Aerosol generating article with a barrier

Abstract

An aerosol-generating article (200) for use in an aerosol-generating system. In one embodiment, the aerosol-generating article (200) comprises a storage portion (210) having an outlet, an aerosol-forming substrate (211) contained within the storage portion (210), and a vaporizable barrier (225) configured to seal the outlet. In another embodiment, the aerosol-generating article (200) comprises the storage portion (210), the aerosol-forming substrate (211) contained within the storage portion (210), a heater (222) configured to heat the aerosol-forming substrate (211), and a vaporizable barrier (225) provided between the storage portion (210) and the heater (222). In both embodiments, the vaporizable barrier (225) comprises one or more polymers. The vaporizable barrier (225) has a polymer content of 1 weight percent or greater and is configured to vaporize during a first heating cycle of the aerosol-generating article (200) during initial use of the aerosol-generating article (200) in an aerosol-generating system.

Description

Technical Field

[0001] The present invention relates to an aerosol generating article provided with a barrier. The present invention also relates to an aerosol generating system provided with an aerosol generating article including a barrier.

Background Art

[0002] An aerosol generating system for delivery to a user typically comprises an atomizer configured to generate an inhalable aerosol from an aerosol-forming substrate. Some known aerosol generating systems comprise a thermal atomizer, such as an electric heater, configured to heat and vaporize the aerosol-forming substrate to generate an aerosol. A typical aerosol-forming substrate for use in an aerosol generating system may be a nicotine formulation, a liquid nicotine formulation comprising an aerosol former such as glycerin and / or propylene glycol. It is desirable to provide an aerosol generating article that exhibits a reduced risk of leakage when used in an aerosol generating system as compared to typical aerosol generating articles.

Summary of the Invention

[0003] An aerosol generating article for use in an aerosol generating system is provided. The aerosol generating article may include a storage portion having an outlet. The aerosol generating article may include an aerosol-forming substrate. The aerosol-forming substrate may be contained within the storage portion. The aerosol generating article may include a vaporizable barrier configured to seal the outlet.

[0004] There is provided an aerosol generating article for use in an aerosol generating system, the aerosol generating article comprising a storage portion having an outlet, an aerosol-forming substrate contained within the storage portion, and a vaporizable barrier configured to seal the outlet.

[0005] There is also provided an aerosol generating article for use in an aerosol generating system. The aerosol generating article may include a storage portion. The aerosol generating article may include an aerosol forming substrate. The aerosol forming substrate may be contained within the storage portion. The aerosol generating article may include a heater. The heater may be configured to heat the aerosol forming substrate. The aerosol generating article may include a vaporizable barrier. The vaporizable barrier may be provided between the storage portion and the heater.

[0006] There is also provided an aerosol generating article for use in an aerosol generating system, the aerosol generating article comprising a storage portion, an aerosol forming substrate contained within the storage portion, a heater configured to heat the aerosol forming substrate, and a vaporizable barrier provided between the storage portion and the heater.

[0007] There is also provided an aerosol generating device for use in an aerosol generating system, the aerosol generating device comprising a storage portion having an outlet, an aerosol forming substrate contained within the storage portion, and a vaporizable barrier configured to seal the outlet.

[0008] There is also provided an aerosol generating device for use in an aerosol generating system, the aerosol generating device comprising a storage portion, an aerosol forming substrate contained within the storage portion, a heater configured to heat the aerosol forming substrate, and a vaporizable barrier provided between the storage portion and the heater.

[0009] There is also provided an aerosol generating system, wherein the aerosol generating article comprises a storage portion having an outlet, an aerosol forming substrate, an aerosol forming substrate contained within the storage portion, and a vaporizable barrier configured to seal the outlet.

[0010] An aerosol generating system is also provided, which comprises a storage part, an aerosol-forming substrate contained in the storage part, a heater configured to heat the aerosol-forming substrate, and a vaporizable barrier provided between the storage part and the heater.

[0011] A method of manufacturing an aerosol generating article is also provided, which includes providing an aerosol generating article comprising a storage part having an outlet and an aerosol-forming substrate contained in the storage part, and providing a vaporizable barrier configured to seal the outlet.

[0012] A method of manufacturing an aerosol generating article is also provided, which includes providing an aerosol generating article comprising a storage part, an aerosol-forming substrate contained in the storage part, and a heater configured to heat the aerosol-forming substrate, and providing a vaporizable barrier between the storage part and the heater.

[0013] A method of manufacturing an aerosol generating device is also provided, which includes providing an aerosol generating device comprising a storage part having an outlet and an aerosol-forming substrate contained in the storage part, and providing a vaporizable barrier configured to seal the outlet.

[0014] A method of manufacturing an aerosol generating device is also provided, which includes providing an aerosol generating device comprising a storage part, an aerosol-forming substrate contained in the storage part, and a heater configured to heat the aerosol-forming substrate, and providing a vaporizable barrier between the storage part and the heater.

[0015] A method of manufacturing an aerosol generating system is also provided, which includes providing an aerosol generating system comprising a storage part having an outlet and an aerosol-forming substrate having an aerosol-forming substrate contained in the storage part, and providing a vaporizable barrier configured to seal the outlet.

[0016] A method of manufacturing an aerosol generating system, comprising providing an aerosol generating system comprising a storage portion, an aerosol-forming substrate contained within the storage portion, and a heater configured to heat the aerosol-forming substrate, and providing a vaporizable barrier between the storage portion and the heater. A method is also provided.

[0017] As used herein, the term "aerosol-forming substrate" relates to a substrate having the ability to release a volatile compound capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate or by other aerosolization means. The aerosol-forming substrate may be a liquid. The liquid may be an e-liquid. The liquid may be a solution. A colloid may have discontinuous solid particles dispersed in a continuous liquid. A colloid may have discontinuous liquid particles dispersed in a continuous liquid. A colloid may have discontinuous liquid particles dispersed in a continuous solid.

[0018] As used herein, the term "vaporizable" means that substantially the entire mass of the seal enters the vapor phase during the normal heating cycle of the aerosol-generating article, aerosol-generating device, or aerosol-generating system. That is, during the normal heating cycle of the aerosol-generating article, it is preferred that at least about 95% of the mass of the seal enters the vapor phase, more preferably at least about 99% of the mass enters the vapor phase, and most preferably all of the mass enters the vapor phase.

[0019] Unless otherwise specified, the weight percentages of the components of the barrier listed herein are based on the total weight of the barrier.

[0020] Advantageously, the vaporizable barrier is a solid-impermeable layer that internally seals the storage portion containing the aerosol-forming substrate. By sealing the storage portion, advantageously, the risk of leakage of the aerosol-forming substrate from the storage portion prior to first use is reduced, thereby improving the shelf life.

[0021] The vaporizable barrier can reduce or prevent leakage even under reduced pressure, such as during transportation by airplane.

[0022] Since the vaporizable barrier can be placed in place during the manufacturing process, a large window for the seal tab is not necessary, which increases the degree of freedom in designing aerosol-generating articles. Also, the absence of a seal tab simplifies the assembly process.

[0023] The solid vaporizable barrier can advantageously be melted or vaporized by a heater during the first use (i.e., during the first heating cycle) of the aerosol-generating article, aerosol-generating device, or aerosol-generating system. This allows the user to use the aerosol-generating article, aerosol-generating device, or aerosol-generating system as normal.

[0024] The vaporizable barrier may be pyrolytic when heated. The vaporizable barrier is preferably pyrolytic when heated to a temperature between 60°C and 300°C. The vaporizable barrier is more preferably pyrolytic when heated to a temperature between 60°C and 270°C. The vaporizable barrier may be pyrolytic when heated to a temperature between 180°C and 300°C. The vaporizable barrier may be pyrolytic when heated to a temperature between 180°C and 270°C.

[0025] The vaporizable barrier may contain a material that is pyrolytic when heated. The vaporizable barrier may contain a material that is pyrolytic when heated to a temperature between 60°C and 300°C. The vaporizable barrier may contain a material that is pyrolytic when heated to a temperature between 60°C and 270°C. The vaporizable barrier may contain a material that is pyrolytic when heated to a temperature between 180°C and 300°C. The vaporizable barrier may contain a material that is pyrolytic when heated to a temperature between 180°C and 270°C.

