comprising an aerosol generating material and configured for use within one of these non-combustion aerosol delivery systems; and Aerosol-free delivery systems that deliver one or more substances (which may or may not include nicotine) to a user orally, nasally, transdermally, or otherwise, without forming an aerosol (including, but not limited to, oral products such as lozenges, gums, patches, consumables comprising powders for inhalation, and oral tobacco, including snus or moist snuff); Includes.

[0106] According to this disclosure, a "combustion-type" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery to the user.

[0107] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned during use to facilitate delivery to a user.

[0108] In some embodiments, the delivery system is a combustion-type aerosol delivery system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0109] In some embodiments, the present disclosure relates to components used in combustion-type aerosol delivery systems, for example, additive release components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads or beads, or papers such as plug wrap, tipping paper or cigarette paper.

[0110] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example a powdered non-combustion aerosol delivery system.

[0111] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0112] In some embodiments, the non-combustion aerosol delivery system is a tobacco heating system, also known as a non-combustion heating system.

[0113] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

[0114] Typically, a non-combustion aerosol delivery system may comprise a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device, however, it is envisioned that a consumable that itself comprises a means for powering an aerosol generating component may itself form a non-combustion aerosol delivery system.

[0115] In some embodiments, the non-combustion aerosol delivery device may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source comprises a carbon substrate that may be energized to distribute electrical power in the form of heat to the aerosol generating material, or a heat conducting material in proximity to the heat generating power source. In some embodiments, a power source, such as a heat generating power source, is provided in the consumable to form the non-combustion aerosol delivery.

[0116] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol-forming material, an aerosol-forming component, an aerosol-forming region, a mouthpiece, and / or a region for receiving the aerosol-forming material.

[0117] In some embodiments, the aerosol-generating component is a heater capable of interacting with the aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol-generating component is capable of generating an aerosol from the aerosol-generating material without the application of heat. For example, the aerosol-generating component may be capable of generating an aerosol from the aerosol-generating material without the application of heat, e.g., via one or more of vibrational, mechanical, pressurized, or electrostatic means.

[0118] The consumable may also be referred to herein as a cartridge. The consumable may be adapted for use in a THP, a hybrid device, or another aerosol generating device. In some examples, the consumable may further comprise a filter and / or a cooling element as previously described. In some examples, the consumable may be surrounded by a packaging material, such as paper.

[0119] Consumables of the present invention may further comprise vent holes. These may be provided in the sidewalls of the consumable. 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 consumable during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0120] The ventilation facilitates the production of visible heated volatiles from the consumable when the consumable is heated during 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.

[0121] 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.

[0122] 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%.

[0123] 1 and 2, there is shown a partially cut-away cross-sectional view and a perspective view of an example of an aerosol-generating consumable 101. The consumable 101 is adapted for use with a device having a power source and a heater. The consumable 101 of this embodiment is particularly suited for use with the device 51 shown in Figures 5-7, described below. In use, the consumable 101 can be removably inserted into the device at an insertion point 20 of the device 51 shown in Figure 5.

[0124] The consumable 101 in one example 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 and chopped form.

[0125] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The consumable 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 consumable 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 at proximal end 113 of consumable 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.

[0126] 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.

[0127] In one example, the overall length of the consumable 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0128] One axial end of the body 103 of aerosol-generating material is visible at the distal end 115 of the consumable 101. However, in other embodiments, the distal end 115 of the consumable 101 may comprise an end member (not shown) that covers one axial end of the body 103 of aerosol-generating material.

[0129] 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.

[0130] 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 volatiles 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 consumable 101 during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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 consumable 101 during insertion into device 51.

[0135] 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.

[0136] 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.

[0137] 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 consumable 101. Therefore, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the consumable 101. Additionally, the filter segment performs a filtration function in the consumable 101.

[0138] 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.

[0139] 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.

[0140] In one example, the filter segment 109 is between 6 mm and 10 mm in length, preferably 8 mm.

[0141] The oral end segment 111 is an annular tube that is disposed around and defines a cavity within the oral end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The oral 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 consumable during manufacture and insertion into the device 51. In one example, the wall thickness of the oral end segment 111 is about 0.29 mm. In one example, the length of the oral end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0142] 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. 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.

[0143] 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.

[0144] 3 and 4, there is shown a partial cutaway cross-sectional view and a perspective view of an example of a consumable 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.

