Aerosol generating article, aerosol generating assembly including the same, and method for manufacturing a tubular substrate

Abstract

To provide an aerosol generation product which is capable of selectively adjusting composition of an aerosol to be sucked and is used for an aerosol generation assembly that can alter and / or enhance composition of aerosol or steam.SOLUTION: An aerosol generation article 101 for being used to an aerosol generation assembly includes: (i) a tubular base material 103 including a first aerosol formation composition 103a including an amorphous solid; and (ii) a second aerosol formation composition 103b different from the first aerosol formation composition.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an aerosol generating article and an aerosol generating assembly including the same, and a method for manufacturing a tubular substrate.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to generate smoke. Some alternatives to these types of smoking articles release an inhalable aerosol or vapor by heating a substrate to release compounds without burning. These may be referred to as non-combustible smoking articles or aerosol generating assemblies.

[0003] As an example of such a product, there is a heating device that releases compounds by heating a solid aerosolizable material without burning. This solid aerosolizable material may optionally include tobacco material. Heating typically volatilizes at least one component of the material that forms an inhalable aerosol. These products are sometimes referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. Various different configurations for volatilizing at least one component of the solid aerosolizable material are known.

[0004] As another example, there are electronic cigarette / tobacco heating product hybrid devices, also known as electronic cigarette hybrid devices. These hybrid devices include a feed liquid (with or without nicotine) that is vaporized by being heated to produce an inhalable vapor or aerosol. The device additionally includes a solid aerosolizable material (which may or may not include tobacco material), and the components of this material are entrained in the inhalable vapor or aerosol to produce an inhalable medium.

[0005] Some conventional aerosol generation involves two or more heaters, each configured to heat different portions of a smoking material during use. This allows those different portions of the smoking material to be heated at different times, thereby enabling the formation of aerosol over an extended period of use. SUMMARY OF THE INVENTION

[0006] In a first aspect of the present invention, there is provided an aerosol generating article for use in an aerosol generating assembly, the aerosol generating article comprising: (i) a tubular substrate comprising a first aerosol-forming composition comprising an amorphous solid; and (ii) a second aerosol-forming composition different from the first aerosol-forming composition.

[0007] In a second aspect of the present invention, there is provided an aerosol generating assembly comprising an aerosol generating article according to the first aspect and a heater configured to heat at least one of the aerosol generating article and the aerosol-forming composition without combustion.

[0008] A further aspect of the present invention provides a method of manufacturing a tubular substrate comprising: (a) forming a slurry comprising components of the first aerosol-forming composition or a precursor thereof; (b) applying the slurry to a sheet-like carrier; (c) curing the slurry to form a gel; (d) drying to form an amorphous solid; and (e) shaping to form a tube.

[0009] A further aspect of the present invention as described herein provides for the use of an aerosol generating article or an aerosol generating assembly in the generation of an inhalable medium.

[0010] Further features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings which are for illustrative purposes only. BRIEF DESCRIPTION OF THE DRAWINGS

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

DETAILED DESCRIPTION OF THE INVENTION

[0012] At least the first aerosol-forming composition described herein includes an aerosol-forming material referred to as an "amorphous solid". The materials described herein as "amorphous solids" may also be referred to alternatively as "monolithic solids" (i.e., non-fibrous) or "dry gels". An amorphous solid is a solid material that holds a fluid such as a liquid inside it. The aerosol-forming materials described herein contain, in some cases, an amorphous solid in an amount of 50 wt%, 60 wt% or 70 wt% to about 90 wt%, 95 wt% or 100 wt%. The aerosol-forming material may consist of an amorphous solid.

[0013] The present invention provides an aerosol generating product for use in an aerosol generating assembly, the generating product comprising (i) a tubular substrate containing a first aerosol-forming composition comprising an amorphous solid, and (ii) a second aerosol-forming composition different from the first aerosol-forming composition.

[0014] One or both of the aerosol-forming compositions generate an aerosol or vapor that is heatable for inhalation during use. By using two or more aerosol-forming compositions, the composition of the aerosol inhaled can be selectively adjusted. The present invention provides an amorphous solid as a component of a first aerosol-forming composition, which solid may contain aerosolizable components (such as aerosol generators, flavorants, nicotine, nicotine derivatives, and aromas). The amorphous solid derived from these aerosolizable components volatilizes and is inhaled during use, and by providing the amorphous solid, the composition of the aerosol or vapor can be changed and / or enhanced. The amorphous solid may contain active substances such as nicotine and / or tobacco extracts.

[0015] The inventor has confirmed that in conventional aerosol-generating assemblies where a uniform aerosol product is used, the delivery rate of the components of the aerosol decreases with use. In this example, it is possible to change the aerosol delivery profile by providing two different aerosol-forming compositions that react differently to heat and are exposed to different heat profiles. The delivery profile can be adjusted depending on which composition and which heat profile are used.

[0016] Due to the tubular shape of the substrate, it is suitable for use in many ways. The aerosol-generating product may be configured to be used with an aerosol-generating assembly in which the heater is disposed inside the tube during use. In another case, the aerosol-generating product may be configured to be used with an aerosol-generating assembly in which the heater is disposed outside the tube during use. In such a case, there are no components of the aerosol-generating assembly disposed within the tube. Rather, the tube provides a flow path for the aerosol or vapor during use, which prevents condensation of the aerosol or vapor on the repeatedly used components of the aerosol-generating assembly, thereby improving consumption efficiency and hygiene. In some such cases, the outer wall of the tube is substantially or completely impermeable to gas / aerosol and further regulates the flow path.

[0017] The tubular substrate may also contain a second aerosol-forming composition.

[0018] The second aerosol-forming composition contains an amorphous solid. This may be a cut sheet made of the amorphous solid, which may be disposed inside the tube of the tubular substrate.

[0019] In another case, the second aerosol-forming composition contains tobacco. The tobacco is reclaimed tobacco and may optionally be in the form of shredded scraps. The tobacco may be disposed in an inner ring in a tubular tube.

[0020] The aerosol-generating article may have first and second sections, and the amount of the first aerosol-forming composition and / or the amount of the second aerosol-forming composition provided in the first section may be different from the respective amounts provided in the second section. In such a case, the different sections may be exposed to different heat profiles during use, thereby providing an inhalable aerosol whose composition changes during the consumption period. That is, the different sections may be heated to different temperatures at different times or speeds, for example. The first and second sections may be spaced along the length of the tube of the tubular substrate. In another case, they may be disposed on opposite sides of the tubular substrate.

[0021] Substantially all of the first aerosol-forming composition may be provided in the first section and substantially all of the second aerosol-forming composition may be provided in the second section. In another case, each section may contain both the first and second forming compositions.

[0022] In another case, substantially all of the first and second aerosol-forming compositions may be exposed to substantially the same heat profile.

[0023] In some specific examples, the tubular substrate may contain the first and second aerosol-forming compositions. These each contain an amorphous solid. In such cases, the amorphous solid may be provided as a layer on the inside of the tubular substrate. There may be a section of the tube that contains both aerosol-forming compositions, and there may be other sections that contain only one composition. These two compositions may be provided as two layers such that one is provided on top of the other. The thickness of the layers may vary along the length of the tube or may be the same. In a further option, the amorphous solid may be provided in different sections of the tubular substrate such that one is provided as a layer closer to the mouth end and the second is provided as a layer closer to the distal end. In some cases, the amorphous solid may be provided as two coaxial tubes arranged end to end. In yet another option, the amorphous solid may be provided as a semi-cylindrical layer inside the tube.

[0024] Some other specific examples where the tubular substrate contains the first and second aerosol-forming compositions provide an aerosol-generating article in which the first aerosol-forming composition contains an amorphous solid and the second aerosol-forming composition contains tobacco. For example, the second aerosol-forming composition may contain a sheet of reconstituted tobacco on which the first aerosol-forming composition is supported. In another example, the amorphous solid of the first aerosol-forming composition may be provided in a first section of the tube and the sheet of tobacco (of the second aerosol-forming composition) may be provided in a second section of the tube. In yet another example, the sheet of tobacco may be arranged along the entire length of the tube and the amorphous solid may be arranged on the sheet of tobacco along only a part of the tube.