[0026] In one embodiment, the vaporizable barrier thermally decomposes when heated and begins to melt.

[0027] The vaporizable barrier may include a material that is vaporizable when heated to a temperature between 180°C and 300°C. The vaporizable barrier may include a material that is vaporizable when heated to a temperature between 180°C and 270°C.

[0028] The vaporizable barrier may be vaporizable when heated to a temperature between 180°C and 300°C. Preferably, the vaporizable barrier may be vaporizable when heated to a temperature between 180°C and 270°C.

[0029] The vaporizable barrier may include one or more polymers.

[0030] The vaporizable barrier may have a polymer content of 1 weight percent or more. The vaporizable barrier may have a polymer content of 2 weight percent or more. The vaporizable barrier may have a polymer content of 3 weight percent or more. The vaporizable barrier may have a polymer content of 4 weight percent or more.

[0031] The vaporizable barrier may have a polymer content of 5 weight percent or more. Advantageously, a polymer content of 5 weight percent or more provides a secure seal. The vaporizable barrier may have a polymer content of 8 weight percent or more. The vaporizable barrier may have a polymer content of 10 weight percent or more. The vaporizable barrier may have a polymer content of 15 weight percent or more. The vaporizable barrier may have a polymer content of 20 weight percent or more. The vaporizable barrier may have a polymer content of 25 weight percent or more. The vaporizable barrier may have a polymer content of 30 weight percent or more. The vaporizable barrier may have a polymer content of 35 weight percent or more.

[0032] The vaporizable barrier may have a polymer content of 50 weight percent or less. The vaporizable barrier may have a polymer content of 45 weight percent or less. The vaporizable barrier may have a polymer content of 40 weight percent or less. The vaporizable barrier may have a polymer content of 35 weight percent or less. The vaporizable barrier may have a polymer content of 30 weight percent or less. The vaporizable barrier may have a polymer content of 25 weight percent or less. The vaporizable barrier may have a polymer content of 20 weight percent or less. The vaporizable barrier may have a polymer content of 15 weight percent or less. The vaporizable barrier may have a polymer content of 10 weight percent or less. The vaporizable barrier may have a polymer content of 8 weight percent or less. The vaporizable barrier may have a polymer content of 5 weight percent or less.

[0033] The vaporizable barrier may have a polymer content of from about 1 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 2 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 3 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 4 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 8 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 10 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 15 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 20 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 25 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 30 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 35 weight percent to about 40 weight percent.

[0034] The vaporizable barrier may have a polymer content of from about 5 weight percent to about 40 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 35 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 30 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 25 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 20 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 15 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 10 weight percent. The vaporizable barrier may have a polymer content of from about 5 weight percent to about 8 weight percent.

[0035] The vaporizable barrier may have a polymer content of from about 8 weight percent to about 35 weight percent. The vaporizable barrier may have a polymer content of from about 10 weight percent to about 35 weight percent. The vaporizable barrier may have a polymer content of from about 10 weight percent to about 30 weight percent. The vaporizable barrier may have a polymer content of from about 15 weight percent to about 30 weight percent. The vaporizable barrier may have a polymer content of from about 15 weight percent to about 25 weight percent. The vaporizable barrier may have a polymer content of from about 20 weight percent to about 25 weight percent.

[0036] The vaporizable barrier may have a polymer content of from about 10 weight percent to about 15 weight percent.

[0037] The vaporizable barrier may be formed from a formulation comprising one or more polymers.

[0038] The formulation may have a polymer content of 1 weight percent or more. The formulation may have a polymer content of 2 weight percent or more. The formulation may have a polymer content of 3 weight percent or more. The formulation may have a polymer content of 4 weight percent or more.

[0039] The formulation may have a polymer content of 5 weight percent or more. Advantageously, a polymer content of 5 weight percent or more provides a secure seal. The formulation may have a polymer content of 8 weight percent or more. The formulation may have a polymer content of 10 weight percent or more. The formulation may have a polymer content of 15 weight percent or more.

[0040] The formulation may have a polymer content of 20% by weight or less. The formulation may have a polymer content of 15% by weight or less. The formulation may have a polymer content of 10% by weight or less. The formulation may have a polymer content of 8% by weight or less. The formulation may have a polymer content of 5% by weight or less. The formulation may have a polymer content of 4% by weight or less. The formulation may have a polymer content of 3% by weight or less. The formulation may have a polymer content of 2% by weight or less.

[0041] The formulation may have a polymer content of from about 1% to about 20% by weight. The formulation may have a polymer content of from about 2% to about 20% by weight. The formulation may have a polymer content of from about 3% to about 20% by weight. The formulation may have a polymer content of from about 4% to about 20% by weight. The formulation may have a polymer content of from about 5% to about 20% by weight. The formulation may have a polymer content of from about 8% to about 20% by weight. The formulation may have a polymer content of from about 10% to about 20% by weight. The formulation may have a polymer content of from about 15% to about 20% by weight.

[0042] The formulation may have a polymer content of from about 1% to about 20% by weight. The formulation may have a polymer content of from about 1% to about 15% by weight. The formulation may have a polymer content of from about 1% to about 10% by weight. The formulation may have a polymer content of from about 1% to about 8% by weight. The formulation may have a polymer content of from about 1% to about 5% by weight. The formulation may have a polymer content of from about 1% to about 4% by weight. The formulation may have a polymer content of from about 1% to about 3% by weight. The formulation may have a polymer content of from about 1% to about 2% by weight.

[0043] The formulation may have a polymer content of from about 5 weight percent to about 15 weight percent. The formulation may have a polymer content of from about 5 weight percent to about 10 weight percent. The formulation may have a polymer content of from about 5 weight percent to about 8 weight percent.

[0044] The formulation may have a polymer content of from about 8 weight percent to about 15 weight percent. The formulation may have a polymer content of from about 8 weight percent to about 10 weight percent.

[0045] The formulation may have a polymer content of from about 10 weight percent to about 15 weight percent.

[0046] One or more polymers may be selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch.

[0047] The polyethylene may be low density polyethylene.

[0048] One or more polymers are preferably selected from the group consisting of polyvinyl alcohol, polyethylene glycol, polypropylene glycol, and starch.

[0049] More preferably, one or more polymers are selected from the group consisting of polyvinyl alcohol, polyethylene glycol, and polypropylene glycol.

[0050] Even more preferably, one or more polymers are selected from the group consisting of polyvinyl alcohol and polyethylene glycol.

[0051] Most preferably, one or more polymers consist of polyvinyl alcohol.

[0052] All starches consist of varying proportions of amylose and amylopectin. The selection of a particular starch for a vaporizable barrier or formulation can be based on the ratio of amylose to amylopectin, depending on the desired function of the starch. The starch may be corn starch or wheat starch. Preferably, the starch is corn starch, and more preferably, the starch is waxy corn starch. Waxy corn starch is essentially pure amylopectin containing only trace amounts of amylose. Waxy corn starch has been found to produce a better and more elastic barrier. Note that the average molecular weight of starch varies due to natural variation.

[0053] One or more polymers may have a weight average molecular weight of 6000 g / mol or more. One or more polymers may have a weight average molecular weight of 60000 g / mol or more. One or more polymers may have a weight average molecular weight of 100000 g / mol or more. One or more polymers may have a weight average molecular weight of 140000 g / mol or more. One or more polymers may have a weight average molecular weight of 200000 g / mol or more.

[0054] One or more polymers may have a weight average molecular weight (M w ) of 8000000 g / mol or less. One or more polymers may have a weight average molecular weight of 5000000 g / mol or less. One or more polymers may have a weight average molecular weight of 2000000 g / mol or less. One or more polymers may have a weight average molecular weight of 1000000 g / mol or less. One or more polymers may have a weight average molecular weight of 500000 g / mol or less. One or more polymers may have a weight average molecular weight of 200000 g / mol or less. One or more polymers may have a weight average molecular weight of 190000 g / mol or less.

[0055] One or more polymers may have a weight average molecular weight of from 6,000 g / mol to 8,000,000 g / mol. One or more polymers may have a weight average molecular weight of from 60,000 g / mol to 500,000 g / mol. One or more polymers may have a weight average molecular weight of from 100,000 g / mol to 200,000 g / mol. One or more polymers may have a weight average molecular weight of from 140,000 g / mol to 190,000 g / mol.