[0145] In the example of the consumable 301 shown in Figures 3 and 4, a ventilation area 317 is provided in the consumable 301 to allow air to flow from the exterior of the consumable 301 to the interior of the consumable 301. In one example, the ventilation area 317 takes the form of one or more ventilation holes 317 formed through an outer layer of the consumable 301. The ventilation holes may be located in the cooling segment 307 to aid in cooling the consumable 301. In one example, the ventilation area 317 comprises one or more rows of holes, preferably each row of holes located along the circumference of the consumable 301 in a cross section substantially perpendicular to the longitudinal axis of the consumable 301.

[0146] In one example, there are 1-4 rows of vent holes to provide ventilation to the consumable 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.

[0147] 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 consumable 301. The vent holes 317 are positioned to effectively cool the consumable 301.

[0148] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the consumable, and preferably 17 mm to 20 mm from the proximal end 313 of the consumable 301. The location of the vent holes 317 is determined such that the vent holes 317 are not blocked by a user when the consumable 301 is in use.

[0149] By providing a row of vent holes 17-20 mm from the proximal end 313 of the consumable 301, the vent holes 317 can be located on the outside of the device 51 when the consumable 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 consumable 301 from outside the device 51 through the vent holes to help cool the consumable 301.

[0150] The length of the cooling segment 307 is such that when the consumable 301 is fully inserted into the device 51 , the cooling segment 307 is partially inserted into the device 51 .

[0151] The length of the cooling segment 307 serves two functions: first, to provide a physical gap between the heating device of the device 51 and the heat sensitive filter device 309; and second, to allow the vent hole 317 to be located within the cooling segment when the consumable 301 is fully inserted into the device 51, while also being located outside the device 51. As can be seen in 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.

[0152] 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.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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 consumables 101, 301 containing aerosol-generating materials into and from the device 51 during use.

[0157] 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.

[0158] 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 in the consumable 101, 301, as discussed further below.

[0159] 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 when needed under the control of control circuitry 25 to heat the aerosol-forming material in the consumable (to volatilize the aerosol-forming material without burning it, as discussed above).

[0160] 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.

[0161] 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 consumable 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.

[0162] 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 consumable 101, 301 is inserted into the device 51, substantially the entire body of the aerosol-generating material 103, 303 of the consumable 101, 301 is inserted into the heating device 23.

[0163] 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.

[0164] 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.

[0165] 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 .

[0166] 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 consumable 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, there is a gap 36 between the hollow chamber 35 and the consumable 101, 301. The gap 36 circumscribes the entire circumference of the consumable 101, 301 over at least a portion of the cooling segment 307.

[0167] 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 the consumable 101, 301 inserted within the device to help secure it within the device 51. Open spaces (not shown) defined by adjacent pairs of the ridges 60 and the consumable 101, 301 form ventilation paths around the outer surface of the consumable 101, 301. These ventilation paths allow hot steam escaping from the consumable 101, 301 to exit the device 51, and allow cooling air to flow within the gap 36 around the consumable 101, 301 into the device 51.

[0168] In operation, the consumable 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 consumable 101, 301) is completely contained within the heating arrangement 23 of the device 51. The proximal end 113, 313 of the consumable 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

[0169] During operation, the heating device 23 heats the consumable 101 , 301 to volatilize at least one component of the aerosol-generating material from the body 103 , 303 of aerosol-generating material.

[0170] The primary flow path for heated volatiles from the body of aerosol-generating material 103, 303 is axially through the consumable 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.

[0171] 3 and 4, cool air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0172] definition

[0173] active substance In some embodiments, the substance to be delivered comprises an active agent.

[0174] 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.

[0175] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0176] In some embodiments, the aerosol-generating material 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).

[0177] The aerosol-forming material may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0178] The aerosol-generating material may comprise cannabidiol (CBD).

[0179] The aerosol-forming material may comprise nicotine and cannabidiol (CBD).

[0180] The aerosol-forming material may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0181] plant matter 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 (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0182] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0183] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0184] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0185] fragrance In some embodiments, the substance delivered comprises a fragrance.

[0186] 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.

[0187] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0188] 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.

[0189] Aerosol-Generating Materials An aerosol-generating material 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 actives and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively 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, e.g., liquid, within it. 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.