[0025] In another specific example, the second aerosol-forming composition preferably contains tobacco in the form of shredded waste. This is recycled tobacco. The tobacco may be provided inside the tube of the tubular substrate. The tobacco may sometimes be provided in the same section of the tube as the first aerosol-forming composition. In another case, the tobacco may be provided in a section of the tube different from the second aerosol-forming composition. In yet another example, the tobacco composition may be provided in two sections of the tube, and the first aerosol-forming composition is provided in only one section. In yet another example, the first aerosol-forming composition may be provided in two sections of the tube, and the tobacco composition is provided in only one section.

[0026] In one example, the first aerosol-forming composition contains a flavorant and an amorphous solid that does not contain tobacco material, and the second aerosol-forming composition contains tobacco material.

[0027] Generally, the amorphous solid component of the tubular substrate is arranged adjacent to the inside of the tube. In some cases, the outer surface of the tubular substrate tube may be surrounded by a wrapper that is substantially or completely impermeable to the aerosol or vapor (to prevent passage of the formed aerosol or vapor to the outside of the tube during use). This guides the components to be inhaled into the tube and prevents the components from condensing on the reusable member (thereby improving the consumer experience and hygiene). The wrapper may be formed, for example, from a metal foil that conducts heat during use.

[0028] The tubular substrate comprises a first aerosol-forming composition which itself contains an amorphous solid. As a result, the tubular substrate may be an amorphous solid sheet that is rolled up to form a tube. The substrate may include a support member. The support member may be embedded in the amorphous solid or may be a carrier on which the amorphous solid is provided. For example, the tubular substrate may include a sheet-like carrier, which may be a sheet made of metal foil or paper or a laminate of metal foil or paper on which the amorphous solid is provided. In some cases, the carrier is selected from one or more materials including metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes such as graphite and graphene, plastics, cardboard, wood, or combinations thereof. In some cases, the carrier may include a tobacco material such as a recycled tobacco sheet or may consist of a tobacco material such as a recycled tobacco sheet. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some cases, the carrier may be a laminated structure including a layer made of a material selected from the above examples. The tubular substrate may be formed as a flat sheet and then rolled up to form a tube. Alternatively, as described above, the carrier sheet may be a sheet containing recycled tobacco, which is a second aerosol-forming composition.

[0029] The surface of the carrier sheet in contact with the amorphous solid is preferably formed from a porous material such as paper or recycled tobacco. This can form a strong adhesion between the amorphous solid and the porous carrier surface. The amorphous solid is formed by drying a gel. Without being limited by any theory, it is believed that when the slurry from which the gel is formed is impregnated into the porous layer and the gel cures and forms crosslinks, the porous layer becomes partially bonded within the gel. In some cases, the carrier includes or consists of a paper sheet. The paper may have a porosity of 0 to 300 Gurley units (CU), preferably 5 to 100 CU or 25 to 75 CU.

[0030] In addition, surface roughness contributes to the strength of the adhesion between the amorphous solid and the carrier. The inventors have found that the roughness of the paper (the surface in contact with the carrier) is preferably from 50 to 1000 Bekk seconds, preferably in the range of 50 to 150 Bekk seconds, and more preferably 100 Bekk seconds (measured in an air pressure interval of 50.66 to 48.00 kPa). (The Bekk smoothness tester is a device used to measure the smoothness of the paper surface where air leaks between a smooth glass surface and a paper sample at a specific pressure, and the time (seconds) for a predetermined amount of air to seep through between these surfaces is the "Bekk smoothness".)

[0031] Conversely, the surface of the carrier opposite to the amorphous solid is arranged in contact with the heater, and the smooth surface transfers heat more efficiently. Thus, in some cases, the carrier is arranged with the rougher side in contact with the amorphous solid and the smoother side opposite to the amorphous material.

[0032] In some cases, one or more of the aerosol-forming compositions may include an embedded heating means such as a resistive or inductive heating element. For example, the heating means may be embedded in the amorphous solid.

[0033] In some cases, the carrier comprises or consists of a foil-paper laminate, the paper is in contact with the gel inside the tube, thereby forming a strong adhesion, and the foil is arranged on the outside of the tube to prevent the aerosol or vapor formed during use from passing to the outside of the tube.

[0034] In another case, the foil layer of the foil supported by the paper is in contact with the amorphous solid. The foil is impermeable and thereby prevents the water provided in the amorphous solid from being absorbed by the paper, which may weaken the structural integrity of the paper.

[0035] In some cases, the carrier is formed from or includes a metal foil such as aluminum foil. The metal carrier can transfer thermal energy better by the amorphous solid. Additionally or alternatively, the metal foil may function as a susceptor of the induction heating system. In certain embodiments, the carrier includes a metal foil layer and a support layer such as cardboard. In these embodiments, the metal foil layer has a thickness of less than 20 μm, for example, about 1 μm to about 10 μm, preferably about 5 μm.

[0036] The aerosol generating article may additionally include a cooling element and / or a filter. When a cooling element is included, it acts or functions to cool the gas or aerosol component. In some cases, the cooling element acts to cool the gas component such that the gas component condenses to form an aerosol. The cooling element also acts to keep the extremely hot parts of the device away from the user. When a filter is included, it may include any suitable filter known in the art such as a cellulose acetate plug.

[0037] In some cases, the cooling element and / or the filter (if included) may be wrapped by a layer that at least partially extends over the tubular substrate. This layer may be a wrapper including the carrier and the amorphous solid.

[0038] The aerosol generating article may further include ventilation openings. These ventilation openings may be provided in the side wall of the generating article. In some cases, the ventilation openings may be provided in the filter and / or the cooling element. These openings can allow cooling air to be drawn into the generating article during use, which can mix with the heated and volatilized components, thereby cooling the aerosol.

[0039] Ventilation increases the generation of visible heated and volatilized components from the generated product when it is heated during use. The heated and volatilized components are visualized by a cooling process of the heated and volatilized components such that supersaturation of the heated and volatilized components occurs. The heated and volatilized components are then formed into droplets, which is also known as nucleation, and ultimately the size of the aerosol particles of the heated and volatilized components increases by further condensation of the heated and volatilized components and solidification of the droplets newly formed from the heated and volatilized components.

[0040] In some cases, the ratio of the cooling air to the total of the heated and volatilized components and the cooling air, known as the ventilation rate, is at least 15%. The heated and volatilized components can be made visible by the above-described method at a ventilation rate of 15%. By making the heated and volatilized components visible, the user can confirm that the heated and volatilized components are emitted and added to the sensory experience of the smoking experience.

[0041] In another example, the ventilation rate is 50% - 85% to further cool the heated and volatilized components. In some cases, the ventilation rate may be at least 60% or 65%.

[0042] A second aspect of the present invention provides an aerosol generating assembly comprising a heater configured to heat at least one of an aerosol generating article and an aerosol-forming composition according to the first aspect without burning them.

[0043] In some cases, the heater may heat to 120°C - 350°C without burning the aerosolizable material during use. In some cases, the heater may heat to 140°C - 250°C without burning the aerosolizable material during use. In some cases, during use, substantially all The amorphous solid is less than about 4 mm, less than 3 mm, less than 2 mm or less than 1 mm away from the heater. In some cases, the solid is arranged about 0.010 mm to 2.0 mm away from the heater, preferably about 0.02 mm to 1.0 mm, preferably 0.1 mm to 0.5 mm. These minimum distances may reflect the thickness of the carrier supporting the amorphous solid. In some cases, the surface of the amorphous solid may be in direct contact with the heater.

[0044] In some cases, the aerosol generating assembly includes an aerosol generating article, in which case the article has first and second sections spaced along the length of the tube of the tubular substrate, and the amount of the first aerosol-forming composition provided in the first section and / or the amount of the second aerosol-forming composition is different from the respective amounts provided in the second section, and the device is configured to provide different heat profiles to each of the first and second sections.

[0045] In some cases, the heating of the first section of the aerosol generating article is started at a different time from the heating of the second section.

[0046] For example, in some specific cases, an assembly configured to heat at least two sections of the aerosol generating assembly is provided. By controlling the temperatures of the first and second sections over time so that the temperature profiles of those sections are different, it becomes possible to control the puff profile of the aerosol during use. The heat supplied to the two sections of the aerosol generating article may be supplied at different times or rates, and by shifting the heating in this way, it becomes possible to generate the aerosol earlier and extend the service life.