[0056] The vaporizable barrier may contain one or more metal salts.

[0057] The vaporizable barrier may have a metal salt content of about 0.1 weight percent or more. The vaporizable barrier may have a metal salt content of about 0.25 weight percent or more. The vaporizable barrier may have a metal salt content of about 0.5 weight percent or more. The vaporizable barrier may have a metal salt content of about 0.75 weight percent or more. The vaporizable barrier may have a metal salt content of about 1 weight percent or more. The vaporizable barrier may have a metal salt content of about 1.25 weight percent or more. The vaporizable barrier may have a metal salt content of about 1.5 weight percent or more. The vaporizable barrier may have a metal salt content of about 1.75 weight percent or more. The vaporizable barrier may have a metal salt content of about 2 weight percent or more. The vaporizable barrier may have a metal salt content of about 3 weight percent or more. The vaporizable barrier may have a metal salt content of about 4 weight percent or more. The vaporizable barrier may have a metal salt content of about 5 weight percent or more. The vaporizable barrier may have a metal salt content of about 6 weight percent or more. The vaporizable barrier may have a metal salt content of about 7 weight percent or more. The vaporizable barrier may have a metal salt content of about 8 weight percent or more. The vaporizable barrier may have a metal salt content of about 9 weight percent or more.

[0058] The vaporizable barrier may have a metal salt content of about 15 weight percent or less. The vaporizable barrier may have a metal salt content of about 12 weight percent or less. The vaporizable barrier may have a metal salt content of about 10 weight percent or less. The vaporizable barrier may have a metal salt content of about 9 weight percent or less. The vaporizable barrier may have a metal salt content of about 8 weight percent or less. The vaporizable barrier may have a metal salt content of about 7 weight percent or less. The vaporizable barrier may have a metal salt content of about 6 weight percent or less. The vaporizable barrier may have a metal salt content of about 5 weight percent or less. The vaporizable barrier may have a metal salt content of about 4 weight percent or less. The vaporizable barrier may have a metal salt content of about 3 weight percent or less. The vaporizable barrier may have a metal salt content of about 2 weight percent or less. The vaporizable barrier may have a metal salt content of about 1.75 weight percent or less. The vaporizable barrier may have a metal salt content of about 1.5 weight percent or less. The vaporizable barrier may have a metal salt content of about 1.25 weight percent or less. The vaporizable barrier may have a metal salt content of about 1 weight percent or less. The vaporizable barrier may have a metal salt content of about 0.75 weight percent or less. The vaporizable barrier may have a metal salt content of about 0.5 weight percent or less. The vaporizable barrier may have a metal salt content of about 0.25 weight percent or less.

[0059] The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 9 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 8 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 7 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 6 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 5 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 4 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 3 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 2 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 1.75 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 1.5 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 1.25 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 1 weight percent. The vaporizable barrier may have a metal salt content of from about 0.1 weight percent to about 0.75 weight percent.

[0060] The vaporizable barrier may have a metal salt content of from about 0.25 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 0.5 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 0.75 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 1 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 1.25 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 1.5 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 1.75 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 2 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 3 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 4 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 5 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 6 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 7 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 8 weight percent to about 10 weight percent. The vaporizable barrier may have a metal salt content of from about 9 weight percent to about 10 weight percent.

[0061] The vaporizable barrier may have a metal salt content of from about 0.25 weight percent to about 9 weight percent. The vaporizable barrier may have a metal salt content of from about 0.5 weight percent to about 9 weight percent. The vaporizable barrier may have a metal salt content of from about 0.5 weight percent to about 8 weight percent. The vaporizable barrier may have a metal salt content of from about 0.75 weight percent to about 8 weight percent. The vaporizable barrier may have a metal salt content of from about 0.75 weight percent to about 7 weight percent. The vaporizable barrier may have a metal salt content of from about 1 weight percent to about 7 weight percent. The vaporizable barrier may have a metal salt content of from about 1 weight percent to about 6 weight percent. The vaporizable barrier may have a metal salt content of from about 1.25 weight percent to about 6 weight percent. The vaporizable barrier may have a metal salt content of from about 1.25 weight percent to about 5 weight percent. The vaporizable barrier may have a metal salt content of from about 1.5 weight percent to about 5 weight percent. The vaporizable barrier may have a metal salt content of from about 1.5 weight percent to about 4 weight percent. The vaporizable barrier may have a metal salt content of from about 1.75 weight percent to about 4 weight percent. The vaporizable barrier may have a metal salt content of from about 1.75 weight percent to about 3 weight percent. The vaporizable barrier may have a metal salt content of from about 2 weight percent to about 3 weight percent.

[0062] The vaporizable barrier may be formed from a formulation comprising one or more metal salts.

[0063] The formulation may have a metal salt content of about 0.1 weight percent or more. The formulation may have a metal salt content of about 0.25 weight percent or more. The formulation may have a metal salt content of about 0.5 weight percent or more. The formulation may have a metal salt content of about 0.75 weight percent or more. The formulation may have a metal salt content of about 1 weight percent or more. The formulation may have a metal salt content of about 1.25 weight percent or more. The formulation may have a metal salt content of about 1.5 weight percent or more. The formulation may have a metal salt content of about 1.75 weight percent or more. The formulation may have a metal salt content of about 2 weight percent or more. The formulation may have a metal salt content of about 3 weight percent or more. The formulation may have a metal salt content of about 4 weight percent or more. The formulation may have a metal salt content of about 5 weight percent or more.

[0064] The formulation may have a metal salt content of about 10 weight percent or less. The formulation may have a metal salt content of about 5 weight percent or less. The formulation may have a metal salt content of about 4 weight percent or less. The formulation may have a metal salt content of about 3 weight percent or less. The formulation may have a metal salt content of about 2 weight percent or less. The formulation may have a metal salt content of about 1.75 weight percent or less. The formulation may have a metal salt content of about 1.5 weight percent or less. The formulation may have a metal salt content of about 1.25 weight percent or less. The formulation may have a metal salt content of about 1 weight percent or less. The formulation may have a metal salt content of about 0.75 weight percent or less. The formulation may have a metal salt content of about 0.5 weight percent or less. The formulation may have a metal salt content of about 0.25 weight percent or less.

[0065] The formulation may have a metal salt content of from about 0.1 weight percent to about 10 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 5 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 4 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 3 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 1.75 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 1.5 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 1.25 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 1 weight percent. The formulation may have a metal salt content of from about 0.1 weight percent to about 0.75 weight percent.

[0066] The formulation may have a metal salt content of from about 0.1 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 0.25 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 0.5 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 0.75 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 1 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 1.25 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 1.5 weight percent to about 2 weight percent. The formulation may have a metal salt content of from about 1.75 weight percent to about 2 weight percent.

[0067] One or more metal salts may be selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

[0068] One or more metal salts may be selected from the group consisting of metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

[0069] One or more metal salts may be selected from the group consisting of metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

[0070] One or more salts may be salts of any suitable metal.

[0071] One or more metal salts are preferably alkali metal salts.

[0072] One or more metal salts are more preferably sodium salts.

[0073] One or more metal salts are preferably non-sugar sodium salts.

[0074] One or more sodium salts are more preferably selected from the group consisting of sodium benzoate, sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propionate, sodium stearate, and sodium undecanoate.

[0075] One or more metal salts are most preferably sodium stearate.

[0076] Advantageously, when the vaporizable barrier contains sodium stearate, the hydrophobicity of the seal is increased, which leads to a decrease in the permeability of the aerosol-forming substrate, thereby resulting in an extended shelf life of the aerosol-generating article, aerosol-generating device, or aerosol-generating system.

[0077] The vaporizable barrier may contain one or more plasticizers.

