Aerosol generation

Abstract

The present invention provides a method of making an amorphous solid, the method comprising: (a) forming a slurry, the slurry comprising 0.5 to 60% by weight of a gelling agent, 5 to 80% by weight of an aerosol-forming material, and 0 to 60% by weight of an active ingredient and / or flavoring, wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) applying a hardening agent to the surface of the slurry to harden the slurry to form a gel; and (d) drying the gel to form an amorphous solid, wherein the amorphous solid has a substantially constant concentration of hardening agent throughout.

Description

Technical Field

[0001] The present invention relates to a method for producing an amorphous solid, an amorphous solid obtainable or obtained by said method, and an article and a non-combustible aerosol supply system incorporating said amorphous solid. Background

[0002] Smoking articles such as cigarettes and cigars generate tobacco smoke by burning tobacco during use. Alternatives to such types of articles release inhalable aerosols or vapors by heating a substrate material without combustion to release compounds therefrom. These may be referred to as non-combustible smoking articles or aerosol generation assemblies, or may be similarly referred to.

[0003] An example of such a product is a heating device that releases compounds by heating a solid aerosol-forming material without burning it. This solid aerosol-forming material may, in some instances, include tobacco material. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat not burn devices, tobacco heating devices, or tobacco heating products. Various different configurations are known for volatilizing at least one component of the solid aerosol-forming material.

[0004] As another example, there are hybrid devices. These hybrid devices include a liquid source (which may or may not contain nicotine) that vaporizes upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-forming material (which may or may not contain tobacco material), and the components of this material are entrained in the inhalable vapor or aerosol to produce an inhalation medium. Summary

[0005] A first aspect of the present invention is a method for producing an amorphous solid, comprising (a) forming a slurry, said slurry comprising 0.5 to 60% by weight of a gelling agent, and 5 to 80% by weight of an aerosol-forming material, and 0 to 60% by weight of an active ingredient and / or a flavoring agent, and comprising, wherein these weights are calculated on a dry weight basis, a step, and (b) a step of shaping the slurry, and (c) a step of applying a curing agent to the surface of the slurry to cure the slurry to form a gel, and (d) a step of drying the gel to form an amorphous solid, and including, providing a method in which the amorphous solid has a substantially constant concentration of a curing agent throughout.

[0006] The inventors have found that ensuring that the curing agent is uniformly distributed in the amorphous solid results in a homogeneous solid having a consistent release profile upon heating.

[0007] A second aspect of the present invention provides an amorphous solid that can be obtained or is obtained by the method of the first aspect.

[0008] A third aspect of the present invention is an amorphous solid, comprising 0.5 to 60% by weight of a gelling agent, and 5 to 80% by weight of an aerosol-forming material, and a curing agent, and 0 to 60% by weight of an active ingredient and / or a flavoring agent, and wherein these weights are calculated on a dry weight basis, providing an amorphous solid in which the amorphous solid has a substantially constant concentration of a curing agent throughout.

[0009] A fourth aspect of the present invention is an article for use in a non-combustion aerosol supply system, the article comprising an amorphous solid according to the second or third aspect. Such an article may also be referred to herein as an aerosol-generating article.

[0010] A fifth aspect of the present invention is a non-combustible aerosol supply system comprising an article according to the fourth aspect and a non-combustible aerosol supply device, the non-combustible aerosol supply device comprising an aerosol generation device for generating an aerosol from the article when the article is used with the non-combustible aerosol supply device. In some examples, the device may comprise a heater for heating the amorphous solid without burning it. Such a system may also be referred to herein as an aerosol generation assembly.

[0011] Further features and advantages of the present invention will become apparent from the following description with reference to the accompanying drawings, which are given by way of example only. BRIEF DESCRIPTION OF THE DRAWINGS

[0012]

Figure 1

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Figure 8a

Figure 8b

[0013] The method described herein produces an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel". An amorphous solid is a solid material that can hold some fluid, such as a liquid, within it.

[0014] As described above, the present invention is a method for making an amorphous solid, comprising: (a) forming a slurry, said slurry comprising: 0.5 to 60 wt% gelling agent, 5 to 80 wt% aerosol-forming material, 0 to 60 wt% active ingredient and / or flavorant, wherein these weights are calculated on a dry weight basis, and (b) shaping the slurry; (c) applying a curing agent to the surface of the slurry to cure the slurry to form a gel; (d) drying the gel to form an amorphous solid, and providing a method wherein the amorphous solid has a substantially constant concentration of curing agent throughout.

[0015] Surprisingly, the inventors have found that even when the curing agent is applied to the slurry surface in step (c), thereby initiating curing of the slurry at the surface, the curing agent is uniformly distributed throughout the resulting amorphous solid. No mixing is required to achieve this uniform distribution; the curing agent appears to be absorbed into the slurry, resulting in a uniform distribution.

[0016] "Substantially constant" means that per unit volume of the amorphous solid...Square The amount of hardener per millimeter is 40% or less, preferably 30%, 20% or 15% or less of the average amount of hardener per millimeter, and varies throughout the solid. Square This means that it varies throughout the solid. 。 In some examples, the hardener is applied to the slurry by spraying it onto its surface.

[0017] In some examples, the hardener comprises calcium. In some examples, the hardener is a calcium source comprising a cation and one or more counterions. These one or more counterions are anionic. 2+ This means that it varies throughout the solid.

[0018] In some examples, the total amount of hardener added to the slurry may be 0.5 to 5 wt% calculated on a dry weight basis. Preferably, the total amount may be about 1 wt%, 2.5 wt% or 4 wt% to about 4.8 wt% or 4.5 wt%. The inventors have found that if the amount of hardener added is too low, an amorphous solid may be obtained in which the amorphous solid components are not stabilized and these components tend to drop out of the amorphous solid. The inventors have found that if the amount of hardener added is too high, an amorphous solid that is very sticky and consequently has poor handleability is obtained.

[0019] If the amorphous solid does not contain tobacco, a greater amount of hardener may need to be applied. In some examples, therefore, the total amount of hardener may be 0.5 to 12 wt%, for example 5 to 10 wt% calculated on a dry weight basis. Preferably, the total amount may be about 5 wt%, 6 wt% or 7 wt% to about 12 wt% or 10 wt%. In this example, the amorphous solid generally does not contain any tobacco.

[0020] In some examples, the amount of hardener applied is dependent on the solids content of the slurry. For a given slurry having a solids content of X wt% (calculated on a dry weight basis), the amount of calcium added (mmol of calcium ions per kg of slurry) may preferably be in the range of about 0.3X or 0.35X to about 0.45X or 0.4X. That is, in some embodiments, it is as follows:

[0021] [Table 1]

[0022] In some examples, forming the slurry may include, for example, spraying, casting or extruding the slurry. In some examples, (b) may include forming a layer of the slurry. In some examples, the hardener is applied to the slurry by spraying it onto an upper layer of the layer. In some examples, the slurry layer is formed by casting the slurry. In some examples, forming may simply be the operation of placing the slurry in a position where it is ready to gel.

[0023] In some examples, the hardener has an average molar mass of less than about 400 gmol -1 The inventors have found that using a calcium source with a lower average molar mass can mean that a smaller mass of hardener can be used in the manufacturing process while maintaining a relatively high amount of Ca 2+ thereby reducing manufacturing costs and / or processing problems.

[0024] In some embodiments, the hardener may have an average molar mass of less than about 300 gmol -1 or less than about 200 gmol -1 In some embodiments, the hardener may have an average molar mass of greater than about 80 gmol -1 or greater than about 100 gmol -1 or greater than about 120 gmol -1It may have an average molar mass above. In some embodiments, the curing agent has an average molar mass of about 80 g / mol -1 to about 400 g / mol -1 or about 100 g / mol -1 to about 300 g / mol -1 or about 120 g / mol -1 to about 200 g / mol -1 may be.

[0025] In some embodiments, each counterion present in the curing agent has a molar mass of less than about 250 g / mol. The inventors have found that using a calcium source in which the counterion(s) have a smaller molar mass can achieve a higher effective Ca -1 concentration on a mass basis in the curing agent. In some embodiments, each counterion present in the curing agent has a molar mass of less than about 150 g / mol 2+ or less than about 100 g / mol -1 or less than about 80 g / mol -1 or less than about 80 g / mol -1 In some embodiments, each counterion present in the curing agent has a molar mass of greater than about 30 g / mol or greater than about 40 g / mol -1 In some embodiments, each counterion present in the curing agent has a molar mass of from about 30 g / mol -1 to 150 g / mol -1 from about 40 g / mol -1 to 150 g / mol -1 from about 40 g / mol -1 to about 100 g / mol -1 or from about 40 g / mol -1 to about 80 g / mol -1 to about 80 g / mol -1 has a molar mass of.