[0047] In one particular example, the assembly may be configured such that a first heating element corresponding to a first section of the aerosol-generating article is immediately heated to a temperature of 240°C at the start of the consumption experience. This first heating element is maintained at 240°C for 145 seconds and then lowered to 135°C (this temperature is maintained for the remainder of the consumption experience). 75 seconds after the start of the consumption experience, a second heating element corresponding to a second section of the aerosol-generating article is heated to a temperature of 160°C. 135 seconds after the start of the consumption experience, the temperature of the second heating element is raised to 240°C (this temperature is maintained for the remainder of the consumption experience). The consumption experience lasts for 280 seconds, at which point both heaters cool to room temperature.

[0048] In some cases, the device may be configured to control the start of heating of each section for the user, thereby enabling the consumer to control the consumption experience.

[0049] In some cases, the aerosol-generating assembly may include at least two heaters, which are arranged to heat each of different sections of the aerosol-generating article without burning them.

[0050] In some cases, the aerosol-generating assembly may be configured such that the heater is disposed inside the tube of the tubular substrate.

[0051] In some cases, the aerosol-generating assembly is configured such that the heater is disposed outside the tube of the tubular substrate. In some cases, the aerosol-generating assembly is configured such that no parts of the aerosol-generating assembly are disposed inside the tube of the tubular substrate during use. The tube may be empty during use and provide a flow path for aspiratable aerosol / gas.

[0052] In some cases, the aerosol generating assembly may be a non-combustion heating device. That is, it may contain a solid tobacco-containing material (not containing a liquid aerosolizable material). In some cases, the amorphous solid may contain a tobacco material. The non-combustion heating device is disclosed in International Application Publication Pamphlet 2015 / 062983 A2, and the entire content thereof is incorporated herein by reference.

[0053] In some cases, the aerosol generating assembly may be an electronic cigarette hybrid device. That is, it may contain a solid aerosolizable material and a liquid aerosolizable material. In some cases, the amorphous solid may contain nicotine. In some cases, the amorphous solid may contain a tobacco material. In some cases, the amorphous solid may contain a tobacco material and a separate nicotine source. The separate aerosolizable materials may be heated by a separate heater or the same heater. In one example, the downstream aerosolizable material may be heated by the hot aerosol generated from the upstream aerosolizable material. The electronic cigarette hybrid device is disclosed in International Application Publication Pamphlet 2016 / 135331 A1, and the entire content thereof is incorporated herein by reference.

[0054] The heater provided for the assembly according to the second aspect may, in some cases, be a thin film electrical resistance heater. In another case, the heater may include an induction heater or the like. The heater may be a combustible heat source or a chemical heat source that generates heat by an exothermic reaction for producing heat during use. The aerosol generating assembly may include a plurality of heaters. One or more heaters may be connected to a battery. When two or more heaters are present, each heater may be the same or different.

[0055] Generally, the or each heater is powered by a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and the like. The battery is electrically connected to the heater and supplies power as needed to heat the smoking material (to volatilize the components of the smoking material without burning the smoking material).

[0056] In one example, the heater is in the shape of a substantially hollow cylindrical tube having a hollow internal heating chamber, and an aerosol generating article is inserted into the chamber for heating during use. Different configurations of the heater are possible. For example, the heater may be formed as a single heater or may be formed of a plurality of heaters aligned along the longitudinal axis of the aerosol generating article. (For the sake of brevity, when the term "heater" is used in this specification, it shall include a plurality of heaters unless the context indicates otherwise.) The heater may be annular or tubular. The heater is sized such that when the substantially entire aerosol generating article is inserted, it is located within one or more heating elements of the heater and the entire aerosolizable material is heated during use. The heater may be configured such that selected regions of the aerosolizable material are heated independently, for example, sequentially (continuously) or together (simultaneously) as needed.

[0057] In another example, the heater may be rod-shaped, and the assembly may be configured such that the heater is at least partially located inside the tubular substrate during use.

[0058] The heater may be surrounded by a heat insulator along at least a portion of its length, which helps to reduce the heat passing from the heater to the outside of the aerosol generating assembly. This generally helps to reduce heat loss and thus helps to reduce the power required for the heater. The heat insulator helps to keep the outside of the aerosol generating assembly cool during operation of the heater.

[0059] Referring to FIGS. 1 and 2, they are an internal view and a perspective view of a cut-out part of an example of the aerosol generator 101. The generator 101 is adapted to be used in a device having a power source and a heater. The generator 101 of this embodiment is particularly suitable for use with the device 51 shown in FIGS. 5 to 7 described below. In use, the generator 101 is removably inserted into the device shown in FIG. 5 at the insertion point 20 of the device 51.

[0060] An example of the generator 101 is substantially cylindrical rod-shaped including the tubular substrate 103 and the rod-shaped filter assembly 105 described in this specification. The tubular substrate 103 is also illustrated in FIG. 8 and includes two aerosol-forming amorphous solid compositions 103a, 103b in sections 104 and 106. Each amorphous solid composition is tubular and they are arranged end-to-end (i.e., coaxially arranged but relatively displaced along their axes). The amorphous solid section 103b is closer to the filter assembly 105 than the amorphous solid section 103a. The tubular substrate in FIG. 8 is shown in the aerosol generators 101, 301 in FIGS. 1 to 4, but in other embodiments the substrates 103, 303 of these generators may have different shapes such as those shown in FIGS. 9 and 10, but are not limited thereto.

[0061] In FIG. 9, the tubular substrate 903 includes two aerosol-forming amorphous solid compositions 903a and 903b. The substrate 903 includes two sections 904 and 906, each containing different amounts of the corresponding amorphous solids 903a and 903b. These sections may be exposed to different heat profiles during use to provide a drawable aerosol whose composition changes throughout the life of the product.

[0062] In FIG. 10, the tubular substrate 1003 includes a first aerosol-forming composition 1003a in the form of an amorphous solid tube and a second aerosol-forming composition 1003b in the form of ground tobacco disposed inside the tube. In the case of the substrates 103 and 903 illustrated in FIGS. 8 and 9, it is clear that the two sections 1004 and 1006 of the tubular substrate 1003 each contain a different amount of aerosol-forming material. These sections may be exposed to different heat profiles during use, providing an inhalable aerosol whose composition changes throughout the life of the product.

[0063] The filter assembly 105 includes three segments such as a cooling segment 107, a filter segment 109, and a mouth end segment 111. The article 101 has a first end 113, also known as the mouth end or proximal end, and a second end 115, also known as the distal end. The tubular substrate 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent to the tubular substrate 103 between the tubular substrate 103 and the filter segment such that the cooling segment 107 is in contact with the tubular substrate 103 and the filter segment. In other examples, there may be a gap between the tubular substrate 103 and the cooling segment 107 and between the tubular substrate 103 and the filter segment 109. The filter segment 109 is located between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located adjacent to the filter segment 109 towards the proximal end 113 of the article 101. In one example, the filter segment 109 is in contact with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is from 37 mm to 45 mm, more preferably the total length of the filter assembly 105 is 41 mm.

[0064] In one example, the tubular substrate 103 has a length of from 34 mm to 50 mm, preferably from 38 mm to 46 mm, preferably 42 mm.

[0065] In one example, the total length of the article 101 is from 71 mm to 95 mm, preferably from 79 mm to 87 mm, preferably 83 mm.

[0066] The tubular substrate 103 is joined to the filter assembly 105 by an annular tipping paper (not shown), which is substantially located around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the tubular substrate 103. In one example, the tipping paper is made of a standard tipping base paper of 58 GSM. In one example, the length of the tipping paper is 42 mm to 50 mm, preferably 46 mm.

[0067] In one example, the cooling segment 107 is an annular tube that is located around and defines a void within the cooling segment. The void provides a chamber through which the heated and volatilized components generated from the tubular substrate 103 flow. The cooling segment 107 is hollow to provide a chamber for the aerosol deposit that is rigid enough to withstand the axial compressive forces and bending moments that occur during manufacture and while the product 101 is inserted into the device 51 during use. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0068] The cooling segment 107 provides physical movement between the tubular substrate 103 and the filter segment 109. The physical movement provided by the cooling segment 107 provides a temperature gradient along the length of the cooling segment 107. In one example, the cooling segment 107 is configured such that the temperature difference between the heated and volatilized component entering the first end of the cooling segment 107 and the heated and volatilized component exiting the second end of the cooling segment 107 is at least 40 °C. In one example, the cooling segment 107 is configured such that the temperature difference between the heated and volatilized component entering the first end of the cooling segment 107 and the heated and volatilized component exiting the second end of the cooling segment 107 is at least 60 °C. This temperature difference across the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperature of the tubular substrate 103 when the tubular substrate 103 is heated by the device 51. If there is no physical movement between the filter segment 109, the tubular substrate 103, and the heating element of the device 51, the temperature-sensitive filter segment 109 will be damaged during use and will not be able to efficiently perform its required function.