[0078] The vaporizable barrier may have a plasticizer content of about 0.1 weight percent or more. The vaporizable barrier may have a plasticizer content of about 0.5 weight percent or more. The vaporizable barrier may have a plasticizer content of about 1 weight percent or more. The vaporizable barrier may have a plasticizer content of about 2 weight percent or more. The vaporizable barrier may have a plasticizer content of about 3 weight percent or more. The vaporizable barrier may have a plasticizer content of about 4 weight percent or more. The vaporizable barrier may have a plasticizer content of about 5 weight percent or more. The vaporizable barrier may have a plasticizer content of about 10 weight percent or more. The vaporizable barrier may have a plasticizer content of about 15 weight percent or more. The vaporizable barrier may have a plasticizer content of about 20 weight percent or more. The vaporizable barrier may have a plasticizer content of about 25 weight percent or more. The vaporizable barrier may have a plasticizer content of about 30 weight percent or more. The vaporizable barrier may have a plasticizer content of about 35 weight percent or more. The vaporizable barrier may have a plasticizer content of about 40 weight percent or more. The vaporizable barrier may have a plasticizer content of about 45 weight percent or more. The vaporizable barrier may have a plasticizer content of about 50 weight percent or more. The vaporizable barrier may have a plasticizer content of about 55 weight percent or more. The vaporizable barrier may have a plasticizer content of about 60 weight percent or more. The vaporizable barrier may have a plasticizer content of about 65 weight percent or more. The vaporizable barrier may have a plasticizer content of about 70 weight percent or more. The vaporizable barrier may have a plasticizer content of about 75 weight percent or more. The vaporizable barrier may have a plasticizer content of about 80 weight percent or more. The vaporizable barrier may have a plasticizer content of about 85 weight percent or more.

[0079] The vaporizable barrier may have a plasticizer content of about 90 weight percent or less. The vaporizable barrier may have a plasticizer content of about 85 weight percent or less. The vaporizable barrier may have a plasticizer content of about 80 weight percent or less. The vaporizable barrier may have a plasticizer content of about 75 weight percent or less. The vaporizable barrier may have a plasticizer content of about 70 weight percent or less. The vaporizable barrier may have a plasticizer content of about 65 weight percent or less. The vaporizable barrier may have a plasticizer content of about 60 weight percent or less. The vaporizable barrier may have a plasticizer content of about 55 weight percent or less. The vaporizable barrier may have a plasticizer content of about 50 weight percent or less. The vaporizable barrier may have a plasticizer content of about 45 weight percent or less. The vaporizable barrier may have a plasticizer content of about 40 weight percent or less. The vaporizable barrier may have a plasticizer content of about 35 weight percent or less. The vaporizable barrier may have a plasticizer content of about 30 weight percent or less. The vaporizable barrier may have a plasticizer content of about 25 weight percent or less. The vaporizable barrier may have a plasticizer content of about 20 weight percent or less. The vaporizable barrier may have a plasticizer content of about 15 weight percent or less. The vaporizable barrier may have a plasticizer content of about 10 weight percent or less. The vaporizable barrier may have a plasticizer content of about 5 weight percent or less. The vaporizable barrier may have a plasticizer content of about 4 weight percent or less. The vaporizable barrier may have a plasticizer content of about 3 weight percent or less.

[0080] The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 85 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 80 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 75 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 70 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 65 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 60 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 55 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 50 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 45 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 40 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 35 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 30 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 25 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 20 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 15 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 10 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 5 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 4 weight percent. The vaporizable barrier may have a plasticizer content of from about 2 weight percent to about 3 weight percent.

[0081] The vaporizable barrier may have a plasticizer content of from about 1 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 3 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 4 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 5 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 10 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 15 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 20 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 25 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 30 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 35 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 40 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 45 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 50 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 55 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 60 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 65 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 70 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 75 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 80 weight percent to about 90 weight percent. The vaporizable barrier may have a plasticizer content of from about 85 weight percent to about 90 weight percent.

[0082] The vaporizable barrier may have a plasticizer content of from about 3 weight percent to about 85 weight percent. The vaporizable barrier may have a plasticizer content of from about 4 weight percent to about 85 weight percent. The vaporizable barrier may have a plasticizer content of from about 4 weight percent to about 80 weight percent. The vaporizable barrier may have a plasticizer content of from about 5 weight percent to about 80 weight percent. The vaporizable barrier may have a plasticizer content of from about 5 weight percent to about 75 weight percent. The vaporizable barrier may have a plasticizer content of from about 10 weight percent to about 70 weight percent. The vaporizable barrier may have a plasticizer content of from about 10 weight percent to about 65 weight percent. The vaporizable barrier may have a plasticizer content of from about 15 weight percent to about 65 weight percent. The vaporizable barrier may have a plasticizer content of from about 15 weight percent to about 60 weight percent. The vaporizable barrier may have a plasticizer content of from about 20 weight percent to about 60 weight percent. The vaporizable barrier may have a plasticizer content of from about 20 weight percent to about 55 weight percent. The vaporizable barrier may have a plasticizer content of from about 25 weight percent to about 55 weight percent. The vaporizable barrier may have a plasticizer content of from about 25 weight percent to about 50 weight percent. The vaporizable barrier may have a plasticizer content of from about 30 weight percent to about 50 weight percent. The vaporizable barrier may have a plasticizer content of from about 30 weight percent to about 45 weight percent. The vaporizable barrier may have a plasticizer content of from about 35 weight percent to about 45 weight percent. The vaporizable barrier may have a plasticizer content of from about 35 weight percent to about 40 weight percent.

[0083] The vaporizable barrier may be formed from a formulation comprising one or more plasticizers.

[0084] The formulation may have a plasticizer content of about 0.1 weight percent or more. The formulation may have a plasticizer content of about 0.5 weight percent or more. The formulation may have a plasticizer content of about 1 weight percent or more. The formulation may have a plasticizer content of about 2 weight percent or more. The formulation may have a plasticizer content of about 3 weight percent or more. The formulation may have a plasticizer content of about 4 weight percent or more. The formulation may have a plasticizer content of about 5 weight percent or more. The formulation may have a plasticizer content of about 10 weight percent or more. The formulation may have a plasticizer content of about 15 weight percent or more. The formulation may have a plasticizer content of about 20 weight percent or more. The formulation may have a plasticizer content of about 25 weight percent or more. The formulation may have a plasticizer content of about 30 weight percent or more. The formulation may have a plasticizer content of about 35 weight percent or more.

[0085] The formulation may have a plasticizer content of about 50 weight percent or less. The formulation may have a plasticizer content of about 45 weight percent or less. The formulation may have a plasticizer content of about 40 weight percent or less. The formulation may have a plasticizer content of about 35 weight percent or less. The formulation may have a plasticizer content of about 30 weight percent or less. The formulation may have a plasticizer content of about 25 weight percent or less. The formulation may have a plasticizer content of about 20 weight percent or less. The formulation may have a plasticizer content of about 15 weight percent or less. The formulation may have a plasticizer content of about 10 weight percent or less. The formulation may have a plasticizer content of about 5 weight percent or less. The formulation may have a plasticizer content of about 4 weight percent or less. The formulation may have a plasticizer content of about 3 weight percent or less.

[0086] The formulation may have a plasticizer content of from about 2% to about 50% by weight. The formulation may have a plasticizer content of from about 2% to about 45% by weight. The formulation may have a plasticizer content of from about 2% to about 40% by weight. The formulation may have a plasticizer content of from about 2% to about 35% by weight. The formulation may have a plasticizer content of from about 2% to about 30% by weight. The formulation may have a plasticizer content of from about 2% to about 25% by weight. The formulation may have a plasticizer content of from about 2% to about 20% by weight. The formulation may have a plasticizer content of from about 2% to about 15% by weight. The formulation may have a plasticizer content of from about 2% to about 10% by weight. The formulation may have a plasticizer content of from about 2% to about 5% by weight. The formulation may have a plasticizer content of from about 2% to about 4% by weight. The formulation may have a plasticizer content of from about 2% to about 3% by weight.

[0087] The formulation may have a plasticizer content of from about 1% to about 35% by weight. The formulation may have a plasticizer content of from about 3% to about 35% by weight. The formulation may have a plasticizer content of from about 4% to about 35% by weight. The formulation may have a plasticizer content of from about 5% to about 35% by weight. The formulation may have a plasticizer content of from about 10% to about 35% by weight. The formulation may have a plasticizer content of from about 15% to about 35% by weight. The formulation may have a plasticizer content of from about 20% to about 35% by weight. The formulation may have a plasticizer content of from about 25% to about 35% by weight. The formulation may have a plasticizer content of from about 30% to about 35% by weight.