[0026] As used herein, the molar mass of "each" counterion refers to the molar mass of 1 equivalent of anion relative to Ca 2+ . For example, if the empirical formula of the curing agent contains multiple anions, the mass of "each" counterion refers to the mass of a single anion. For example, the empirical formula of calcium acetate is Ca(C 2 H 3 O 2 ) 2and the molar mass of each counter ion is 59 g / mol -1 , that is, the molar mass of acetate anion [C 2 H 3 O 2 - .

[0027] In some embodiments, Ca 2+ is present in the curing agent in an amount of at least 15% by weight of the combined molar mass of the Ca 2+ ions of the curing agent and the counter ion. The inventors have found that a higher proportion of Ca 2+ ions in the curing agent may mean that a smaller amount of the curing agent can be used to achieve the same curing effect. In some embodiments, Ca 2+ is present in the curing agent in an amount of at least about 25% by weight. In some embodiments, Ca 2+ is present in the curing agent in an amount of less than about 40% by weight, or less than about 30% by weight.

[0028] In some embodiments, one or more counter ions of the curing agent comprise acetate, formate, carbonate, bicarbonate (also known as hydrogen carbonate), lactate, chloride, citrate, or combinations thereof.

[0029] In some embodiments, one or more counter ions of the curing agent comprise acetate, formate, carbonate, bicarbonate (also known as hydrogen carbonate), lactate, chloride, or combinations thereof.

[0030] In some embodiments, one or more counter ions of the curing agent comprise acetate, formate, carbonate, bicarbonate (also known as hydrogen carbonate), lactate, or combinations thereof.

[0031] In some embodiments, one or more counter ions of the curing agent comprise acetate, formate, bicarbonate (also known as hydrogen carbonate), lactate, or combinations thereof.

[0032] ​Suitably, one or more counterions of the curing agent comprise an acetate, a formate, a bicarbonate (also known as a hydrogen carbonate), or a combination thereof. In these embodiments, the curing agent may comprise calcium acetate, calcium formate, calcium bicarbonate, or a combination thereof.

[0033] In some embodiments, one or more counterions are composed of carbon, oxygen, and optionally hydrogen. In certain embodiments, one or more counterions are organic anions. The inventors have found that by using a curing agent containing a carbon-based counterion, an amorphous solid can be provided that has fewer undesirable components in the inhalable aerosol produced when heated, compared to an amorphous solid prepared using a curing agent containing a non-carbon-based counterion. In some embodiments, one or more counterions do not contain chloride.

[0034] In one embodiment, the curing agent may be provided by combining a calcium source with an acid (preferably a weak acid) to provide the curing agent. In one embodiment, calcium carbonate is treated with a weak acid such as benzoic acid or lactic acid to obtain calcium bicarbonate (also known as calcium hydrogen carbonate). This embodiment uses a relatively inexpensive calcium source and converts it into a more soluble curing agent.

[0035] In some embodiments, the curing agent is supplied as a slurry in an aqueous vehicle. For example, the curing agent may be provided in an aqueous curing agent suspension and / or an aqueous curing agent solution. Preferably, the curing agent has a solubility such that at least a portion of the curing agent is dissolved in the aqueous solvent.

[0036] In some embodiments, the curing agent has a water solubility of about 1 g / 100 mL or more at 20 °C (i.e., 0.1 g / L at 20 °C). In some embodiments, the curing agent has a water solubility of about 5 g / 100 mL or more, or about 10 g / 100 mL or more at 20 °C. In some embodiments, the curing agent has a water solubility of less than about 80 g / 100 mL at 20 °C, or less than about 50 g / 100 mL at 20 °C. The inventors have found that by using a curing agent with a higher solubility to prepare an amorphous solid, the curing agent can be better incorporated into the slurry. On the other hand, using a curing agent with too high a solubility may reduce the curing activity.

[0037] In some examples, the curing agent comprises calcium and is provided as an aqueous solution, where the calcium concentration in the aqueous solution is 0.2 - 0.8 mol·dm -3 , preferably about 0.3 - 0.7 mol·dm -3 , preferably about 0.4 - 0.6 mol·dm -3 , preferably about 0.5 mol·dm -3 .

[0038] The following table shows the physical properties of a series of curing agents.

[0039]

Table 2

[0040] In an example, the curing agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the curing agent comprises or consists of calcium formate and / or calcium lactate. In a specific example, the curing agent comprises or consists of calcium formate. The inventors have confirmed that typically, using calcium formate as the curing agent results in an amorphous solid with greater tensile strength and greater elongation resistance.

[0041] The temperature of the slurry when the hardening agent is applied may be in the range of about 42°C to about 70°C. The temperature of the hardening agent when applied to the slurry may be in the range of about 20°C to about 60°C.

[0042] In some examples, the hardening agent is applied to the slurry and is done up to 2 minutes before drying begins. In some examples, the total time from the application of the hardening agent to the end of drying is about 10 to about 15 minutes.

[0043] In some examples, drying includes heating the gel at a temperature in the range of about 80°C to about 140°C for a time less than 60 minutes. (Note that these temperatures are the conditions to which the gel is exposed, not the temperature the gel reaches.) In some examples, (d) includes flowing air over the gel for a time less than 60 minutes, and the air temperature is in the range of about 80°C to about 140°C. In some examples, the air flow rate is less than about 30 m / s, preferably 10 m / s to 30 m / s. In some examples, the air flow rate is about 20 m / s. In some examples, the second time period includes flowing air over the gel for less than about 40 minutes, 30 minutes, or 20 minutes. In some examples, the second time period includes heating the gel for at least about 10 minutes. In some examples, the air temperature is in the range of about 80°C, 85°C, or 90°C to about 130°C, 120°C, or 110°C.

[0044] In some examples, (b) includes forming the slurry on a thermally conductive support, and drying (d) includes heating the thermally conductive support. In some examples, the support is heated to at least 100°C. In some such examples, the support is a metal band.

[0045] In some examples, drying (d) includes (di) heating a thermally conductive support to at least about 100 °C, (dii) flowing air over the gel (where the air temperature ranges from about 80 °C to about 140 °C), and (diii) heating the thermally conductive support to at least about 100 °C, where (di) and (dii) are performed simultaneously or sequentially, and (diii) is performed after (dii) is completed. In some examples, there are three drying zones corresponding to (di), (dii), and (diii), and the gel is moved between the zones over time. In particular, the support material may be a band, and the band is driven by rollers, thereby moving the gel between the zones.

[0046] In some examples, the thermally conductive support can be heated, for example, by contact with hot air / vapor (where the air / vapor does not contact the gel). In other examples, the thermally conductive support is such that it is heated by the application of an electric current.

[0047] In some examples, drying (d) may remove about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% of the water in the slurry (by WWB).

[0048] In some examples, the resulting amorphous solid comprises about 1 wt% to about 15 wt% water calculated on a wet weight basis. Preferably, the resulting amorphous solid comprises about 5 wt% to about 15 wt% water calculated on a wet weight basis (WWB). Preferably, the water content of the amorphous solid may be about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (by WWB), and most preferably may be about 10 wt%.

[0049] The inventors have found that the drying process is important because it controls the final water content of the amorphous solid. In particular, if the water content of the amorphous solid is too high, its performance during use is impaired. The high heat capacity of water means that when the water content is too high, more energy is required to generate the aerosol, which means a decrease in operating efficiency. Furthermore, if the water content is too high, the puff profile may become less satisfactory to the consumer due to the occurrence of a hot, wet puff (a sensation known in the art as a "hot puff"). Additionally, if the water content is too high, microbial growth can occur. Conversely, if the water content is too low, the material may become brittle and difficult to handle. The hygroscopicity of the aerosol-forming material may mean that when the water content is too low, moisture is drawn into the material from the atmosphere, destabilizing the material.

[0050] The inventors have also found that if the drying process is carried out too rapidly, cracks are observed in the amorphous solid. An aerosol generated from a cracked amorphous solid by heating has lower consistency compared to a solid that did not crack. Thus, the drying process is important because it affects aerosol generation and user satisfaction.

[0051] Furthermore, the inventors have found that if the drying temperature is too high, the content of the desired components of the amorphous solid (e.g., the aerosol-forming material, the active ingredient, and / or the flavorant) may be reduced beyond the desired level.