[0069] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is 20 mm to 30 mm, particularly 23 mm to 27 mm, particularly 25 mm to 27 mm, and preferably 25 mm.

[0070] The cooling segment 107 is made of paper, which means that it is composed of a material that does not generate problematic compounds such as, for example, toxic compounds when used adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spirally wound paper tube can meet the strict dimensional accuracy requirements regarding the length, outer diameter, roundness, and straightness of the tube for the manufacturing process performed at high speed.

[0071] In another example, the cooling segment 107 is a recess formed from a rigid plug wrapper or tipping paper. The rigid plug wrapper or tipping paper is manufactured to have a rigidity sufficient to withstand the axial compressive forces and bending moments that occur during manufacture and while the product 101 is inserted into the device 51 during use.

[0072] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated and volatilized components from the tubular substrate. In one example, the filter segment 109 is made of a monoacetate material such as cellulose acetate. The filter segment 109 reduces the cold stimulus from the heated and volatilized components without dropping the quality of the heated and volatilized components to a level that the user is dissatisfied with.

[0073] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be disposed substantially centrally within the filter segment 109 across the diameter of the filter segment 109 and along the length of the filter segment 109. In another case, the capsule may be offset in one or more dimensions. The capsule, when included, may contain a volatile component such as a flavorant or an aerosol generating agent.

[0074] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the product 101. Thus, the selection of the material for the filter segment 109 is important in controlling the draw resistance of the product 101. Further, the filter segment performs a filtering function in the product 101.

[0075] In one example, the filter segment 109 is made of an 8Y15 grade filter material, which provides a filtering effect for the heated and volatilized components and reduces the size of the condensed aerosol droplets resulting from the heated and volatilized components.

[0076] The filter segment 109 provides an insulating effect by further cooling the heated and volatilized components that have exited the cooling segment 107. This further cooling effect lowers the temperature at the surface of the filter segment 109 when the user's lips touch it.

[0077] In one example, the length of the filter segment 109 is 6 mm to 10 mm, preferably 8 mm.

[0078] The mouthpiece end segment 111 is an annular tube that is located around and defines a void within the mouthpiece end segment 111. The void provides a chamber for the heated and volatilized components flowing from the filter segment. The mouthpiece end segment 111 is hollow to provide a chamber for aerosol deposits that is rigid enough to withstand the axial compressive forces and bending moments that occur during manufacture and when the product is inserted into the device 51 during use. In one example, the wall thickness of the mouthpiece end segment 111 is about 0.29 mm. In one example, the length of the mouthpiece end segment 111 is 6 mm to 10 mm, preferably 8 mm.

[0079] The mouthpiece end segment 111 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while maintaining critical mechanical rigidity. The spirally wound paper tube can meet the strict dimensional accuracy requirements regarding the tube length, outer diameter, roundness, and straightness of the manufacturing process that is carried out at high speed.

[0080] The mouthpiece end segment 111 provides the function of preventing any liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0081] Of course, in one example, the mouthpiece end segment 111 and the cooling segment 107 may be formed of a single tube, and the filter segment 109 is located within the tube that separates the mouthpiece end segment 111 and the cooling segment 107.

[0082] Referring to FIGS. 3 and 4, a cross-sectional view and a perspective view of a part of the generated product 301 of an example with a cutout are shown. The reference numerals shown in FIGS. 3 and 4 are equivalent to those shown in FIGS. 1 and 2, but 200 is added.

[0083] In the example of the generated product 301 shown in FIGS. 3 and 4, the ventilation area 317 is provided inside the generated product, and air can flow from the outside of the generated product 301 to the inside of the generated product 301. In one example, the ventilation area 317 is in the form of one or more ventilation holes formed through the outer layer of the generated product 301. The ventilation holes are located in the cooling segment 107 to assist in cooling the generated product 301. In one example, the ventilation holes 317 include one or more rows of holes, and preferably the rows of holes are circumferentially arranged around the generated product in a cross-section substantially perpendicular to the longitudinal axis of the generated product 301.

[0084] In one example, there are 1 to 4 rows of ventilation holes for ventilating the generated product 301. Each row of ventilation holes has 12 to 36 ventilation holes 317. The ventilation holes 317 have a diameter of, for example, 100 to 500 μm. In one example, the axial spacing between the rows of ventilation holes 317 is 0.25 mm to 0.7 5 mm, preferably 0.5 mm.

[0085] In one example, the size of the ventilation holes 317 is uniform. In another example, the sizes of the ventilation holes 317 are different. The ventilation holes can be provided using one or more of any suitable techniques, such as laser techniques, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before it is formed in the generated product 301. The ventilation holes 317 are arranged to effectively cool the generated product 301.

[0086] In one example, the rows of ventilation holes 317 are located at least 11 mm from the proximal end 313 of the generated product, preferably 17 mm to 20 mm from the proximal end 313 of the generated product 301. The position of the ventilation holes 317 is arranged so that the user does not block the ventilation holes 317 during use of the generated product 301.

[0087] By providing a row of ventilation holes 17 mm to 20 mm away from the proximal end 313 of the generated product 301, as is clear from FIGS. 6 and 7, when the generated product 301 is completely inserted into the device 51, the ventilation holes 317 can be arranged outside the device 51. By arranging the ventilation holes outside the device, unheated air can enter the generated product 301 from outside the device 51 through the ventilation holes, assisting in cooling the generated product 301.

[0088] The cooling segment 307 is sized such that when the generated product is fully inserted into the device 51, a portion of the cooling segment 307 is inserted into the device 51. The length of the cooling segment 307 provides a first function of creating a physical gap between the heater device of the device 51 and the heat-sensitive filter device 309 when the generated product 301 is inserted into the device, and a second function of being arranged outside the device 51 and allowing the ventilation holes 317 to be arranged within the cooling segment. As can be seen from FIGS. 6 and 7, most of the cooling member 307 is located within the device 51. However, there is a portion of the cooling member 307 that extends outside the device 51. The ventilation holes 317 are located in this portion of the cooling member 307 that extends outside the device 51.

[0089] Referring now more particularly to FIGS. 5 - 7, there is shown an example of a device 51 configured to heat an aerosol-generating material and volatilize at least one of its components to form an aerosol, typically for inhalation. The device 51 is a heating device that heats the aerosol-generating material without burning it to release a compound.

[0090] The first end 53 may here also be referred to as the mouthpiece or proximal end 53 of the device 51, and the second end 55 may here also be referred to as the distal end of the device 51. The device 51 has an on / off button 57 that allows the device 51 as a whole to be turned on and off in response to user requirements.

[0091] The device 51 includes a housing 59 for positioning and protecting various internal components of the device 51. In the illustrated example, the housing 59 includes an integral sleeve 11 that surrounds the device 51 and is closed at the top by an upper panel 17 that generally defines the "top" of the device 51 and at the bottom by a bottom panel 19 that generally defines the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a set of opposing side panels in addition to the upper panel 17 and the bottom panel 19.

[0092] The upper panel 17 and / or the bottom panel 19 may be removably fixed to the integral sleeve 11 so as to be easily accessible inside the device 51, or may be "permanently" fixed to the integral sleeve 11 so that, for example, a user cannot access the inside of the device 51. In one example, the panels 17 and 19 are made of a plastic material including glass fiber-reinforced nylon formed, for example, by injection molding, and the integral sleeve 11 is made of aluminum, although other materials and other manufacturing methods may be used.

[0093] The upper panel 17 of the device 51 has an opening 20 at the suction port end 53 of the device 51, through which generated products 101, 301 including a tubular substrate are inserted into and removed from the device 51 by the user during use.

[0094] The housing 59 has a heater device 23, a control circuit 25, and a power supply 27 located or fixed therein. In this example, the heater device 23, the control circuit 25, and the power supply 27 are adjacent to each other laterally (i.e., adjacent when viewed from the end), and the control circuit 25 is located between the heater device 23 and the power supply 27, although other arrangements are possible.

[0095] The control circuit 25 may include a controller such as a microprocessor device configured and arranged to control the heating of the tubular substrate in the generated products 101, 301, as further described below.