[0088] Advantageously, by including one or more plasticizers in the barrier, the barrier becomes more stretchable or less rigid or brittle.

[0089] One or more plasticizers may include one or more carboxylic acids.

[0090] One or more plasticizers preferably include one or more carboxylic acids. Advantageously, by including one or more carboxylic acids, crosslinking within the vaporizable barrier can be improved.

[0091] One or more plasticizers may include citric acid, lactic acid, tartaric acid, oxalic acid, maleic acid, or combinations thereof.

[0092] Advantageously, by including one or more carboxylic acids in the vaporizable barrier, a barrier with low hygroscopicity can be provided, and a vaporizable barrier with low water absorption from the environment can be provided.

[0093] Advantageously, by including plasticizers containing carboxylic acids with multiple functional groups such as polycarboxylic acids, or carboxylic acids containing additional functional groups such as lactic acid, crosslinking within the vaporizable barrier can be improved.

[0094] Advantageously, by including carboxylic acids in the barrier, the amount of aerosol former required can be reduced.

[0095] One or more plasticizers may include citric acid. One or more plasticizers may include lactic acid. One or more plasticizers may include tartaric acid. One or more plasticizers may include oxalic acid. One or more plasticizers may include maleic acid.

[0096] One or more plasticizers may include one or more aerosol formers.

[0097] One or more aerosol formers may include one or more polyhydric alcohols. One or more polyhydric alcohols may include one or more water-miscible polyhydric alcohols. As used herein, the term "water-miscible polyhydric alcohol" describes a polyhydric alcohol that is liquid at 20 °C and mixes with water in any ratio to form a homogeneous solution.

[0098] One or more aerosol formers may be selected from the group consisting of 1,3 - butanediol, glycerin, propylene glycol, triethylene glycol, and sorbitol. Glycerin may include vegetable glycerin. Glycerin may be synthetic glycerin.

[0099] The aerosol former is preferably sorbitol. Advantageously, sorbitol has lower hygroscopicity compared to other aerosol formers, less water absorption from the environment, and can provide a more stable vaporizable barrier under humid conditions.

[0100] The aerosol former is preferably glycerin. Advantageously, glycerin has lower volatility compared to other aerosol formers, particularly propylene glycol, less water absorption from the environment, and can provide a more stable vaporizable barrier under humid conditions.

[0101] The aerosol former is preferably propylene glycol. Advantageously, including propylene glycol can improve the flexibility of the barrier and the vaporization efficiency of the barrier.

[0102] One or more aerosol formers may include a combination of sorbitol and glycerin. One or more aerosol formers may include a combination of sorbitol and propylene glycol. One or more aerosol formers may include a combination of sorbitol, glycerin, and propylene glycol. Sorbitol can improve the hygroscopic properties of the vaporizable barrier, but if there is too much sorbitol in the barrier, a relatively inflexible barrier may result, and it may not be able to cope well with pressure changes or defects in the material to which the barrier is connected. Adding another aerosol former, or a carboxylic acid, to the barrier can mitigate this problem.

[0103] Advantageously, both glycerin and sorbitol may be less volatile than propylene glycol and may evaporate under high temperature conditions. The relative amounts of the different aerosol formers in the barrier can be adjusted to provide a barrier that is appropriate for the intended use and ambient conditions.

[0104] The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the vaporizable barrier may be about 1 or more. A vaporizable barrier having a high ratio of glycerin to propylene glycol can result in a harder vaporizable barrier than in a vaporizable barrier having a high ratio of propylene glycol to glycerin. Providing a hard vaporizable barrier can advantageously improve the seal.

[0105] The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the vaporizable barrier may be about 1.5 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the vaporizable barrier may be about 2 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the vaporizable barrier may be about 2.5 or more. The ratio of the weight percentage of glycerin content to the weight percentage of propylene glycol content in the vaporizable barrier may be about 3 or more.

[0106] The one or more plasticizers may include a combination of one or more carboxylic acids and one or more aerosol formers. The one or more plasticizers may include a combination of one or more carboxylic acids and one or more polyhydric alcohols. In some embodiments, the vaporizable barrier includes a combination of sorbitol, glycerin, propylene glycol, and one or more carboxylic acids.

[0107] The vaporizable barrier may include water.

[0108] The vaporizable barrier may have a water content of about 0.1 weight percent or more. The vaporizable barrier may have a water content of about 0.5 weight percent or more. The vaporizable barrier may have a water content of about 1 weight percent or more. The vaporizable barrier may have a water content of about 2 weight percent or more. The vaporizable barrier may have a water content of about 3 weight percent or more. The vaporizable barrier may have a water content of about 4 weight percent or more. The vaporizable barrier may have a water content of about 5 weight percent or more. The vaporizable barrier may have a water content of about 8 weight percent or more. The vaporizable barrier may have a water content of about 10 weight percent or more. The vaporizable barrier may have a water content of about 12 weight percent or more. The vaporizable barrier may have a water content of about 15 weight percent or more.

[0109] The vaporizable barrier may have a water content of about 20 weight percent or less. The vaporizable barrier may have a water content of about 15 weight percent or less. The vaporizable barrier may have a water content of about 12 weight percent or less. The vaporizable barrier may have a water content of about 10 weight percent or less. The vaporizable barrier may have a water content of about 8 weight percent or less. The vaporizable barrier may have a water content of about 5 weight percent or less. The vaporizable barrier may have a water content of about 4 weight percent or less. The vaporizable barrier may have a water content of about 3 weight percent or less. The vaporizable barrier may have a water content of about 2 weight percent or less. The vaporizable barrier may have a water content of about 1 weight percent or less. The vaporizable barrier may have a water content of about 0.5 weight percent or less. The vaporizable barrier may have a water content of about 0.1 weight percent or less.

[0110] The vaporizable barrier may have a water content of from about 0.1 weight percent to about 20 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 12 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 10 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 8 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 5 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 4 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 3 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 2 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 1 weight percent. The vaporizable barrier may have a water content of from about 0.1 weight percent to about 0.5 weight percent.

[0111] The vaporizable barrier may have a water content of from about 0.5 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 1 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 2 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 3 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 4 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 5 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 8 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 10 weight percent to about 15 weight percent. The vaporizable barrier may have a water content of from about 12 weight percent to about 15 weight percent.

[0112] The vaporizable barrier may be formed from a formulation containing water.

[0113] The formulation may have a water content of about 40 weight percent or more. The formulation may have a water content of about 43 weight percent or more. The formulation may have a water content of about 45 weight percent or more. The formulation may have a water content of about 50 weight percent or more. The formulation may have a water content of about 55 weight percent or more. The formulation may have a water content of about 60 weight percent or more. The formulation may have a water content of about 65 weight percent or more. The formulation may have a water content of about 70 weight percent or more. The formulation may have a water content of about 75 weight percent or more. The formulation may have a water content of about 80 weight percent or more. The formulation may have a water content of about 85 weight percent or more. The formulation may have a water content of about 90 weight percent or more. The formulation may have a water content of about 95 weight percent or more.

[0114] The formulation may have a water content of about 97 weight percent or less. The formulation may have a water content of about 95 weight percent or less. The formulation may have a water content of about 90 weight percent or less. The formulation may have a water content of about 85 weight percent or less. The formulation may have a water content of about 80 weight percent or less. The formulation may have a water content of about 75 weight percent or less. The formulation may have a water content of about 70 weight percent or less. The formulation may have a water content of about 65 weight percent or less. The formulation may have a water content of about 60 weight percent or less. The formulation may have a water content of about 55 weight percent or less. The formulation may have a water content of about 50 weight percent or less. The formulation may have a water content of about 45 weight percent or less.

[0115] The preparation may have a water content of about 43% to about 97% by weight. The preparation may have a water content of about 43% to about 95% by weight. The preparation may have a water content of about 43% to about 90% by weight. The preparation may have a water content of about 43% to about 85% by weight. The preparation may have a water content of about 43% to about 80% by weight. The preparation may have a water content of about 43% to about 75% by weight. The preparation may have a water content of about 43% to about 70% by weight. The preparation may have a water content of about 43% to about 65% by weight. The preparation may have a water content of about 43% to about 60% by weight. The preparation may have a water content of about 43% to about 55% by weight. The preparation may have a water content of about 43% to about 50% by weight. The preparation may have a water content of about 43% to about 45% by weight.