[0052] Thus, when attempting to dry a gel to form an amorphous solid, there are a number of competing objectives that must be balanced. The claimed process has been found by the inventors to be particularly suitable.

[0053] In some examples, drying results in an amorphous solid having a thickness of about 5% to 20% of the slurry thickness, preferably about 10%. In some examples, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of 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 a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the total thickness of these layers.

[0054] In some examples, the method includes forming a layer of slurry having a thickness of less than about 4 mm. Preferably, the thickness of the slurry layer is in the range of about 1 mm to about 3 mm, preferably about 1.5 mm to about 2.5 mm. In some examples, the thickness of the slurry layer is about 2 mm.

[0055] The inventors have found that when the slurry layer is too thick, it can be difficult to form an amorphous solid with the required water content by drying and at the same time minimize cracking of the solid during drying.

[0056] The inventors have found that when the amorphous solid for aerosol formation is too thick, the heating efficiency is impaired. This has an adverse effect on the power consumption during use. Conversely, when the amorphous solid for aerosol formation is too thin, manufacturing and handling are difficult. That is, very thin materials are more difficult to cast and are also fragile, which may impair aerosol formation during use.

[0057] The inventors have found that the thickness of the amorphous solid as defined herein optimizes the material properties considering these competing considerations.

[0058] Any thickness defined herein is an average thickness. In some examples, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0059] In some examples, the surface temperature of the gel during drying does not exceed about 100 °C.

[0060] Alginate is a derivative of alginic acid and is typically a high molecular weight polymer (10 - 600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked together by (1,4)-glycosidic bonds to form a polysaccharide. When calcium cations are added, the alginate crosslinks to form a gel. The inventors have determined that alginates having a high G monomer content form gels more readily upon addition of a calcium source. Thus, in some examples, the slurry may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0061] In some examples, a carrier is provided and the slurry is formed on the carrier in (b). The carrier functions as a support on which an amorphous solid layer is formed, facilitating manufacture. The carrier may impart rigidity to the amorphous solid layer, facilitating handling. The carrier may be any suitable material that can be used to support the amorphous solid. In some examples, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or combinations thereof. In some examples, the carrier may comprise or consist of a tobacco material (such as a sheet of reconstituted tobacco). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some examples, the carrier comprises paper. In some examples, the carrier itself is a laminated structure comprising layers of a plurality of materials selected from the aforementioned list. In some examples, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with a flavorant or a tobacco extract.

[0062] Preferably, the thickness of the carrier layer may be in the range of about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The carrier may comprise two or more layers, and the thickness described herein refers to the total thickness of these layers.

[0063] In some examples, the carrier may be non-magnetic.

[0064] In some examples, the carrier may be magnetic. This function may be used to fix the carrier to the assembly during use, or may be used to generate a specific amorphous solid shape. In some examples, the amorphous solid may comprise one or more magnets that can be used to fix the solid to an induction heater during use.

[0065] In some examples, the carrier 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 can also be utilized to prevent the gas / aerosol from condensing or otherwise depositing on the surface of, for example, a heater provided in a non-combustible aerosol supply system during use. In this way, in some examples, the consumption efficiency and hygiene can be improved.

[0066] In some examples, the surface of the carrier in contact with the amorphous solid may be porous. For example, in one example, the carrier comprises paper. The inventors have found that a porous carrier such as paper is particularly suitable for the present invention, and that a porous (e.g., paper) layer in contact with the amorphous solid layer forms a strong bond. The amorphous solid is formed by drying a gel, and, without being limited by theory, the slurry forming the gel is partially impregnated into the porous carrier (e.g., paper), such that the carrier is partially bonded to the gel when the gel cures to form crosslinks. This results in a strong bond between the gel and the carrier (and between the dried gel and the carrier).

[0067] In addition to this, surface roughness can contribute to the strength of the bond between the amorphous material and the carrier. The inventors have found that the roughness of the paper (of the surface in contact with the carrier) is preferably in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure range of 50.66 to 48.00 kPa). (The Bekk smoothness tester is a device used to measure the smoothness of a paper surface. In this tester, air at a specific pressure is introduced between a smooth glass surface and a paper sample. The time (seconds) for a certain fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

[0068] Conversely, the surface of the carrier that does not face the amorphous solid may be arranged in contact with a heater, and a smoother surface may provide more efficient heat transfer. Thus, in some examples, the carrier is arranged to have a rougher surface in contact with the amorphous material and a smoother surface that does not face the amorphous material.

[0069] In one specific example, the carrier may be a foil lined with paper, where the paper layer abuts the amorphous solid layer and the properties discussed in the previous paragraphs are brought about by this abutment. The foil lining is substantially impermeable and provides control of the aerosol flow path. The metal foil lining may also serve to transfer heat to the amorphous solid both during drying and in use.

[0070] In another example, the foil layer of the paper-lined foil abuts the amorphous solid. The foil is substantially impermeable and prevents moisture imparted into the amorphous solid from being absorbed by the paper (which could potentially weaken the structural integrity of the paper).

[0071] In some examples, the carrier is formed from a metal foil (such as an aluminum foil) or comprises a metal foil. The metal carrier may enable better transfer of thermal energy to the amorphous solid both during drying and in use. Additionally, or alternatively, the metal foil may function as a susceptor within an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0072] In some examples, the carrier may have a thickness from about 0.017 mm to about 2.0 mm, preferably about 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0073] In some examples, the slurry may comprise from 1 to 60 weight % of a gelling agent, where these weights are calculated on a dry weight basis. Preferably, the slurry may comprise from about 1 weight %, 5 weight %, 10 weight %, 15 weight %, 20 weight %, or 25 weight % to about 60 weight %, 50 weight %, 45 weight %, 40 weight %, 35 weight %, 30 weight %, or 27 weight % of a gelling agent (all calculated on a dry weight basis). For example, the slurry may comprise from 1 to 50 weight %, 5 to 40 weight %, 10 to 30 weight %, or 15 to 27 weight % of a gelling agent.

[0074] In some examples, the gelling agent comprises a hydrophilic colloid. In some examples, the gelling agent comprises one or more compounds selected from the group consisting of alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginate and / or pectin and may be combined with a curing agent (such as a calcium source) during the formation of the amorphous solid. In some examples, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0075] In some examples, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10 to 30% by weight (calculated on a dry weight basis) of the amorphous solid. In some examples, the 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.

[0076] In some examples, the slurry may include a gelling agent comprising carrageenan.

[0077] The gelling agent may comprise one or more compounds selected from cellulose gelling agents, non-cellulose gelling agents, guar gum, acacia gum, and mixtures thereof.

[0078] In some embodiments, the cellulose gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0079] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose (CMC), guar gum, or acacia gum.

[0080] In some embodiments, the gelling agent comprises (or is) one or more of non-cellulose 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 a preferred embodiment, the non-cellulose gelling agent is alginate or agar.

[0081] Preferably, the amorphous solid may comprise from about 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of an aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming material may act as a plasticizer. For example, the slurry may comprise from 10 to 60 wt%, 15 to 50 wt%, or 20 to 40 wt% of an aerosol-forming material. In some examples, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-forming material comprises glycerol, consists essentially of glycerol, or consists of glycerol. The inventors have found that if the content of the plasticizer is too high, the amorphous solid may absorb water, and as a result, a material that does not produce an appropriate consumer experience during use may be obtained. The inventors have found that if the content of the plasticizer is too low, the amorphous solid may become brittle and may break easily. The plasticizer content specified herein provides an amorphous solid flexibility that allows the amorphous solid sheet to be wound around a bobbin, which is useful for the manufacture of articles used in aerosol generation.

[0082] In some embodiments, the aerosol-forming material comprises one or more of a polyhydric alcohol, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerol, an ester of a polyhydric alcohol, such as glycerol mono-, di-, or triacetate, and / or an aliphatic ester of a mono-, di-, or polycarboxylic acid, such as dimethyldodecanedioate and dimethyltetradecanedioate.

[0083] In some examples, the slurry may comprise a fragrance. Preferably, the amorphous solid may comprise up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt%, or 5 wt% of the fragrance. In some examples, the amorphous solid may comprise at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% of the fragrance (calculated on an all dry weight basis). For example, the amorphous solid may comprise 0.1 - 60 wt%, 1 - 60 wt%, 5 - 60 wt%, 10 - 60 wt%, 20 - 50 wt%, or 30 - 40 wt% of the fragrance. In some examples, the fragrance (if present) comprises menthol, consists essentially of menthol, or consists of menthol. In some examples, the amorphous solid does not comprise a fragrance.