[0096] The power source 27 may be, for example, a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically connected to the heater device 23 to supply power when needed and under the control of the control circuit 25, and heats the tubular substrate of the product to be generated (in order to volatilize the aerosol-forming composition without burning it as described).

[0097] The advantage of arranging the power source 27 adjacent to the side of the heater device 23 is that a physically large power source 25 can be used without making the entire device 51 overly long. Naturally, generally a physically large power source 25 has a large capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.), and the battery life of the device 51 can be extended.

[0098] In one example, the heater device 23 is in the shape of a substantially hollow cylindrical tube having a hollow internal heating chamber 29, and articles 101, 301 containing the tubular substrate are inserted into the chamber for heating during use. In the illustrated assembly, no parts of the heater device are inserted into the hollow tubes of the tubular substrates 103, 303. (Of course, there are no parts of the device 51 inserted into the hollow tubes of the tubular substrates 103, 303.) Different configurations of the heater device 23 are possible. For example, the heater device 23 may include a single heating element, or may be formed of a plurality of heating elements aligned along the longitudinal axis of the heater device 23. The or each heating element may be annular or tubular, or may be at least partially annular or partially tubular at its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating devices are also possible, including, for example, induction heating, an infrared heater element that heats by infrared irradiation, or a resistive heating element formed, for example, by a resistive electrical winding. In another example (not shown), the heater may be in the form of blades or rods inserted into the hollow tubes of the tubular substrates 103, 303.

[0099] In one particular example, the heater device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater device 23 is dimensioned such that when the articles 101, 301 are inserted into the device 51, substantially the entire length of the tubular substrates 103, 303 of the articles 101, 301 are inserted into the heater device 23.

[0100] The or each heating element may be configured such that selected regions of the tubular substrate are heated independently, as needed, for example, in sequence (over time as described above) or together (simultaneously).

[0101] The heater device 23 of this example is surrounded by a heat insulating material 31 along at least a part of its length. The heat insulating material 31 serves to reduce the heat passing from the heater device 23 to the outside of the device 51. This generally helps to reduce heat loss and thus helps to suppress the power required for the heater device 23. Also, the heat insulating material 31 helps to keep the outside of the device 51 cool during the operation of the heater device 23. In one example, the heat insulating material 31 may be a sleeve with a double wall, which provides a low pressure region between the two walls of the sleeve. That is, the heat insulating material 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially degassed to minimize heat transfer by conduction and / or convection. Other configurations of the insulating material 31 are possible, including using, in addition to or instead of the double-walled sleeve, a heat insulating material that includes, for example, any suitable foamed material.

[0102] The housing 59 may further include various internal support structures 37 for supporting not only the heating device 23 but also all internal components.

[0103] The device 51 further includes a collar 33 that extends around the opening 20 and projects into the interior of the housing 59 therefrom, and a substantially tubular chamber 35 that is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f that are spaced along the outer surface of the chamber 35 and are respectively disposed around the outer surface of the chamber 35. When the products 101, 301 are inserted into at least a part of the length of the hollow chamber 35 of the device 51, a gap is formed between the hollow chamber 35 and the products 101, 301. The gap 36 covers at least a part of the cooling segment 307 and exists all around the circumference of the products 101, 301.

[0104] Color 33 is disposed circumferentially around the opening 20 and includes a plurality of protrusions 60 protruding into the opening 20. The protrusions 60 take up space within the opening 20 such that the opening width of the opening is smaller at the location of the protrusions 60 than the opening width of the opening 20 at a position without the opening 60. The protrusions 60 are configured to engage with the generated products 101, 301 inserted into the device to assist in fixing the generated products within the device 51. The opening spaces (not shown) defined by adjacent pairs of protrusions 60 and the generated products 101, 301 form a ventilation path around the outer circumference of the generated products 101, 301. These ventilation paths allow the hot vapor escaping from the generated products to exit the device 51 and allow cold air to flow into the device 51 around the generated products 101, 301 within the void 36.

[0105] During operation, the generated products 101, 301 are removably inserted into the insertion point 20 of the device 51 as shown in FIGS. 5 - 7. Referring particularly to FIG. 6, in one example, the tubular substrates 103, 303 located towards the distal ends 115, 315 of the generated products 101, 301 are entirely housed within the heater device 23 of the device 51. The proximal ends 113, 313 of the generated products 101, 301 extend from the device 51 and function as a mouthpiece assembly for the user.

[0106] During operation, the heater device 23 heats the generated products 101, 301 and volatilizes at least one component of the aerosol - forming composition from the tubular substrates 103, 303.

[0107] The main flow path for the components heated and volatilized from the tubular substrates 103, 303 is axial through the generated products 101, 301. In some examples, such as the example shown in FIGS. 5 - 7 where no components of the device 51 are disposed inside the hollow tubes of the tubular substrates 103, 303 during use, the components heated and volatilized from the tubular substrates flow through the hollow tubes. The heated and volatilized components then pass through the inner chambers of the cooling segments 107, 307, through the filter segments 109, 309, and through the suction - end segments 111, 313 to flow to the user.

[0108] In one example, the temperature of the heated and volatilized components emitted from the tubular substrate is between 60°C and 250°C, which is higher than the acceptable suction temperature for the user. When the heated and volatilized components move through the cooling segments 107, 307, the components cool down, and some of the volatilized components liquefy on the inner surfaces of the cooling segments 107, 307.

[0109] In the example of the generated product 301 shown in FIGS. 3 and 4, cold air can enter the cooling segment 307 through the ventilation holes 317 formed in the cooling segment 307. This cold air mixes with the heated and volatilized components and further cools the heated and volatilized components.

[0110] Aerosol-forming material

[0111] The amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventor has found that a material with a thickness of 0.2 mm is particularly suitable. The amorphous solid may include two or more layers, and the thickness described herein means the total thickness of these layers.

[0112] The inventor has confirmed that if the aerosol-forming amorphous solid is too thick, the heating efficiency will be impaired. This has an adverse effect on the power consumption during use. Conversely, if the aerosol-forming amorphous solid is too thin, handling including the formation of aerosol during manufacture and use becomes difficult, and very thin materials are difficult to cast and are prone to breakage.

[0113] The inventor has confirmed that the thickness of the amorphous solid defined herein optimizes the material properties in view of these conflicting matters.

[0114] The thickness defined herein is the average thickness of the material. In some cases, the thickness of the amorphous solid may vary within 25%, 20%, 15%, 10%, 5% or 1%.

[0115] In some cases, the amorphous solid may contain 1 to 60 wt% of a gelling agent, and these weights are calculated on a dry weight basis.

[0116] Preferably, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 27 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 1 to 50 wt%, 5 to 40 wt%, 10 to 30 wt% or 15 to 27 wt% of a gelling agent.

[0117] Preferably, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 27 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 5 to 40 wt%, 10 to 30 wt% or 15 to 27 wt% of a gelling agent.

[0118] In some embodiments, the gelling agent includes a hydrophilic colloid. In some embodiments, the gelling agent includes one or more compounds selected from alginates, pectins, starches (and derivatives), celluloses (and derivatives), rubbers, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum acacia, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and / or pectin and may be mixed with a curing agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may include calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0119] In some embodiments, the gelling agent comprises alginate, and the alginate is included in the amorphous solid in an amount of 10 to 30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent included in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent such as pectin.

[0120] In some embodiments, the amorphous solid may include a gelling agent that includes carrageenan.

[0121] Preferably, the amorphous solid may include an aerosol generating agent in an amount of about 5 wt%, 10 wt%, 15 wt% or 20 wt% to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt% or 35 wt% (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may include an aerosol generating agent in an amount of 5 to 60 wt%, 10 to 50 wt% or 20 to 40 wt%. In some cases, the aerosol generating agent includes one or more compounds selected from erythritol, propylene glycol, glycerin, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises glycerin, consists essentially of glycerin or consists of glycerin. The inventors have confirmed that if the content of the plasticizer is too high, the amorphous solid absorbs water and becomes a material that does not provide a suitable consumer experience during use. The inventors have confirmed that if the content of the plasticizer is too low, the amorphous solid becomes brittle and easily breakable. The amounts of plasticizer specified herein impart flexibility to the amorphous solid so that the amorphous solid sheet can be wound around a bobbin useful for the manufacture of aerosol generating articles.