[0116] The preparation may have a water content of about 45% to about 97% by weight. The preparation may have a water content of about 50% to about 97% by weight. The preparation may have a water content of about 45% to about 97% by weight. The preparation may have a water content of about 50% to about 97% by weight. The preparation may have a water content of about 55% to about 97% by weight. The preparation may have a water content of about 60% to about 97% by weight. The preparation may have a water content of about 65% to about 97% by weight. The preparation may have a water content of about 70% to about 97% by weight. The preparation may have a water content of about 75% to about 97% by weight. The preparation may have a water content of about 80% to about 97% by weight. The preparation may have a water content of about 85% to about 97% by weight. The preparation may have a water content of about 90% to about 97% by weight. The preparation may have a water content of about 95% to about 97% by weight.

[0117] A vaporizable barrier can be formed by drying the formulation.

[0118] A vaporizable barrier may be formed by providing a formulation containing the components in the amounts described above and drying the formulation. The step of drying the formulation reduces the water content of the formulation and provides a barrier material having the amounts of the components described above.

[0119] The barrier or its formation method may include combining the components of the barrier to provide a barrier formulation and then drying the formulation to provide the barrier material. In some embodiments, the method may involve heating the components either before or after combining.

[0120] The components are preferably heated to a high temperature above 60 °C, preferably above 70 °C, preferably above 90 °C.

[0121] The formulation is preferably maintained at a high temperature for at least about 5 minutes, preferably at least about 10 minutes, preferably at least about 15 minutes, preferably at least about 20 minutes.

[0122] In some embodiments, it may be advantageous to combine the components of the barrier / formulation in a specific order. In some embodiments, one or more plasticizers may be combined with one or more polymers before adding any further components. Advantageously, combining the components in this order can improve the processability of the formulation during manufacture.

[0123] The step of drying the formulation may occur at a high temperature, and the drying step may occur at a temperature of at least 40 °C. Alternatively, the step of drying the formulation may occur under ambient conditions or standard temperature and pressure.

[0124] As discussed below, the formulation may be dried to form a barrier material, and then the barrier applied to the storage portion or the formulation may be dried in-situ to provide the barrier.

[0125] The vaporizable barrier may be provided internally within the storage portion.

[0126] The vaporizable barrier may be attached to the storage portion. The vaporizable barrier may be attached to the inner surface of the storage portion.

[0127] The vaporizable barrier may be mechanically fixed to a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system.

[0128] The vaporizable barrier may be mechanically fixed to a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system by pressing the vaporizable barrier onto the component.

[0129] The vaporizable barrier may be mechanically fixed to a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system by at least partially dissolving a portion of the vaporizable barrier and pressing the vaporizable barrier onto the component. Advantageously, by partially dissolving a portion of the barrier and then fixing the barrier to the component, the adhesion may be improved. As disclosed below, the barrier may be formed in situ by melt casting. This may advantageously increase the adhesion between the barrier and the component.

[0130] The vaporizable barrier may be mechanically fixed to the liquid side of a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system.

[0131] The vaporizable barrier may be formed on a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system. The vaporizable barrier may be formed on the liquid side of a component of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system.

[0132] A vaporizable barrier can be formed on a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system by being cast onto the component. A vaporizable barrier can be formed on a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system by being cast onto the component during assembly of the aerosol-generating article, the aerosol-generating device, or the aerosol-generating system.

[0133] A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a heater. A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a moving element. A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a wicking material. A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a mesh layer.

[0134] The liquid side with respect to the position of the barrier in the present invention means that the barrier is formed between the aerosol-forming substrate and the components of the aerosol-forming article. Considering the nature of the barrier disclosed herein and the nature of the components of the aerosol-forming article, it will also be understood that the barrier may partially overlap the component. For example, when the component is a moving element, the barrier may partially penetrate the moving element structure. This may particularly be the case when the barrier is formed on the component. Advantageously, when the vaporizable barrier is formed on the liquid side of the component, the vaporizable barrier can be held in place by the pressure exerted thereon by the liquid.

[0135] The method may include providing an internally vaporizable barrier within the storage portion.

[0136] The method may include attaching a vaporizable barrier to the storage portion. The method may include attaching a vaporizable barrier to the inner surface of the storage portion.

[0137] The method may include casting a vaporizable barrier and then mechanically fixing the vaporizable barrier to a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system.

[0138] The method may include mechanically fixing the vaporizable barrier to a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system by pressing the vaporizable barrier onto the component.

[0139] The method may include at least partially dissolving a portion of the vaporizable barrier and then mechanically fixing the vaporizable barrier to the component by pressing the vaporizable barrier onto the component. Advantageously, by partially dissolving a portion of the barrier and then fixing the barrier to the component, the adhesion may be improved. As disclosed below, the barrier may be formed in situ by melt casting. This may advantageously increase the adhesion between the barrier and the component.

[0140] The method may include casting a vaporizable barrier and then mechanically fixing the vaporizable barrier to the liquid side of a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system.

[0141] The method may include solvent casting a vaporizable barrier and then drying the vaporizable barrier.

[0142] The method may include drying the vaporizable barrier at a temperature of about 15 degrees Celsius or more. The method may include drying the vaporizable barrier at a temperature of about 25 degrees Celsius or more. The method may include drying the vaporizable barrier at a temperature of about 30 degrees Celsius or more. The method may include drying the vaporizable barrier at a temperature of about 40 degrees Celsius or more. The method may include drying the vaporizable barrier at a temperature of about 40 degrees Celsius or more.

[0143] The method may include drying the vaporizable barrier at a temperature of about 70 degrees Celsius or less. The method may include drying the vaporizable barrier at a temperature of about 60 degrees Celsius or less. The method may include drying the vaporizable barrier at a temperature of about 50 degrees Celsius or less. The method may include drying the vaporizable barrier at a temperature of about 40 degrees Celsius or less. The method may include drying the vaporizable barrier at a temperature of about 30 degrees Celsius or less.

[0144] The method may include drying the vaporizable barrier at a temperature of about 15 degrees Celsius to about 70 degrees Celsius. The method may include drying the vaporizable barrier at a temperature of about 25 degrees Celsius to about 60 degrees Celsius. The method may include drying the vaporizable barrier at a temperature of about 35 degrees Celsius to about 50 degrees Celsius.

[0145] The method may include melt-casting the vaporizable barrier.

[0146] The method may include forming a vaporizable barrier on a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system. The method may include forming a vaporizable barrier on the liquid side of a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system. The vaporizable barrier may be formed in situ.

[0147] The method may include casting a vaporizable barrier on a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system. The method may include casting a vaporizable barrier on the liquid side of a component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system. The vaporizable barrier may be cast in situ.

[0148] A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a heater. A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a moving element. A component of an aerosol-generating article, an aerosol-generating device, or an aerosol-generating system may be a mesh layer.

[0149] The vaporizable barrier may be heat-treated after formation.

[0150] The method may include heat-treating the vaporizable barrier. The method may include heat-treating the vaporizable barrier after the vaporizable barrier is formed.

[0151] The vaporizable barrier may be heat-treated at a temperature of about 50 degrees Celsius or more. The vaporizable barrier may be heat-treated at a temperature of about 75 degrees Celsius or more. The vaporizable barrier may be heat-treated at a temperature of about 100 degrees Celsius or more. The vaporizable barrier may be heat-treated at a temperature of about 125 degrees Celsius or more. The vaporizable barrier may be heat-treated at a temperature of about 150 degrees Celsius or more.

[0152] The vaporizable barrier may be heat-treated at a temperature of about 200 degrees Celsius or less. The vaporizable barrier may be heat-treated at a temperature of about 175 degrees Celsius or less. The vaporizable barrier may be heat-treated at a temperature of about 150 degrees Celsius or less. The vaporizable barrier may be heat-treated at a temperature of about 125 degrees Celsius or less. The vaporizable barrier may be heat-treated at a temperature of about 100 degrees Celsius or less.