[0084] In some examples, the slurry further comprises an active ingredient. For example, in some examples, the slurry further comprises a tobacco material and / or nicotine. For example, the slurry may further comprise powdered tobacco and / or nicotine and / or a tobacco extract. In some examples, the slurry may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of the active ingredient. In some examples, the slurry may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of the tobacco material and / or nicotine.

[0085] In some examples, the slurry comprises an active ingredient such as a tobacco extract. In some examples, the amorphous solid may comprise 5 to 60 wt% (calculated on a dry weight basis) of the tobacco extract. In some examples, the slurry may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 55 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis) of the tobacco extract. For example, the slurry may comprise 5 to 60 wt%, 10 to 55 wt%, or 25 to 55 wt% of the tobacco extract. The tobacco extract may contain nicotine at a concentration such that the slurry comprises from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% (calculated on a dry weight basis) of nicotine. In some examples, nicotine other than that provided by the tobacco extract may not be present in the slurry.

[0086] In some embodiments, the slurry does not comprise tobacco material but comprises nicotine. In some of such examples, the slurry may comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 15 wt%, 10 wt%, or 5 wt% (calculated on a dry weight basis) of nicotine. For example, the slurry may comprise 1 to 20 wt% or 2 to 5 wt% of nicotine.

[0087] In some examples, the total content of the active ingredient and / or flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some examples, the total content of the active ingredient and / or flavor may be less than about 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0088] In some examples, the total content of the tobacco material, nicotine, and flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some examples, the total content of the tobacco material, nicotine, and flavor may be less than about 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0089] 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 contain 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.

[0090] 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.

[0091] 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.

[0092] Including an acid is particularly preferred in embodiments where the amorphous solid comprises nicotine. In such embodiments, the presence of oxygen can stabilize dissolved species in the slurry in which the amorphous solid is formed. The presence of the acid can reduce or substantially prevent the evaporation of nicotine during drying of the slurry, thereby reducing the loss of nicotine during manufacture.

[0093] In certain embodiments, the amorphous solid comprises a gelling agent including a cellulose gelling agent and / or a non-cellulose gelling agent, an active ingredient, and an acid.

[0094] The amorphous solid may comprise a colorant. The addition of the colorant may change the appearance of the amorphous solid. The presence of the colorant in the amorphous solid may improve the appearance of the amorphous solid and the aerosol - generating material comprising the amorphous solid. By adding the colorant to the amorphous solid, the amorphous solid may be color - matched with other components of the aerosol - generating material or other components of an article comprising the amorphous solid.

[0095] 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 envisioned. Natural or synthetic colorants, such as natural or synthetic dyes, food colorants and pharmaceutical colorants, may be used. In certain embodiments, the colorant is caramel, and the caramel imparts a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) of the aerosol - generating material comprising the amorphous solid. In some embodiments, the addition of the colorant to the amorphous solid makes the amorphous solid visually indistinguishable from other components of the aerosol - generating material.

[0096] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry comprising the material for forming the amorphous solid) or applied after the amorphous solid has been formed (e.g., by spraying the colorant onto the amorphous solid).

[0097] In some embodiments, the slurry comprises less than 60 wt% filler, e.g., 1 wt% - 60 wt%, or 5 wt% - 50 wt%, or 5 wt% - 30 wt%, or 10 wt% - 20 wt% filler (all calculated on a dry weight basis).

[0098] In other embodiments, the slurry comprises less than 20 wt%, preferably less than 10 wt% or less than 5 wt% filler. In some examples, the slurry comprises less than 1 wt% filler, and in some examples, the slurry comprises no filler.

[0099] When a filler is present, the filler may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). The filler may comprise one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In certain examples, the amorphous solid does not comprise calcium carbonate such as chalk.

[0100] In certain embodiments comprising 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 cellulose derivatives. 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 can be particularly advantageous in examples where the amorphous solid is provided as a sheet, such as when an amorphous solid sheet surrounds a rod of aerosol-forming material.

[0101] In some embodiments, the slurry does not comprise tobacco fibers. In certain embodiments, the slurry does not comprise fibrous material.

[0102] In some examples, the slurry may consist essentially of, or consist of, a gelling agent, an aerosol-forming material, a tobacco material and / or a nicotine source, water, and optionally a flavorant.

[0103] The resulting amorphous solid may have any suitable areal density, for example, 30 g / m 2 ~120 g / m 2 , preferably about 30 - 70 g / m 2 or about 40 - 60 g / m 2 . In some embodiments, the resulting amorphous solid has about 80 - 120 g / m 2 , or about 70 - 110 g / m 2 , or particularly about 90 - 110 g / m 2It may have a surface density such that. Such a surface density can be particularly suitable when the amorphous solid is included in the aerosol generating article / non-combustible aerosol supply system in sheet form or as shredded sheets (further described below).

[0104] As described above, a further aspect of the present invention is An amorphous solid obtainable or obtained by the method of the first aspect An article for use in a non-combustible aerosol supply system, the article comprising an amorphous solid obtainable or obtained by the method of the first aspect, and A non-combustible aerosol supply system comprising an article according to the third aspect and a non-combustible aerosol supply device, the non-combustible aerosol supply device comprising an aerosol generation device for generating an aerosol from the article when the article is used with the non-combustible aerosol supply device. Some examples, the device may comprise a heater configured to heat the amorphous solid without combustion.

[0105] In some examples, the heater may heat the amorphous solid to 120°C to 350°C without combustion during use. In some examples, the heater may heat the amorphous solid to 140°C to 250°C without combustion during use. In some examples, during use, substantially the entire amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some examples, the solid is disposed at about 0.010 mm to 2.0 mm, preferably about 0.02 mm to 1.0 mm, preferably 0.1 mm to 0.5 mm from the heater. These minimum distances may, in some examples, reflect the thickness of the carrier supporting the amorphous solid. In some examples, the surface of the amorphous solid may be in direct contact with the heater.

[0106] The heater is configured to heat without burning the amorphous solid. In some examples, the heater may be an electric resistance heater, such as a thin film electric resistance heater. In other examples, the heater may comprise an induction heater or other heaters. The heater may be a combustible heat source or a chemical heat source that generates heat by causing an exothermic reaction during use. The non-combustion aerosol supply system may comprise a plurality of heaters. These heaters may be powered by a battery.

[0107] The non-combustion aerosol supply system may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gas component or the aerosol component. In some examples, the cooling element may act to cool the gas component such that the gas component condenses to form an aerosol. The cooling element may also act to space apart very hot portions of the device from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0108] In some examples, the non-combustion aerosol supply system may be a heat-not-burn device. That is, the non-combustion aerosol supply system may comprise a solid tobacco-containing material (and does not comprise a liquid aerosol-generating material). In some examples, the amorphous solid may comprise a tobacco material. Heat-not-burn devices are disclosed in WO2015 / 062983A2, the entire disclosure of which is incorporated herein by reference.

[0109] In some examples, the non-combustion aerosol supply system may be a hybrid system. That is, the non-combustion aerosol supply system may include a solid aerosol-generating material and a liquid aerosol-generating material. In some examples, the amorphous solid may comprise nicotine. In some examples, the amorphous solid may comprise a tobacco material. In some examples, the amorphous solid may comprise a tobacco material and a separate nicotine source. These separate aerosol-generating materials may be heated by separate heaters, by the same heater, or in some instances, the downstream aerosol-generating material may be heated by the hot aerosol generated from the upstream aerosol-generating material. Hybrid devices are disclosed in WO2016 / 135331A1, the entire disclosure of which is incorporated herein by reference.

[0110] Aspects of the article for use in a non-combustion aerosol supply system (which may also be referred to herein as an aerosol-generating article, cartridge, or consumable) may be adapted for use in a THP, hybrid device, or another aerosol-generating device. In some examples, the article may further comprise a filter and / or a cooling element (described above). In some examples, the article may comprise an aerosol-generating material surrounded by a packaging material such as paper.

[0111] The article may further comprise ventilation holes. These may be provided in the side wall of the article. In some examples, the ventilation holes may be provided in the filter and / or the cooling element. These holes allow cold air to be drawn into the article during use, and this cold air can mix with the heated volatile components and thereby cool the aerosol.