[0122] In some cases, the amorphous solid may contain a flavoring agent. Preferably, the amorphous solid may contain up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt% or 5 wt% of the flavoring agent. In some cases, the amorphous solid may contain at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt% or 30 wt% of the flavoring agent (calculated on a dry weight basis). For example, the amorphous solid may contain 0.1 to 60 wt%, 1 to 60 wt%, 5 to 60 wt%, 10 to 60 wt%, 20 to 50 wt% or 30 to 40 wt% of the flavoring agent. In some cases, the flavoring agent (if any) contains menthol, consists essentially of menthol or consists of menthol. In some cases, the amorphous solid does not contain a flavoring agent.

[0123] In some cases, the amorphous solid additionally contains an active substance. For example, in some cases, the amorphous solid additionally contains tobacco material and / or nicotine. For example, the amorphous solid may additionally contain powdered tobacco and / or nicotine and / or tobacco extract. In some cases, the amorphous solid may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the active substance. In some cases, the amorphous solid may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the tobacco material and / or nicotine.

[0124] In some cases, the amorphous solid contains an active substance such as a tobacco extract. In some cases, the amorphous solid may contain 5 to 60 wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the amorphous solid may contain about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 55 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the tobacco extract. For example, the amorphous solid may contain 5 to 60 wt%, 10 to 55 wt% or 25 to 55 wt% of the tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid contains 1 wt%, 1.5 wt%, 2 wt% or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine. In some cases, there is no nicotine in the amorphous solid other than that obtained from the tobacco extract.

[0125] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such cases, the amorphous solid may contain about 1 wt%, 2 wt%, 3 wt% or 4 wt% to about 20 wt%, 15 wt%, 10 wt% or 5 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20 wt% or 2 to 5 wt% of nicotine.

[0126] In some cases, the total content of the active substance and / or flavorant may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt% or 30 wt%. In some cases, the total content of the active substance and / or flavorant may be less than about 80 wt%, 70 wt%, 60 wt%, 50 wt% or 40 wt% (all calculated on a dry weight basis).

[0127] In some cases, the total content of tobacco material, nicotine and flavoring may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt% or 30 wt%. In some cases, the total content of tobacco material, nicotine and flavoring may be less than about 80 wt%, less than 70 wt%, less than 60 wt%, less than 50 wt% or less than 40 wt% (all calculated on a dry weight basis).

[0128] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, less than 12 wt% or less than 10 wt% water calculated on a wet weight basis (WWB). In some cases, the hydrogel may contain at least about 1 wt%, 2 wt% or at least about 5 wt% water. In some cases, the amorphous solid contains from about 1 wt% to about 15 wt% or from about 5 wt% to about 15 wt% water calculated on a wet weight basis. Preferably, the moisture content of the amorphous solid is from about 5 wt%, 7 wt% or 9 wt% to about 15 wt%, 13 wt% or 11 wt% (WWB), most preferably about 10 wt%.

[0129] The amorphous solid may be made from a gel, and the gel may additionally contain a solvent present in an amount of 0.1 - 50 wt%. However, the inventor has confirmed that adding a solvent in which the flavoring is soluble reduces the stability of the gel and the flavoring crystallizes out of the gel. Thus, in some cases, the gel does not contain a solvent in which the flavoring is soluble.

[0130] In some embodiments, the amorphous solid contains a filler of less than 60 wt%, such as from 1 wt% to 60 wt% or from 5 wt% to 50 wt% or from 5 wt% to 30 wt% or from 10 wt% to 20 wt%.

[0131] In other embodiments, the amorphous solid contains a filler of less than 20 wt%, preferably less than 10 wt% or less than 5 wt%. In some cases, the amorphous solid contains less than 1 wt% filler and in some cases contains no filler.

[0132] When a filler is included, it may include one or more of suitable inorganic adsorbents such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate and molecular sieves. The filler may include one or more organic fillers such as wood pulp, cellulose and cellulose derivatives. In certain cases, the amorphous solid contains calcium carbonate such as chalk. The filler may include one or more organic fillers such as wood pulp, cellulose and cellulose derivatives. In certain cases, the amorphous solid contains calcium carbonate such as chalk.

[0133] In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous filler such as wood pulp, hemp fiber, cellulose or cellulose derivative. Without wishing to be bound by any theory, it has been confirmed that incorporating a fibrous filler into the amorphous solid increases the tensile strength of the material. This is particularly advantageous in examples where the amorphous solid is provided as a sheet, such as when the amorphous solid sheet surrounds a rod made of an aerosolizable material.

[0134] In some embodiments, the amorphous solid does not contain tobacco fibers. In certain embodiments, the amorphous solid does not contain fibrous materials.

[0135] In some embodiments, the aerosol generating material does not contain tobacco fibers. In certain embodiments, the aerosol generating material does not contain fibrous materials.

[0136] In some embodiments, the aerosol generating substrate does not contain tobacco fibers. In certain embodiments, the aerosol generating substrate does not contain fibrous materials.

[0137] In some embodiments, the aerosol generating article does not contain tobacco fibers. In certain embodiments, the aerosol generating article does not contain fibrous materials.

[0138] In some cases, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol generating agent, one or more active substances (such as tobacco material and / or nicotine source), water and optionally a flavorant.

[0139] The amorphous solid may have any suitable areal density such as 30 g / m 2 ~120 g / m 2 In some embodiments, the aerosol generating material may have an areal density of about 30 - 70 g / m 2 or about 40 - 60 g / m 2 In some embodiments, the amorphous solid may have an areal density of about 80 - 120 g / m 2 or about 70 - 110 g / m 2 or particularly about 90 - 110 g / m 2 of areal density.

[0140] In some examples, the sheet-like amorphous solid may have a tensile strength of about 200 N / m to about 900 N / m. In some examples where the amorphous solid does not contain a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m or 200 N / m to 300 N / m or about 250 N / m. Such embodiments are particularly useful when the amorphous solid is engraved to form the second aerosol-forming composition. In some examples where the amorphous solid contains a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m or 700 N / m to 900 N / m or about 800 N / m. Such tensile strength is particularly suitable when the amorphous solid is disposed (in the first and / or second aerosol-forming composition) as part of an annular substrate.

[0141] Method for manufacturing a tubular substrate

[0142] The substrate may be manufactured by a method comprising: (a) forming a slurry comprising components of a first aerosol-forming composition or a precursor thereof; (b) applying the slurry to a sheet-like carrier; (c) curing the slurry to form a gel; (d) drying to form an amorphous solid; and (e) rolling to form a tube.

[0143] Forming the slurry layer in step (b) may include, for example, spraying, casting or extruding the slurry. In some cases, the layer is formed by electrospraying the slurry. In some cases, the layer is formed by casting a sleeve.

[0144] In some cases, steps (b) and / or (c) and / or (d) may be carried out at least partially simultaneously (e.g., while electrospraying). In some cases, these steps may be carried out in sequence.

[0145] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, for example about 14 to 16 Pa·s at 46.5°C.

[0146] The step (c) of curing the gel may include adding a curing agent to the slurry. For example, the slurry may include sodium alginate, potassium alginate or ammonium alginate as a gel precursor and a calcium source (such as calcium chloride), and may include a curing agent added to the slurry to form a calcium alginate gel.

[0147] The total amount of the curing agent such as the calcium source may be 0.5 to 5 wt% (calculated on a dry weight basis). The inventor has discovered that if the addition amount of the curing agent is too small, the resulting gel cannot stabilize the gel components, and as a result, these components will spill out of the gel. The inventor has discovered that if the addition amount of the curing agent is too large, the resulting gel will be sticky and difficult to handle.

[0148] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10 - 600 kDa). Alginic acid is a copolymer in which β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) are linked by (1,4)-glycosidic bonds to form a polysaccharide. The addition of calcium crosslinks the alginate to form a gel. The inventors have discovered that alginates with a high G monomer content readily form gels by adding a calcium source. Thus, in some cases, the gel precursor may comprise an alginate in which at least 40%, 45%, 50%, 55%, 60% or 70% of the monomer units of the alginic acid copolymer are α-L-guluronic acid (G) units.

[0149] In certain particular cases, both the first and second aerosol-forming compositions comprise an amorphous solid. One contains a flavorant and the other contains a tobacco material. Optionally, one contains a flavorant and neither a tobacco material nor nicotine, and the second composition contains a tobacco material and no flavorant.