[0153] The vaporizable barrier may be heat-treated at a temperature of approximately 75 degrees Celsius to 200 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 75 degrees Celsius to 175 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 75 degrees Celsius to 150 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 75 degrees Celsius to 125 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 75 degrees Celsius to 100 degrees Celsius.

[0154] The vaporizable barrier may be heat-treated at a temperature of approximately 50 degrees Celsius to 175 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 100 degrees Celsius to 175 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 125 degrees Celsius to 175 degrees Celsius. The vaporizable barrier may be heat-treated at a temperature of approximately 150 degrees Celsius to 175 degrees Celsius.

[0155] The vaporizable barrier may be heat-treated in an oven. The vaporizable barrier may be heat-treated in a ventilated oven.

[0156] Advantageously, by heat-treating the vaporizable barrier after the vaporizable barrier is formed, the expansion of the vaporizable barrier can be reduced. The heat treatment of the vaporizable barrier can improve the cross-linking between one or more polymers and one or more plasticizers.

[0157] The storage portion may include a storage part.

[0158] The heater may be an electric heater. The electric heater may include a resistive heating element. The electric heater may include an inductive heating element.

[0159] The heater may include a heating element. The heating element may be a grid element. The heating element may be a grid layer. The heating element may be a mesh element. The heating element may be a mesh layer. In such embodiments, the aerosol-forming substrate may flow through the interstitial spaces that form the grid or mesh.

[0160] To avoid doubt, the above-described features regarding the aerosol-generating article may also, where appropriate, relate to an aerosol-generating device and an aerosol-generating system, and vice versa.

[0161] By way of example only, specific embodiments will now be described with reference to the following examples and the accompanying drawings.

Brief Description of the Drawings

[0162]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

DETAILED DESCRIPTION OF THE INVENTION

[0163] An aerosol generation system for delivery to a user typically comprises an atomizer configured to generate an inhalable aerosol from an aerosol-forming substrate. Some known aerosol generation systems comprise a thermal atomizer, such as an electric heater, configured to heat and vaporize the aerosol-forming substrate to generate an aerosol. Other known aerosol generation systems comprise a non-thermal atomizer configured to generate an aerosol from the aerosol-forming substrate using, for example, impinging jets, ultrasonic, or vibrating mesh technology. A typical aerosol-forming substrate for use in an aerosol generation system can be a nicotine formulation, such as a liquid nicotine formulation comprising an aerosol former such as glycerin and / or propylene glycol.

[0164] An aerosol generating system may comprise an aerosol generating device and an aerosol generating article containing an aerosol forming substrate. Typical aerosol generating systems may suffer from the problem of unwanted leakage of the aerosol forming substrate from the aerosol generating article. Leakage of the aerosol forming substrate can occur, for example, when there is too much aerosol forming substrate in the storage part of the aerosol generating article, when the material forming one or more parts of the aerosol generating article or system does not hold the aerosol forming substrate as designed, due to a change in pressure (e.g., when at a high altitude during transport by plane), or when at a high temperature (e.g., due to a high outside air temperature), etc., in many different situations.

[0165] It is desirable to provide an aerosol generating article that reduces the risk of leakage of the aerosol forming substrate from the aerosol generating article or system as compared to typical aerosol generating articles.

[0166] Figures 1 and 2 show an aerosol generating system including an aerosol generating device 10 and an aerosol generating article 20. In this embodiment, the aerosol generating article 20 is a cartridge.

[0167] The aerosol generating device 10 is configured to receive the aerosol generating article 20 within a cavity 18. The aerosol generating article 20 includes a housing 24. The housing 24 defines a storage portion 22. The storage portion 22 has a storage portion opening that can be covered by a removable cover 26. The aerosol forming substrate is disposed within the storage portion 22.

[0168] In the embodiment shown in Figures 1 and 2, the aerosol generating article 20 includes an atomizer configured to generate an aerosol from the aerosol forming substrate within the storage portion 22. The atomizer may be a thermal atomizer. In the embodiment shown in Figures 1 and 2, the atomizer is an electric heater 30. In another embodiment, the atomizer may be another type of atomizer, such as a non-thermal atomizer.

[0169] In the embodiments of FIGS. 1 and 2, the aerosol generating article 20 contains an aerosol forming substrate and an atomizer and can thus be referred to as an "atomizer".

[0170] The aerosol generating article 20 is replaceable by the user when the aerosol forming substrate provided within the storage portion 22 is depleted.

[0171] FIG. 1 shows the aerosol generating article 20 immediately before insertion into the aerosol generating device 10. Arrow 1 in FIG. 1 indicates the direction of insertion of the aerosol generating article 20 into the aerosol generating device 10.

[0172] The aerosol generating device 10 is portable and has a size comparable to that of a conventional cigar or cigarette. The aerosol generating device 10 comprises a body 11 and a mouthpiece portion 12. The body 11 comprises a battery 14 (such as a lithium iron phosphate battery), a control electronic circuit 16, and a cavity 18.

[0173] The mouthpiece portion 12 is connected to the body 11 by a hinged connection 21 and is movable between an open position shown in FIG. 1 and a closed position shown in FIG. 2. The mouthpiece portion 12 is positioned in the open position to allow insertion and removal of the aerosol generating article 20 and is positioned in the closed position when the aerosol generating system is used to generate an aerosol.

[0174] The mouthpiece portion 12 comprises a plurality of air inlets 13 and an air outlet 15. In use, the user sucks or inhales at the outlet 15 to draw air from the air inlets 13 through the mouthpiece portion to the outlet 15 and then into the user's mouth or lungs. An internal baffle 17 is provided to force the flow of air passing through the aerosol generating article 20 through the mouthpiece portion 12.

[0175] The housing 24 contains a capillary material immersed within the aerosol forming substrate. In this embodiment, the capillary material is positioned adjacent to the electric heater 30.

[0176] The cavity 18 has a circular cross-section and is sized to receive the housing 24 of the aerosol-generating article 20. The electrical connector 19 is provided on the side of the cavity 18 to provide an electrical connection between the control electronics circuit 16 and the battery 14 and corresponding electrical contacts on the aerosol-generating article 20. This setup enables power to be supplied to the electric heater 30.

[0177] Figure 2 shows the aerosol-generating article 20 inserted into the cavity 18 of the aerosol-generating device 10. In this position, the electrical connector 19 is positioned relative to corresponding electrical contacts on the aerosol-generating article 20. The cover 26 has been completely removed and the mouthpiece portion 12 has moved to the closed position.

[0178] The mouthpiece portion 12 is held in the closed position by a fastening mechanism (not shown). It will be apparent to those skilled in the art that other suitable mechanisms (such as snap-on attachment or magnetic closure) may be used to hold the mouthpiece in the closed position.

[0179] The mouthpiece portion 12 in the closed position holds the aerosol-generating article 20 in electrical contact with the electrical connector 19 so that a good electrical connection is maintained during use, regardless of the orientation of the aerosol-generating system.

[0180] During use, when the aerosol-generating device 10 is activated by the user, the electric heater 30 aerosolizes at least a portion of the aerosol-forming substrate in the storage portion 22. As the user inhales or smokes at the outlet 15, air flows through the air inlet 13 over the electric heater 30 and the capillary material. The air flowing over the electric heater 30 and the capillary material entrains the volatilized aerosol constituents from the vaporized aerosol-forming substrate. Next, the air with the entrained aerosol-forming substrate flows out through the outlet 15 to the user. This air flow regime is shown in Figure 2.

[0181] Figure 3 shows an alternative aerosol generation system. The embodiment shown in Figure 3 functions in substantially the same manner as the embodiments shown in Figures 1 and 2. However, in the embodiment of Figure 3, the aerosol generating article 20 is not removable from the aerosol generating device 10. Instead, after the aerosol generating substrate in the storage portion 22 is depleted, the storage portion 22 can be refilled by the user through the storage portion opening 40.

[0182] In Figure 3, the storage portion opening 40 is shown in an open position where the aerosol generating substrate can be refilled. However, the storage portion opening 40 may be sealed with a closure such as a cap (not shown).

[0183] The embodiment shown in Figure 3 functions in other respects in the same manner as the aerosol generation systems shown in Figures 1 and 2.