[0112] Ventilation promotes the generation of visible heating volatile components from the article when the article is heated during use. The heating volatile components are visualized by a process of cooling the heating volatile components such that supersaturation of the heating volatile components occurs. The heating volatile components then undergo droplet formation (also known as nucleation), and ultimately, the size of the aerosol particles of the heating volatile components increases by further condensation of the heating volatile components and by aggregation of newly formed droplets from the heating volatile components.

[0113] In some examples, the ratio of cold air to the sum of the heating volatile components and cold air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% enables the heating volatile components to be visualized by the method described above. The visibility of the heating volatile components allows the user to identify that the volatile components have been generated, enhancing the perceptual experience of the smoking experience.

[0114] In another example, the ventilation ratio is 50% - 85% to further cool the heating volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0115] In some examples, the amorphous solid may be included in the article / non-combustible aerosol supply system in sheet form. In some examples, the amorphous solid may be included as a flat sheet. In some examples, the amorphous solid may be included as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or as a rolled sheet (e.g., in the form of a tube). In some of such examples, the amorphous solid may be included in the article / non-combustible aerosol supply system as a sheet, for example, as a sheet surrounding a rod of aerosol-generating material (such as tobacco). In some other examples, the amorphous solid may be formed as a sheet and then shredded and incorporated into the article. In some examples, the shredded sheet may be mixed with cut-rag tobacco and incorporated into the article.

[0116] In some examples, the sheet-shaped amorphous solid 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 a tensile strength can be particularly suitable for embodiments in which the amorphous solid is formed as a sheet, then shredded, and incorporated into an article. 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 a tensile strength can be particularly suitable for embodiments in which the amorphous solid is included in an article / non-combustible aerosol supply system in the form of a wound sheet, preferably in the form of a tube.

[0117] The non-combustible aerosol supply system may comprise an integrated article and a heater, or alternatively a heating device into which the article is inserted during use.

[0118] Referring to FIGS. 1 and 2, a partially broken cross-sectional view and a perspective view of an example of an aerosol-generating article 101 are shown. The article 101 is adapted to be used with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 51 shown in FIGS. 5 to 7 described below. In use, the article 101 can be removably inserted into the device at the insertion location 20 of the device 51 shown in FIG. 5.

[0119] An example of the article 101 is in the form of a generally cylindrical rod including an aerosol-generating material body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises the amorphous solid described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in the form of shredded sheets. In some embodiments, the aerosol-generating material described herein may be incorporated in both sheet form and shredded form.

[0120] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouth-end segment 111. The article 101 has a first end 113, also known as the mouth-end or proximal end, and a second end 115, also known as the distal end. The aerosol-generating material body 103 is disposed on the side of the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the aerosol-generating material body 103 between the aerosol-generating material body 103 and the filter segment 109 such that the cooling segment 107 is in contact with the aerosol-generating material 103 and the filter segment 109. In other examples, there may be a separation between the aerosol-generating material body 103 and the cooling segment 107 and between the aerosol-generating material body 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the mouth-end segment 111. The mouth-end segment 111 is disposed on the side of the proximal end 113 of the article 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in contact with the mouth-end segment 111. In one embodiment, the overall length of the filter assembly 105 is from 37 mm to 45 mm, and more preferably, the overall length of the filter assembly 105 is 41 mm.

[0121] In one example, the rod of the aerosol-generating material 103 has a length of from 34 mm to 50 mm, preferably from 38 mm to 46 mm, and preferably 42 mm.

[0122] In one example, the overall length of the article 101 is from 71 mm to 95 mm, preferably from 79 mm to 87 mm, and preferably 83 mm.

[0123] One axial end of the aerosol-generating material body 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) that covers one axial end of the aerosol-generating material body 103.

[0124] The aerosol generating material body 103 is joined to the filter assembly 105 by an annular tipping paper (not shown), the annular tipping paper being disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extending partially along the length of the aerosol generating material body 103. In one example, the tipping paper is made from 58GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0125] In one example, the cooling segment 107 is an annular tube and is disposed around the void within the cooling segment and defines the void. This void provides a chamber through which the heated volatile components generated from the aerosol generating material body 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation but has sufficient rigidity to withstand the axial compressive forces and bending moments that can occur during manufacture and during use while the article 101 is inserted into the device 51. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0126] 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 results in a thermal gradient between the two ends of the cooling segment 107 in its longitudinal direction. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated and volatile components entering the first end of the cooling segment 107 and the heated and volatile components 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 °C between the heated and volatile components entering the first end of the cooling segment 107 and the heated and volatile components exiting the second end of the cooling segment 107. This temperature difference between the two ends of the cooling element 107 in its longitudinal direction protects the temperature - sensitive filter segment 109 from the high temperature 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 be damaged during use and may not effectively perform its required function.

[0127] 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 from 20 mm to 30 mm, more specifically from 23 mm to 27 mm, more specifically from 25 mm to 27 mm, and preferably 25 mm.

[0128] The cooling segment 107 is made of paper, which means that the cooling segment 107 is composed of a material that does not produce any concerning compounds (such as toxic compounds) when it is adjacent to the heater of the device 51 during use. In one example, the cooling segment 107 is manufactured from a spiral - wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spiral - wound paper tube can meet the strict dimensional accuracy requirements of a high - speed manufacturing process with respect to the tube length, outer diameter, roundness, and straightness.

[0129] In another example, the cooling segment 107 is a recess made from a rigid plug wrap or tipping paper. The rigid plug wrap or tipping paper is manufactured to have sufficient rigidity to withstand the axial compressive forces and bending moments that can occur during manufacturing and while the article 101 is being inserted into the device 51.

[0130] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components of the aerosol - generating material. In one example, the filter segment 109 is made from a mono - acetate material such as cellulose acetate. The filter segment 109 provides cooling and irritation reduction of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0131] In some embodiments, capsules (not shown) may be provided within the filter segment 109. These capsules may be disposed substantially at the center of the filter segment 109 in both the radial and longitudinal directions of the filter segment 109. In other examples, the capsules may be offset from the center in one or more dimensions. In some examples, when capsules are present, the capsules may contain volatile components such as flavorants or aerosol - forming materials.

[0132] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109 and thus the draw resistance of the article 101. Therefore, the selection of the material of the filter segment 109 is important in controlling the draw resistance of the article 101. Further, the filter segment performs a filtering function in the article 101.

[0133] In one example, the filter segment 109 is made from an 8Y15 grade filter tow material. This filter tow material provides a filtering effect on the heated volatile material while reducing the size of the condensed aerosol droplets resulting from the heated volatile material.

[0134] The presence of the filter segment 109 provides a heat insulation effect by further cooling the heated volatile components exiting the cooling segment 107. This further cooling effect reduces the contact temperature of the user's lips with the surface of the filter segment 109.

[0135] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0136] The mouth-side end segment 111 is an annular tube and is arranged around the void within the mouth-side end segment 111 to define the void. This void provides a chamber for the heated volatile components flowing from the filter segment 109. The mouth-side end segment 111 is hollow to provide a chamber for aerosol accumulation, but has sufficient rigidity to withstand the axial compressive forces and bending moments that can occur during manufacturing and while the article is in use during insertion into the device 51. In one example, the wall thickness of the mouth-side end segment 111 is about 0.29 mm. In one example, the length of the mouth-side end segment 111 is 6 mm to 10 mm, preferably 8 mm.

[0137] The mouth-side end segment 111 may be manufactured from a spiral-wound paper tube that provides a hollow internal chamber but maintains important mechanical rigidity. The spiral-wound paper tube can meet the stringent dimensional accuracy requirements of a high-speed manufacturing process with respect to the tube length, outer diameter, roundness, and straightness.

[0138] The mouth-side end segment 111 provides the function of preventing the liquid condensate accumulating at the outlet of the filter segment 109 from coming into direct contact with the user.

[0139] It should be understood that in one example, the mouth-side end segment 111 and the cooling segment 107 are formed from a single tube and the filter segment 109 is disposed within the tube, and the mouth-side end segment 111 and the cooling segment 107 may be separated.

[0140] Referring to FIGS. 3 and 4, a partial cutaway cross-sectional view and a perspective view of an example of the article 301 are shown. The reference numerals shown in FIGS. 3 and 4 correspond to those shown in FIGS. 1 and 2, except that the numbers are increased by 200 only.

[0141] In the example of the article 301 shown in FIGS. 3 and 4, a ventilation region 317 is provided in the article 301 to allow air to flow from the outside of the article 301 into the inside of the article 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301. These ventilation holes may be arranged in the cooling segment 307 to assist in cooling the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, and preferably each row of holes is arranged along the outer periphery of the article 301 in a cross-section substantially perpendicular to the longitudinal axis of the article 301.