[0150] The slurry itself may also form part of the present invention. In some cases, the slurry solvent may consist essentially of water or may consist of water. In some cases, the slurry may contain about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% of a solvent (WWB).

[0151] When the solvent consists of water, the content of the slurry by dry weight coincides with the content of the amorphous solid by dry weight. Thus, the discussions herein regarding the solid composition are to be considered as being disclosed in combination with the slurry aspect of the present invention.

[0152] Exemplary embodiments

[0153] In some embodiments, the amorphous solid comprises menthol.

[0154] Certain embodiments that include menthol-containing amorphous solids are particularly suitable for inclusion in aerosol generating articles / assemblies as scored sheets. In such embodiments, the amorphous solid has a composition (DWB) of a gelling agent (preferably including alginate, more preferably including alginate and pectin) in an amount of about 20 wt% to about 40 wt% or about 25 wt% to 35 wt%, menthol in an amount of about 35 wt% to about 60 wt% or about 40 wt% to 55 wt%, and an aerosol generating agent (preferably including glycerin) in an amount of about 10 wt% to about 30 wt% or about 15 wt% to about 25 wt% (DWB).

[0155] In one embodiment, the amorphous solid includes about 32 - 33 wt% of an alginate / pectin gelling agent blend, about 47 - 48 wt% of a flavorant, and about 19 - 20 wt% glycerin aerosol generating agent (DWB).

[0156] The amorphous solids of these embodiments may have any suitable moisture content. For example, the amorphous solid may have a moisture content of about 2 wt% to about 10 wt%, or about 5 wt% to about 8 wt% or about 6 wt%.

[0157] As described above, the amorphous solids of these embodiments may be included in the aerosol generating articles / assemblies as scored sheets (i.e., within the second aerosol forming composition). The scored sheets may be provided blended with cut tobacco in the generating articles / assemblies. Alternatively, the amorphous solid may be provided as an unscored sheet (within the first or second aerosol forming composition). Preferably, the scored or unscored sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0158] ​Certain embodiments of the menthol-containing amorphous solid are particularly suitable for inclusion in an aerosol-generating article / assembly as a sheet (i.e., in a first or second aerosol-forming composition as part of a tubular substrate), for example, a sheet surrounding a rod of an aerosolizable material (e.g., a second aerosol-forming composition such as tobacco). In these embodiments, the amorphous solid has a composition (DWB) of a gelling agent (preferably including alginate, more preferably including alginate and pectin) in an amount of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt%, menthol in an amount of about 10 wt% to about 50 wt% or about 15 wt% to 40 wt%, an aerosol-generating agent (preferably including glycerin) in an amount of about 5 wt% to about 40 wt% or about 10 wt% to about 35 wt%, and any filler in an amount of 60 wt% or less, for example, 5 wt% to 20 wt% or about 40 wt% to 60 wt% (DWB).

[0159] In one of these embodiments, the amorphous solid includes about 11 wt% of an alginate / pectin gelling agent blend, about 56 wt% of a wood pulp filler, about 18% of a menthol flavorant, and about 15 wt% of glycerin (DWB).

[0160] In another example of these embodiments, the amorphous solid includes about 22 wt% of an alginate / pectin gelling agent blend, about 12 wt% of a wood pulp filler, about 36 wt% of a menthol flavorant, and about 30 wt% of glycerin (DWB).

[0161] As described above, the amorphous solid of these embodiments may be included as a sheet (which may be part of a tubular substrate). In one embodiment, the sheet is provided on a carrier including paper. In one embodiment, the sheet is provided on a carrier including a metal foil, preferably an aluminum metal foil. In this embodiment, the amorphous solid is in contact with the metal foil.

[0162] In one embodiment, the sheet forms part of a laminate material having layers (preferably including paper) attached to the top and bottom surfaces of the sheet. Preferably, the sheet of the amorphous solid has a thickness of about 0.015 mm to about 1 mm.

[0163] In some embodiments, the amorphous solid comprises a flavorant that does not include menthol. In these embodiments, the amorphous solid has a composition (DWB) such as a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 35 wt%, or about 20 wt% to about 35 wt%, a flavorant in an amount of about 0.1 wt% to about 40 wt, about 1 wt% to about 30 wt%, or about 1 wt% to about 20 wt%, or about 5 wt% to about 20 wt%, an aerosol generating agent (preferably including glycerin) in an amount of about 15 wt% to about 75 wt%, or about 30 wt% to about 70 wt%, or about 50 wt% to about 65 wt%, and an optional filler (preferably wood pulp) in an amount of less than about 60 wt%, or less than about 20 wt%, or less than about 10 wt%, or about 5 wt% (preferably the amorphous solid does not include a filler).

[0164] In one of these embodiments, the amorphous solid comprises about 27 wt% alginate gelling agent, about 14 wt% flavorant, and about 57 wt% glycerin aerosol generating agent (DWB).

[0165] In another example of these embodiments, the amorphous solid comprises about 29 wt% alginate gelling agent, about 9 wt% flavorant, and about 60 wt% glycerin (DWB).

[0166] The amorphous solids of these embodiments may optionally be included in an aerosol generating article / assembly as a scored sheet (i.e., as part of the first and / or second aerosol-forming composition) blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in an aerosol generating article / assembly (within the first and second aerosol-forming compositions) as a sheet such as a sheet surrounding a rod made of an aerosolizable material (e.g., a second aerosol-forming composition such as tobacco) (as part of a tubular substrate).

[0167] In some embodiments, the amorphous solid contains tobacco extract. In these embodiments, the amorphous solid has a composition (DWB) such as a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt% or about 15 wt% to about 25 wt%, tobacco extract in an amount of about 30 wt% to about 60 wt or about 40 wt% to 55 wt% or about 45 wt% to about 50 wt%, and an aerosol generating agent (preferably including glycerin) in an amount of about 10 wt% to about 50 wt% or about 20 wt% to about 40 wt% or about 25 wt% to about 35 wt% (DWB). In one embodiment, the amorphous solid contains about 20 wt% of an alginate gelling agent, about 48 wt% of Virginia tobacco extract, and about 32 wt% of glycerin (DWB).

[0168]

[0169] The amorphous solids of these embodiments may have any suitable moisture content. For example, the amorphous solid may have a moisture content of about 5 wt% to about 15 wt%, or about 7 wt% to about 13 wt%, or about 10 wt%.

[0170] The amorphous solids of these embodiments may optionally be included in an aerosol generating article / assembly as a scored sheet (i.e., the first and / or second aerosol-forming composition) blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in an aerosol generating article / assembly (i.e., within the first and second aerosol-forming compositions) as a sheet such as a sheet surrounding a rod made of an aerosolizable material (e.g., a second aerosol-forming composition such as tobacco), such as a tubular substrate. Preferably, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0171] ​The slurry for forming this amorphous solid may also form part of the present invention. In some cases, the slurry may have an elastic modulus (also referred to as storage elastic modulus) of about 5 to 1200 Pa, and in some cases, the slurry may have a viscosity coefficient (also referred to as loss coefficient) of about 5 to 600 Pa.

[0172] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5 °C, for example about 14 to 16 Pa·s at 46.5 °C.

[0173] Definition

[0174] The active substance used in the present invention is a physiologically active material that is a material intended to achieve or enhance a physiological reaction. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active substance may include one or more of the components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0175] In some embodiments, the active substance includes nicotine.

[0176] In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0177] As described herein, the active substance may include one or more of the components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0178] Cannabinoids are a group of natural or synthetic compounds that act on intracellular cannabinoid receptors (i.e., CB1 and CB2) in the brain to suppress neurotransmitter release. Cannabinoids may be naturally occurring from plants such as cannabis (phytocannabinoids), or naturally occurring from animals (zoocannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis seeds exhibit at least 85 different phytocannabinoids and are classified into subclasses including cannaguerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols, cannabinodiols and other cannabinoids. Cannabinoids found in the genus Cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabinocyclol (CBL), cannabinovaline (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA) and tetrahydrocannabivarinic acid (THCV A).