[0184] Figures 4 and 5 are schematic cross-sectional views of an alternative aerosol generating article 200. Figure 4 shows the aerosol generating article 200 before use by the user. The aerosol generating article 200 includes a body 212 that defines a storage portion 210 having a storage portion opening 215. An aerosol forming substrate 211 is disposed within the storage portion 210. The aerosol generating article 200 includes a heater 222 positioned across the storage portion opening 215. In this example, the heater 222 has a heating element in the form of a mesh layer 223. The aerosol generating article 200 also includes a moving element 224. The moving element 224 is preferably formed from a porous material. In the embodiment of Figure 4, the moving element 224 is formed from a layer of glass fibers. The moving element 224 provides control of the flow of the aerosol forming substrate 211 from the storage portion 210 to the mesh layer 213 of the heater 222.

[0185] In use, the aerosol forming substrate flows from the storage portion 210 to the porous moving element 224. The aerosol forming substrate then flows to the mesh layer 223 of the heater 222 where it is thermally vaporized into an aerosol.

[0186] Figure 4 shows that the aerosol generating article also includes a vaporizable barrier 225. The vaporizable barrier 225 is provided during the manufacture of the aerosol generating article 200. The vaporizable barrier 225 seals the storage portion 210 by blocking the flow of the aerosol forming substrate 211 from the storage portion 210 to the heater 222.

[0187] In the embodiment of Figure 4, the vaporizable barrier 225 is attached to the inner surface of the storage portion 210. In this particular embodiment, the vaporizable barrier 225 is attached to the heater 222 that forms the surface of the storage portion 210.

[0188] The vaporizable barrier 225 may be connected to the aerosol generating article 200 via the use of a number of different methods. In the embodiment of Figure 4, the vaporizable barrier 225 is mechanically fixed to the heater 222 after the vaporizable barrier 225 is formed. In another embodiment, the vaporizable barrier 225 may be formed on the aerosol generating article 200 by casting droplets of the barrier formulation onto the aerosol generating article 200.

[0189] The vaporizable barrier 225 is formed to vaporize after the first use of the aerosol generating article 200. That is, all of the mass of the vaporizable barrier 225 enters the vapor phase during the first heating cycle of the aerosol generating article 200.

[0190] Figure 4 shows the aerosol generating article 200 before the first use and after manufacture, and the vaporizable barrier 225 is in place. Figure 5 shows the aerosol generating article 200 after the first use, and the vaporizable barrier 225 is vaporized by the heater 222 during the first use.

[0191] Advantageously, the vaporizable barrier 225 applied to the aerosol-generating article 200 during the manufacture of the aerosol-generating article 200 physically blocks the flow of the aerosol-forming substrate 211 from the storage portion 210 before the aerosol-generating article 200 is used for the first time. Thereby, the vaporizable barrier 225 can prevent leakage of the aerosol-forming substrate 211 from the aerosol-generating article 200 before the first use, and can improve the storage life of the aerosol-generating article 200. The vaporizable barrier 225 can also reduce or prevent leakage even under pressure, such as during transportation by airplane.

[0192] Furthermore, considering that the vaporizable barrier 225 is positioned in place during the manufacturing process, a large window for a seal tab is not required, which increases the degree of freedom in designing the aerosol-generating article 200. Also, the absence of a seal tab simplifies the assembly process.

[0193] The vaporizable barrier 225 can be melted or vaporized by the heater 222 during the first use of the aerosol-generating article 200 (i.e., during the first heating cycle). This enables the user to use the aerosol-generating article 200 in the normal manner.

Example

[0194] To form a vaporizable barrier according to the present invention, two mixtures (Examples A and B) were prepared to have the compositions shown in Table 1.

Table 1

[0195] Examples A and B were mixed with polyvinyl alcohol, glycerin, and propylene glycol at 90 degrees Celsius, sodium stearate was added to the mixture, while stirring, the formulation was maintained at 90 degrees Celsius for 20 minutes, the formulation was dried at 40 degrees Celsius for a certain period to form the examples, and It was prepared by adding an example to the aerosol generating article 200.

[0196] The step of adding the example to the aerosol generating article 200 depends on whether the vaporizable barrier 225 is attached to the aerosol generating article 200 or formed on the aerosol generating article 200.

[0197] In the examples of FIGS. 4 and 5, the vaporizable barrier 225 is mechanically fixed between the storage portion 210 and the heater 222. In this example, Examples A and B are dried, for example, in a ventilation oven. The resulting film is then mechanically fixed to the aerosol generating article 200 to provide the vaporizable barrier 225.

[0198] In another example, droplets of an exemplary mixture are cast onto components of the aerosol generating article 200. The mixture then solidifies into the vaporizable barrier 225.

[0199] After the formation of the vaporizable barrier 225, the storage portion 210 of the aerosol generating article 200 can be refilled with the aerosol forming substrate 211.

[0200] The above-described exemplary embodiments are not intended to limit the scope of the claims. Other embodiments consistent with the above-described exemplary embodiments will be apparent to those skilled in the art. Features described with respect to one embodiment may also apply to other embodiments.

Claims

1. An aerosol generating article for use in an aerosol generating system, wherein the aerosol generating article comprises: a storage portion having an outlet; an aerosol forming substrate contained within the storage portion; a vaporizable barrier configured to seal the outlet; wherein the vaporizable barrier comprises one or more polymers; wherein the vaporizable barrier has a polymer content of 1 weight percent or more; wherein the vaporizable barrier is configured to vaporize during a first heating cycle of the aerosol generating article during a first use of the aerosol generating article in the aerosol generating system; wherein the vaporizable barrier comprises one or more metal salts, and the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates, and preferably, the vaporizable barrier comprises one or more metal stearates. An aerosol generating article.

2. An aerosol generating article for use in an aerosol generating system, wherein the aerosol generating article comprises: a storage portion; an aerosol forming substrate contained within the storage portion; a heater configured to heat the aerosol forming substrate; a vaporizable barrier provided between the storage portion and the heater; wherein the vaporizable barrier comprises one or more polymers; wherein the vaporizable barrier has a polymer content of 1 weight percent or more; wherein the vaporizable barrier is configured to vaporize during a first heating cycle of the aerosol generating article during a first use of the aerosol generating article in the aerosol generating system; wherein the vaporizable barrier comprises one or more metal salts, and the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates, and preferably, the vaporizable barrier comprises one or more metal stearates. An aerosol generating article.

3. The aerosol generating article according to claim 1 or 2, wherein the vaporizable barrier is pyrolytic when heated to a temperature between 60°C and 300°C.

4. The aerosol generating article according to claim 3, wherein the vaporizable barrier comprises a material that is vaporizable when heated to a temperature between 180°C and 300°C.

5. The aerosol generating article according to claim 1 or 2, wherein the vaporizable barrier has a polymer content of from about 5 weight percent to about 40 weight percent.

6. The aerosol generating article according to any one of claims 1, 2, and 5, wherein the one or more polymers are selected from the group consisting of polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, low density polyethylene, and starch.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the vaporizable barrier comprises starch.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the vaporizable barrier is mechanically fixed to the liquid side of a component of the aerosol generating article.

9. The aerosol generating article according to any one of claims 1 to 7, wherein the vaporizable barrier is formed on a component of the aerosol generating article.

10. The aerosol generating article according to claim 8 or 9, wherein the component of the aerosol generating article is a heater or a wicking material.

11. An aerosol generating system, comprising: an aerosol generating article according to any one of claims 1 to 10; and an aerosol generating device.

12. A method of manufacturing an aerosol generating article, the method comprising: providing an aerosol generating article comprising a storage portion, an aerosol forming substrate contained within the storage portion, and a heater configured to heat the aerosol forming substrate; and providing a vaporizable barrier between the storage portion and the heater, wherein the vaporizable barrier comprises one or more polymers, and wherein the vaporizable barrier has a polymer content of 1 weight percent or more. The vaporizable barrier is configured to be vaporized during a first heating cycle of the aerosol-generating article during a first use of the aerosol-generating article in the aerosol-generating system, The vaporizable barrier contains one or more metal salts, and the one or more metal salts are selected from the group consisting of metal alginates, metal benzoates, metal cinnamates, metal cycloheptanecarboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates, and preferably, the vaporizable barrier contains one or more metal stearates.

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