[0142] In one example, there are 1 to 4 rows of ventilation holes to provide ventilation to the article 301. Each row of ventilation holes may have 12 to 36 ventilation holes 317. The diameter of the ventilation holes 317 can be, for example, 100 to 500 μm. In one example, the axial spacing between the rows of ventilation holes 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0143] In one example, the ventilation holes 317 have a uniform size. In another example, the ventilation holes 317 have various sizes. The ventilation holes can be made using any suitable technique, such as laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The ventilation holes 317 are positioned to effectively cool the article 301.

[0144] In one example, the rows of ventilation holes 317 are located at least 11 mm from the proximal end 313 of the article, preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The position of the ventilation holes 317 is determined so that the user does not block the ventilation holes 317 during use of the article 301.

[0145] By providing a row of ventilation holes from 17 mm to 20 mm from the proximal end 313 of the article 301, as can be seen in FIGS. 6 and 7, the ventilation holes 317 can be arranged outside the device 51 when the article 301 is fully inserted into the device 51. By arranging the ventilation holes outside the device, unheated air can enter the article 301 through the ventilation holes from the outside of the device 51, which can help cool the article 301.

[0146] The length of the cooling segment 307 is such that when the article 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 provides a first function of providing a physical gap between the heating device of the device 51 and the heat-sensitive filter device 309, and a second function that enables the ventilation holes 317 to be arranged within the cooling segment while also being arranged outside the device 51 when the article 301 is fully inserted into the device 51. As can be seen from FIGS. 6 and 7, most of the cooling element 307 is arranged within the device 51. However, the cooling element 307 has a portion that extends outside the device 51. The ventilation holes 317 are arranged in this portion of the cooling element 307 that extends outside the device 51.

[0147] Referring now more particularly to FIGS. 5 - 7, an example of a device 51 configured to heat an aerosol - generating material to volatilize at least one component of the aerosol - generating material to typically form an inhalable aerosol is shown. The device 51 is a heating device that releases compounds by heating the aerosol - generating material without burning it.

[0148] The first end 53 may be referred to herein as the mouth - side end 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, and the user can start / stop the entire device 51 as desired.

[0149] 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 single-piece sleeve 11 that surrounds the outer edge of the device 51, and this sleeve 11 is covered by 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 the bottom panel 19, a front panel, a rear panel, and a pair of opposing side panels.

[0150] The top panel 17 and / or the bottom panel 19 may be removably fixed to the single-piece sleeve 11 to enable easy access to the interior of the device 51, or may be "permanently" fixed to the single-piece sleeve 11, for example, to prevent a user from accessing the interior of the device 51. In one example, the panels 17 and 19 are made of a plastic material (including, for example, glass-filled nylon formed by injection molding), and the single-piece sleeve 11 is made of aluminum, but other materials and other manufacturing processes may be used.

[0151] The top panel 17 of the device 51 has an opening 20 at the mouth-side end 53 of the device 51, and during use, a user can insert articles 101, 301 containing an aerosol-generating material through this opening 20 into the device 51 and also remove them from the device 51.

[0152] The housing 59 has a heating device 23, a control circuit 25, and a power supply 27 arranged or fixed therein. In this example, the heating device 23, the control circuit 25, and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuit 25 is generally located between the heating device 23 and the power supply 27, but other arrangements are possible.

[0153] The control circuit 25 may include a controller such as a microprocessor device that is configured and arranged to control the heating of the aerosol-generating material in the articles 101, 301, as further discussed below.

[0154] The power source 27 may be, for example, a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically coupled to the heating device 23 and supplies power under the control of the control circuit 25 when necessary to heat the aerosol-generating material within the article (as described above, to volatilize the aerosol-generating material without burning the aerosol-generating material).

[0155] The advantage of arranging the power source 27 in a laterally proximate position to the heating device 23 is that a physically large power source 25 can be used without making the entire device 51 overly long. Naturally, generally, a physically large power source 25 has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.), and thus, the battery life of the device 51 can be made longer.

[0156] In one example, the heating device 23 generally has the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which articles 101, 301 comprising the aerosol-generating material are inserted for heating during use. Various configurations are possible for the heating device 23. For example, the heating device 23 may comprise a single heating element or may be formed from a plurality of heating elements aligned along the longitudinal axis of the heating device 23. The heating element or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its outer periphery. In one example, the heating element or each heating element may be a thin-film heater. In another example, the heating element or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina ceramic, aluminum nitride ceramic, and silicon nitride ceramic, which may be laminated and sintered. Other heating configurations are possible and include, for example, resistance heating elements formed by induction heating, infrared heating elements (which heat by emitting infrared rays), resistance electric windings, and the like.

[0157] In one particular example, the heating device 23 is supported by a stainless - steel support tube and comprises a polyimide heating element. The heating device 23 is dimensioned such that when the articles 101, 301 are inserted into the device 51, substantially the entire body of the aerosol - generating material 103, 303 of the articles 101, 301 is inserted into the heating device 23.

[0158] The heating element or each heating element may be arranged so as to be able to independently heat a selected plurality of zones (regions) of the aerosol - generating material, for example, sequentially (over time as desired) or together (simultaneously), as described above.

[0159] The heating device 23 in this example is surrounded by a heat insulator 31 along at least a part of its length. The heat insulator 31 serves to reduce the heat passing from the heating device 23 to the outside of the device 51. This generally reduces heat loss and thus helps to keep the power requirements of the heating device 23 low. The heat insulator 31 also helps to keep the outside of the device 51 cool during operation of the heating device 23. In one example, the heat insulator 31 may be a double - wall sleeve that provides a low - pressure region between two walls of the sleeve. That is, the heat insulator 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 heat insulator 31 are possible and include using a heat - insulating material (e.g., including a suitable foamed - type material) in addition to or instead of the double - wall sleeve.

[0160] The housing 59 may further comprise various internal support structures 37 for supporting all the internal components, similar to the heating device 23.

[0161] The device 51 further includes a collar 33 that extends around the opening 20 and protrudes into the housing 59 from the opening 20, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f spaced along the outer surface of the chamber 35, and each cooling fin is disposed so as to surround the outer surface of the chamber 35. When the articles 101, 301 are 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 articles 101, 301. The gap 36 surrounds the entire outer circumference of the articles 101, 301 over at least a portion of the cooling segment 307.

[0162] The collar 33 includes a plurality of ridges 60 disposed so as to surround the outer circumference of the opening 20, and these ridges protrude into the opening 20. The ridges 60 occupy the space within the opening 20 such that the opening distance of the opening 20 at the position of the ridges 60 is smaller than the opening distance of the opening 20 at the position without the ridges 60. The ridges 60 are configured to engage with the articles 101, 301 inserted into the device and assist in fixing them within the device 51. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the articles 101, 301 form a ventilation path around the outer surfaces of the articles 101, 301. These ventilation paths allow the hot vapor escaping from the articles 101, 301 to exit the device 51 and allow the cooling air to flow into the device 51 around the articles 101, 301 within the gap 36.

[0163] During operation, the articles 101, 301 are removably inserted into the insertion location 20 of the device 51 as shown in FIGS. 5 - 7. Referring particularly to FIG. 6, in one example, the aerosol - generating material bodies 103, 303 (which are disposed on the distal - end 115, 315 sides of the articles 101, 301) are fully received within the heating device 23 of the device 51. The proximal ends 113, 313 of the articles 101, 301 extend out of the device 51 and function as a mouthpiece assembly for the user.

[0164] During operation, the heating device 23 heats the articles 101, 301 to volatilize at least one component of the aerosol-forming material from the aerosol-forming material bodies 103, 303.

[0165] The primary flow path for the heat-volatile components from the aerosol-forming material bodies 103, 303 passes axially through the articles 101, 301, through the chambers inside the cooling segments 107, 307, through the filter segments 109, 309, and through the mouth-side end segments 111, 313 to reach the user. In one example, the temperature of the heat-volatile components generated from the aerosol-forming material body is 60°C to 250°C, which may exceed the acceptable inhalation temperature for the user. As the heat-volatile components move through the cooling segments 107, 307, they are cooled, and some of the volatile components condense on the inner surfaces of the cooling segments 107, 307.

[0166] In the example of the article 301 shown in FIGS. 3 and 4, cold air can enter the cooling segment 307 through the ventilation holes 317 formed in the cooling segment 307. This cold air mixes with the heat-volatile components to further cool the heat-volatile components.