[0190] The aerosol-generating material may comprise one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0191] Aerosol-forming materials The aerosol forming material may comprise one or more components capable of forming an aerosol. 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 mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0192] 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.

[0193] functional materials The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0194] acid 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.

[0195] 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.

[0196] 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.

[0197] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-generating material comprises nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-generating material 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.

[0198] In certain embodiments, the aerosol-forming material or amorphous solid comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid. base body The material may be on or in a support to form a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0199] consumables A consumable is an article that comprises or consists of an aerosol-generating material that is intended to be consumed in part or in whole during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that generates heat upon use to cause the generation of an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0200] Susceptor A susceptor is a material that can be heated by the penetration of a varying magnetic field, for example an alternating magnetic field. The susceptor may be an electrically conductive material, in which case its penetration with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, in which case its penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, in which case the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0201] Aerosol Generator An aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, high pressure, or electrostatic energy.

[0202] 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.

[0203] 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.

[0204] 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. A method for producing a consumable for use in a non-combustion aerosol delivery system, comprising: the consumable comprises an aerosol-forming material comprising an amorphous solid; a) forming a slurry comprising a particulate plant matter material, a gelling agent, and an aerosol forming material; b) forming a layer of said slurry; c) drying the slurry to obtain the amorphous solid; Equipped with the step of forming a layer of slurry comprises forming the layer of the slurry on a support comprising a susceptor material; the support is a carrier sheet, The method comprises incorporating the amorphous solid and the support comprising a susceptor material into the consumable.

2. The method of claim 1 , comprising the step of casting the slurry formed in (a) onto the support movable along a transport direction.

3. 3. The method of claim 1 or claim 2, wherein the amorphous solid is in the form of a sheet.

4. The method comprises the step of casting the slurry formed in (a) onto the support movable along a transport direction, d) slitting said sheet along said transport direction while said sheet is moving along said transport direction to form separated sheets of said amorphous solid. The method of claim 3 further comprising:

5. 5. A method according to claim 3 or claim 4, comprising the step of winding the sheet onto a bobbin.

6. The method of any one of claims 1 to 5, wherein the slurry comprises a filler.

7. The method of claim 6 , wherein the filler comprises wood pulp and / or cellulose or its derivatives.

8. The method of claim 1 , wherein the susceptor material comprises aluminum foil.

9. A method according to any one of claims 1 to 8, comprising corrugating the amorphous solid.

10. 10. The method of any one of claims 1 to 9, comprising gathering the amorphous solid into a rod and surrounding the rod with a wrapping paper to form a consumable for use in a non-combustion aerosol delivery system.

11. wherein the step of drying the slurry comprises drying the slurry to obtain a sheet of the amorphous solid, the method comprising: d) corrugating the sheet to form a corrugated sheet; e) gathering the corrugated sheet; The method according to any one of claims 1 to 10, comprising:

12. 12. The method according to any one of claims 1 to 11, wherein the drying step removes 50 to 95% by weight of water calculated on a wet weight basis in the slurry.

13. A method according to any one of the preceding claims, wherein the amorphous solid obtained comprises from 1% to 15% by weight of water, calculated on a wet weight basis.

14. 1. A consumable for use in a non-combustion aerosol delivery system, the consumable comprising an aerosol-generating material comprising an amorphous solid, the amorphous solid comprising an active agent, a gelling agent and an aerosol former comprising a particulate botanical material, the aerosol-generating material being disposed on a support comprising a susceptor material, the support being a carrier sheet.

15. 15. The consumable product of claim 14, wherein the amorphous solid is in the form of a sheet.

16. 16. The consumable product of claim 15, wherein the sheet is a corrugated and gathered sheet.

17. The consumable product of any one of claims 14 to 16, comprising a wrapper surrounding the aerosol-forming material.

18. A non-combustion aerosol delivery system comprising a consumable according to any one of claims 14 to 17 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device for generating an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

19. The consumable product comprises an aerosol-forming material including an amorphous solid, the amorphous solid comprising: 1 to 50% by weight of said gelling agent; 0.1 to 50% by weight of the aerosol forming agent; 30-60% by weight of the active material, said active material comprising particulate plant matter; 20. The non-combustion aerosol delivery system of claim 18, comprising:

20. 18. Use of the consumable according to any one of claims 14 to 17 in a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device for generating an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

Images