[0167] Exemplary embodiments Descriptions of a number of exemplary embodiments are as follows. Each refers to an amorphous solid that can be obtained by the method of the present invention. When the composition of the amorphous solid is given (DWB), the slurry can have the same DWB composition as the amorphous solid (i.e., contain only additional water).

[0168] In some embodiments, the amorphous solid comprises menthol.

[0169] Certain embodiments comprising menthol-containing amorphous solids may be particularly suitable for inclusion as shredded sheets in an article / non-combustible aerosol delivery system. In these embodiments, the amorphous solid may have the following composition (DWB), namely, a gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 20 wt% to about 40 wt%, or about 25 wt% to 35 wt% (in DWB), menthol in an amount of about 35 wt% to about 60 wt%, or about 40 wt% to 55 wt%, and an aerosol-forming material (preferably comprising glycerol) in an amount of about 10 wt% to about 30 wt%, or about 15 wt% to about 25 wt%. FIG. 8a shows the calcium distribution in such an amorphous solid comprising a gelling agent, the gelling agent comprising alginic acid and pectin. FIG. 8b shows the calcium distribution in such an amorphous solid comprising alginate as the gelling agent. In each of FIGS. 8a and 8b, the image shows a cross-section of the solid (the upper surface of the solid is the higher one in the image, and this upper surface corresponds to the upper surface of the slurry to which the calcium hardening agent is applied).

[0170] In one embodiment, the amorphous solid comprises an alginate / pectin gelling agent blend of about 32 - 33 wt% (in DWB), a menthol flavor of about 47 - 48 wt%, and a glycerol aerosol-forming material of about 19 - 20 wt%.

[0171] The amorphous solids of these embodiments may have any suitable water content. For example, the amorphous solid may have a water content of about 2 wt% to about 10 wt%, or about 5 wt% to about 8 wt%, or about 6 wt%.

[0172] As described above, the amorphous solids of these embodiments may be included in an article / non-combustible aerosol delivery system as shredded sheets. The shredded sheets may be blended with cut tobacco and provided to the article / non-combustible aerosol delivery system. Alternatively, the amorphous solid may be provided as a non-shredded sheet. Preferably, the shredded or non-shredded sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0173] Certain embodiments of the menthol-containing amorphous solid may be particularly suitable for inclusion in a sheet, such as a sheet surrounding a rod of aerosol-forming material (such as tobacco), in a smoking article / non-combustible aerosol delivery system. In these embodiments, the amorphous solid may have the following composition (DWB), namely, a gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt% (by DWB), menthol in an amount of about 10 wt% to about 50 wt%, or about 15 wt% to 40 wt%, an aerosol-forming material (preferably comprising glycerol) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to about 35 wt%, and optionally a filler in an amount up to 60 wt% (such as in an amount of 5 wt% to 20 wt%, or 40 wt% to 60 wt%).

[0174] In one of these embodiments, the amorphous solid comprises about 11 wt% of an alginate / pectin gelling agent blend, about 56 wt% of a wood pulp filler, about 18% of a menthol flavorant, and about 15 wt% of glycerol (by DWB).

[0175] In another one of these embodiments, the amorphous solid comprises about 22 wt% of an alginate / pectin gelling agent blend, about 12 wt% of a wood pulp filler, about 36% of a menthol flavorant, and about 30 wt% of glycerol (by DWB).

[0176] As described above, the amorphous solids of these embodiments may be included as a sheet. In one embodiment, the sheet is disposed on a carrier comprising paper. In one embodiment, the sheet is disposed on a carrier comprising a metal foil, preferably an aluminum metal foil. In this embodiment, the amorphous solid may be in contact with the metal foil. In one embodiment, the sheet forms part of a laminate material together with layers (preferably comprising paper) attached to the top and bottom surfaces of the sheet. Preferably, the sheet of the amorphous solid has a thickness of about 0.015 mm to about 1 mm.

[0177] In some embodiments, the amorphous solid comprises a flavorant that does not include menthol. In these embodiments, the amorphous solid may have the following composition (DWB), i.e., a gelling agent (preferably comprising alginate) in an amount of about 5% to about 40% by weight, or about 10% to about 35% by weight, or about 20% to about 35% by weight (in DWB), a flavorant in an amount of about 0.1% to about 40% by weight, about 1% to about 30% by weight, about 1% to about 20% by weight, or about 5% to about 20% by weight, an aerosol-forming material in an amount of 15% to 75% by weight, about 30% to about 70% by weight, or about 50% to about 65% by weight (preferably comprising glycerol), and optionally a filler in an amount of less than about 60% by weight, about 20% by weight, about 10% by weight, or about 5% by weight (suitably wood pulp) (preferably, the amorphous solid does not comprise a filler).

[0178] In one of these embodiments, the amorphous solid comprises about 27% by weight alginate gelling agent, about 14% by weight flavorant, and about 57% by weight glycerol aerosol-forming material (in DWB).

[0179] In another one of these embodiments, the amorphous solid comprises about 29% by weight alginate gelling agent, about 9% by weight flavorant, and about 60% by weight glycerol (in DWB).

[0180] The amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as shredded sheets, optionally blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as a sheet, e.g., a sheet surrounding a rod of aerosol-forming material (such as tobacco). Alternatively, the amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as a layer portion disposed on a carrier.

[0181] In some embodiments, the amorphous solid comprises a tobacco extract. In these embodiments, the amorphous solid may have the following composition (DWB), i.e., a gelling agent (preferably comprising alginate) in an amount of about 5 wt% to about 40 wt%, about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt% (in DWB), a tobacco extract in an amount of about 30 wt% to about 60 wt%, about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, and an aerosol forming material (preferably comprising glycerol) in an amount of about 10 wt% to about 50 wt%, about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt%.

[0182] In one embodiment, the amorphous solid comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (in DWB).

[0183] The amorphous solids of these embodiments may have any suitable water content. For example, the amorphous solid may have a water content of about 5 wt% to about 15 wt%, or about 7 wt% to about 13 wt%, or about 10 wt%.

[0184] The amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as shredded sheets, optionally blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as a sheet, e.g., a sheet surrounding a rod of aerosol forming material (such as tobacco). Alternatively, the amorphous solids of these embodiments may be included in an article / non-combustible aerosol supply system as a layer portion disposed on a carrier. Preferably, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0185] The slurry for forming this amorphous solid can also form part of the present invention. In some examples, the slurry may have a modulus of elasticity (also called storage modulus) of about 5 to 1200 Pa, and in some examples, the slurry may have a viscosity (also called loss modulus) of about 5 to 600 Pa.

[0186] Definition As used herein, the active ingredient can be a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active ingredient may be selected, for example, from functional foods, nootropic substances, and psychoactive substances. The active ingredient may be naturally occurring or synthetically obtained. The active ingredient may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C, etc.), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active ingredient may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

[0187] In some embodiments, the active ingredient comprises nicotine.

[0188] In some embodiments, the active ingredient comprises caffeine, melatonin, or vitamin B12.

[0189] As described herein, the active ingredient may comprise one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0190] Cannabinoids are a class of natural or synthetic compounds that act on intracellular cannabinoid receptors (i.e., CB1 and CB2) in the brain to suppress neurotransmitter release. Cannabinoids can be naturally found in plants such as cannabis (phytocannabinoids), from animals (endogenous cannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis seeds represent at least 85 different phytocannabinoids and are divided into multiple subcategories. These subcategories include cannabigerol, cannabinochromene, cannabidiol, tetrahydrocannabinol, cannabinol, and cannabinodiol, and other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabinochromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabinocyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabinochromvarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0191] In some embodiments, the active ingredient comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic 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 cannabinol (CBE), cannabinicitran (CBT).

[0192] The active ingredient may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0193] The active ingredient may comprise cannabidiol (CBD).

[0194] The active ingredient may comprise nicotine and cannabidiol (CBD).

[0195] The active ingredient may comprise nicotine, cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0196] As described herein, the active ingredient may comprise, or be derived from, one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, skins, etc. Alternatively, the material may comprise active compounds that are naturally present in the botanical material or obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, chips, sheets, etc. Examples of botanical materials are tobacco, eucalyptus, star anise, hemp, cacao, cannabis, aster, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo leaf extract, nettles, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, nasturtium flower, vanilla, wintergreen, perilla, turmeric, sandalwood, silantro, bergamot, orange flower, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, vervain, tarragon, geranium, mulberry, burdock, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties, namely, Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens.

[0197] In some embodiments, the plant material is selected from eucalyptus, star anise, cocoa, and hemp.

[0198] In some embodiments, the plant material is selected from rooibos and perilla.

[0199] As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other bodily sensations in products for adult consumers when permitted by local regulations. They include naturally occurring flavor materials, botanical materials, extracts of botanical materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phyllostachys bambusoides leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anis), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, redberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange flower, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pepper, ginger, coriander, coffee, hemp, mint oil obtained from any variety of the mint genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, nettles, hibiscus, laurel, mate, orange peel, rose, tea (green tea, black tea, etc.), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, curcuma, silantro, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators, or stimulants, sugars and / or alternative sugars (e.g., sucralose,acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and may also contain other additives such as charcoal, chlorophyll, minerals, vegetable materials, or breath fresheners. They may be of artificial, synthetic, or natural origin, or blends thereof. They can be in any suitable form, such as liquid (e.g., oil), solid (e.g., powder), or gas.

[0200] The flavoring preferably comprises one or more mint flavorings, preferably mint oil obtained from any variety of the mint genus. The flavoring preferably comprises menthol, consists essentially of menthol, or consists of menthol.

[0201] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint.

[0202] In some embodiments, the flavoring comprises flavor components of cucumber, blueberry, citrus fruit, and / or redberry.

[0203] In some embodiments, the flavoring comprises eugenol.

[0204] In some embodiments, the flavoring comprises flavor components extracted from tobacco.

[0205] In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0206] In some embodiments, the fragrance may comprise a sensory agent for the purpose of achieving a somatosensory perception that is normally 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. Suitable heat effect agents may include, but are not limited to, vanillyl ethyl ether, and suitable coolants may include, but are not limited to, eucalyptol and WS-3.

[0207] As used herein, the term "aerosol-forming material" refers to an agent that promotes the generation of an aerosol. The aerosol-forming material may promote the generation of an aerosol by facilitating the initial volatilization and / or condensation of a gas into an inhalable solid and / or liquid aerosol.

[0208] Suitable aerosol-forming materials include, but are not limited to, polyols such as erythritol, sorbitol, glycerol, and glycols such as propylene glycol and triethylene glycol, and non-polyols such as monohydric alcohols, high-boiling hydrocarbons, acids (such as lactic acid), glycerol derivatives, esters (such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates (including ethyl myristate and isopropyl myristate)), and aliphatic carboxylic acid esters (such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate). The aerosol-forming material may preferably have a composition that does not dissolve menthol. The aerosol-forming material may preferably comprise glycerol, consist essentially of glycerol, or consist of glycerol.

[0209] In some embodiments, the aerosol-forming material comprises one or more of a polyhydric alcohol such as propylene glycol, triethylene glycol, 1,3 - butanediol and glycerin; an ester of a polyhydric alcohol such as glycerol mono -, di - or triacetate; and / or an aliphatic ester of a mono -, di - or polycarboxylic acid such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0210] As used herein, the term "tobacco material" refers to any material comprising tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stalks, reconstituted tobacco, and / or tobacco extracts.

[0211] The tobacco used to produce the tobacco material may be any suitable tobacco, including Virginia and / or Burley and / or Oriental, in a single grade or blend, cut rag or whole leaf, etc. It may also be "fine powder" or dust of tobacco particles, expanded tobacco, stalks, expanded stalks, and other processed stalk materials (such as rolled cut stalks). The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibers and may be formed by casting, a fourdrinier approach with back - addition of tobacco extracts, or extrusion.

[0212] All weight percentages (expressed 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. The weight shown on a dry weight basis refers to the whole of the extract, slurry or material other than water and may include components that are liquid per se at room temperature and room pressure, such as glycerol. Conversely, weight percentages shown on a wet weight basis refer to all components including water.

[0213] To avoid misunderstanding, when the term "comprising" is used in this specification to define the invention or a feature of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising". A reference to a material "comprising" certain features means that those features are included in, contained in, or retained within the material.

[0214] The above embodiments should be understood as illustrative of the invention. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with any other feature described, and may also be used in combination with one or more features of any other embodiment, or any combination of any other embodiments. Further, equivalents and modifications not described above may also be used without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for producing an amorphous solid, comprising: (a) forming a slurry, said slurry comprising: 0.5 to 60% by weight of a gelling agent; 5 to 80% by weight of an aerosol-forming material; 0 to 60% by weight of an active ingredient and / or flavorant; wherein these weights are calculated on a dry weight basis, and (b) shaping said slurry; (c) applying a curing agent to the surface of said slurry to cure said slurry and form a gel; (d) drying said gel to form an amorphous solid; wherein the amorphous solid has a substantially constant concentration of the curing agent throughout, and substantially constant means that the amount of the curing agent per cubic millimeter of the amorphous solid is 40% or less of the average amount of the curing agent per cubic millimeter and varies throughout the amorphous solid.

2. The method according to claim 1, wherein the curing agent comprises calcium.

3. The method according to claim 1 or claim 2, wherein the step of applying the curing agent comprises spraying the curing agent onto the slurry.

4. The hardening agent includes calcium and is provided as an aqueous solution, and the concentration of the calcium in the aqueous solution is 0.2 to 0.8 mol.dm －３ The method according to any one of claims 1 to 3, wherein the method is as described above.

5. The method according to any one of claims 1 to 4, wherein the total amount of the curing agent added to the slurry is 0.5 to 5% by weight calculated on a dry weight basis of the slurry.

6. The curing agent comprises calcium, and the amount of the curing agent applied to the slurry is an amount such that the amount of calcium applied is 0.3X to 0.45X mmol per kilogram of the slurry, where X is the weight percentage solids of the slurry (wet weight basis). The method according to any one of claims 1 to 5.

7. The method according to any one of claims 1 to 6, wherein the step of shaping the slurry comprises forming a layer of the slurry.

8. The method according to claim 7, wherein the step of applying the curing agent to the slurry comprises spraying the curing agent onto the upper surface of the layer.

9. The method according to any one of claims 1 to 8, wherein the step of drying comprises heating the gel at a temperature in the range of 80°C to 140°C for a time of less than 60 minutes.

10. The method according to claim 9, wherein the step of drying comprises flowing air over the gel for a time of less than 60 minutes, and the air temperature is in the range of 80°C to 140°C.

11. The method according to any one of claims 1 to 10, wherein the step of forming comprises forming the slurry on a heat-conductive support, and the step of drying comprises heating the heat-conductive support.

12. The method according to any one of claims 1 to 11, wherein the step of drying removes 50 to 95% by weight of water (in terms of WWB) in the slurry.

13. The method according to any one of claims 1 to 12, wherein the resulting amorphous solid comprises 1 to 15% by weight of water calculated on a wet weight basis.

14. The method according to any one of claims 1 to 13, wherein the step of forming comprises forming a layer of the slurry, and the layer has a thickness of less than 4 mm.

15. The method according to claim 14, wherein the thickness of the layer ranges from 1 mm to 3 mm.

16. The method according to claim 14 or claim 15, wherein the step of drying results in an amorphous solid having a thickness of 5% to 20% of the thickness of the layer.

17. The method according to any one of claims 1 to 16, wherein a carrier is provided, and the step of forming the slurry comprises forming the slurry on the carrier.

18. The method according to any one of claims 1 to 17, wherein the slurry comprises 10 to 60% by weight of the active ingredient and / or flavorant.

19. The method according to any one of claims 1 to 18, wherein the gelling agent is selected from pectin, alginate, and mixtures thereof.

20. The method according to any one of claims 1 to 19, wherein the aerosol-forming material is selected from erythritol, propylene glycol, glycerol, and mixtures thereof.

21. An amorphous solid, comprising 0.5 to 60% by weight of a gelling agent, 5 to 80% by weight of an aerosol-forming material, a curing agent, 0 to 60% by weight of an active ingredient and / or flavorant, wherein these weights are calculated on a dry weight basis, the amorphous solid having a substantially constant concentration of the curing agent throughout, and substantially constant means that the amount of the curing agent per cubic millimeter of the amorphous solid varies by no more than 40% of the average amount of the curing agent per cubic millimeter throughout the amorphous solid.

22. An article for use in a non-combustible aerosol supply system, the article comprising the amorphous solid according to claim 21. Claim 23 A non-combustible aerosol supply system comprising the article according to claim 22 and a non-combustible aerosol supply device, the non-combustible aerosol supply device comprising an aerosol generation device for generating an aerosol from the article when the article is used together with the non-combustible aerosol supply device.

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