[0179] As described herein 、 The active substance may include a plant (botanicals / botanicals) or its components, derivatives or extracts, or may be derived therefrom. As used herein, the term "plant" botanicals / botanicals) includes, but is not limited to, any material derived from plants such as extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Separately body(plants / plants) the material may contain active compounds naturally present in the synthesized plant 、 The material (botanical / botanical) The material may contain active compounds naturally present in the synthesized plant. The material isIt may be in the form of liquids, gases, solids, powders, dusts, crushed particles, grains, pellets, chips, strips, sheets, etc. Plants (botanicals / botanicals) Examples of plants include tobacco, eucalyptus, Cryptomeria japonica, Pteridium aquilinum var. latiusculum, cocoa, cannabis, Perilla frutescens, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, Artemisia princeps, hibiscus, laurel, licorice, matcha, mate tea, orange peel, papaya, rose, sage, green tea or black tea, thyme, star anise, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, Nasturtium officinale flower, vanilla, Aspergillus oryzae, Cichorium endivia, turmeric, curcumin, sandalwood, silantro, bergamot, neroli, Citrus junos, blackcurrant, Lithospermum erythrorhizon, pimento, mace, Damiana, Sarcandra glabra, olive, lemon balm, lemon basil, chive, Perilla frutescens, vervain, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint species (Mentha canadensis, Mentha spicata, Mentha arvensis, Mentha piperita, Mentha suaveolens, Mentha × villosa, Mentha × gracilis, Mentha × cardiaca, Mentha × villosa, Mentha × piperita, Mentha pulegium, Mentha × gracilis and Mentha × rotundifolia).

[0180] In some embodiments, the plant is selected from eucalyptus, Cryptomeria japonica, cocoa and hemp.

[0181] In some embodiments, the plant is selected from rooibos and Perilla frutescens.

[0182] As used herein, the terms "flavoring agent" and "flavor enhancer" are permitted by local regulations and are used to produce tastes, scents, or other somatic sensory stimuli desired by adult consumers. They are natural-occurring flavor materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phyllostachys bambusoides leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, kojic acid, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, Chinese angelica, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chaat, naswa) - Mint, cumin, cardamom, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, neroli, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pimento, ginger, coriander, coffee, mugwort, peppermint oil from any species of the genus Mentha. Eucalyptus, camphor tree, cocoa, lemongrass, rooibos, flax, ginkgo, nettle, hibiscus, laurel, mate tea, orange peel, rose, tea such as green tea or black tea, thyme, myrtle, nasturtium flower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, artemisia, turmeric, cilantro, ginger lily, blackcurrant, bugbane, pimento, mace, damiana, sweet cicely, olive, lemon balm, lemon basil, chive, perilla, vervain, tarragon, limonene, thymol, camphene), seasonings, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.) and other additives such as charcoal, chlorophyll, minerals, plants or odor eliminators. These materials may be imitation, synthetic or natural ingredients, or blends thereof. They may be in any suitable form such as a liquid such as an oil, a solid such as a powder or a gas.

[0183] The flavoring preferably contains one or more mint flavorings and preferably contains peppermint oil from any species of the genus Mentha. The flavoring preferably contains, consists essentially of, or consists of menthol.

[0184] In some embodiments, the flavoring contains menthol, spearmint and / or peppermint.

[0185] In some embodiments, the flavoring contains flavor components of cucumber, blueberry, citrus and / or redberry.

[0186] In some embodiments, the flavorant includes eugenol.

[0187] In some embodiments, the flavorant includes flavor components extracted from tobacco.

[0188] In some embodiments, the flavorant includes flavor components extracted from cannabis.

[0189] In some embodiments, the flavorant may include a sensory agent, which is chemically induced and recognized by stimulation of the trigeminal nerve (the fifth cranial nerve) in addition to or instead of the aroma or taste nerves, and they may include agents that give a heating, cooling, tingling, or numbing sensation. Suitable heat agents include, but are not limited to, vanillyl ethyl ether, and suitable coolants include, but are not limited to, eucalyptol and WS-3.

[0190] As used herein, the term "aerosol generator" means an agent that promotes the generation of an aerosol. The aerosol generator may promote the generation of an aerosol by promoting initial vaporization and / or condensation of a gas into a solid and / or liquid aerosol that can be aspirated.

[0191] Suitable aerosol generators include, but are not limited to, polyols such as erythritol, sorbitol, glycerin, and glycols such as propylene glycol or triethylene glycol, monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerin derivatives, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, and myristic acid esters including isopropyl myristate, methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate, and other esters such as aliphatic carboxylic acid esters. The aerosol generator preferably has a composition that does not dissolve menthol. The aerosol generator preferably contains glycerin, consists essentially of glycerin, or consists of glycerin.

[0192] In this specification, the term "tobacco material" means any material including tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco or tobacco substitutes. The tobacco material may include one or more of powdered tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stalks, reclaimed tobacco and / or tobacco extracts.

[0193] The tobacco used to make the tobacco material may be any suitable tobacco including single grades or blends including Virginia and / or Burley and / or Oriental, cut scraps or whole leaves. It may also be other processed stalk materials such as tobacco particles "fine powder" or dust, expanded tobacco, stalks, expanded stalks and cut and rolled stalks. The tobacco material may be powdered tobacco or reclaimed tobacco material. The reclaimed tobacco material may be tobacco fiber and may be formed by casting, Ford linear papermaking methods with subsequent addition of tobacco extracts or extrusion.

[0194] In this specification, the terms "volatile substances" and "aerosolizable components" mean any component of the inhaled aerosol including, but not limited to, aerosol generators, flavorants, tobacco flavorants and aromas and nicotine. Terms such as "volatile substances derived from amorphous solids" and "aerosolizable components derived from amorphous solids", "tobacco volatiles" etc. represent the members of the aerosol generating article in which the volatile substances / aerosolizable components are disposed or obtained.

[0195] In this specification, the term "rod" means an elongate body generally in a shape suitable for use in an aerosol generating assembly. In some cases the rod is substantially cylindrical.

[0196] Weight percentages (expressed as wt%) reported herein are calculated on a dry weight basis unless otherwise stated. All weight ratios are also calculated on a dry weight basis. Weights expressed on a dry weight basis refer to the total amount of extract or slurry or material other than water, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages on a wet weight basis refer to all ingredients, including water.

[0197] As used herein, "heat profile," "heating profile," and the like, refer to temperature exposure over time. Thus, "different" heat profiles may vary in the duration of heating, initiation or termination of heating, the time or rate at which the temperature is changed. Also, "different" heat profiles may vary, for example, in the maximum and minimum temperatures employed, or the temperature at any given time may be different.

[0198] To avoid any doubt, in the specification, "comprises" is used to define the invention or a feature of the invention. When used in this sense, the term "substantially consisting of" is used in place of "comprises." Also disclosed are embodiments that can be defined using "consists essentially of" or "consists of." When a material "comprises" certain features, it means that those features are contained, included or retained in the material.

[0199] The above-described embodiments should be understood as illustrative examples of the present invention. It should be understood that any feature described in any one embodiment may be used alone or in combination with other features described, and may be used in combination with one or more features of any of the other embodiments or in any combination of any of the other embodiments. Moreover, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, which is defined in the appended claims.

Claims

1. An aerosol generating article for use in an aerosol generating assembly, wherein the aerosol generating article comprises: (i) a tubular substrate comprising a first aerosol-forming composition containing an amorphous solid, the amorphous solid containing an active substance and / or a flavorant; and (ii) a second aerosol-forming composition different from the first aerosol-forming composition; The aerosol generating article, wherein the amorphous solid contains 5 wt% to 80 wt% of an aerosol generating agent.

2. The aerosol generating article according to claim 1, wherein the amorphous solid contains a tobacco extract.

3. The aerosol generating article according to claim 1 or 2, wherein the amorphous solid contains nicotine.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the amorphous solid contains less than 20 wt% of water.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the active substance comprises a plant or is derived from the plant.

6. The aerosol generating article according to claim 5, wherein the plant is a material derived from a plant body.

7. The aerosol generating article according to claim 6, wherein the material derived from the plant body contains an extract, leaf, bark, fiber, stem, root, seed, flower, fruit, pollen, shell or pod.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the amorphous solid is a dry gel.

9. The aerosol generating article has first and second sections spaced along the length of the tube of the tubular substrate, and the amount of the first aerosol-forming composition and / or the amount of the second aerosol-forming composition provided in the first section is different from the respective amounts provided in the second section. The aerosol generating article according to any one of claims 1 to 8.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the tubular substrate comprises an amorphous solid sheet wound to form a tube.

11. An aerosol generating assembly comprising the aerosol generating article according to any one of claims 1 to 10 and a device comprising a heater configured to heat without burning the amorphous solid.

12. The aerosol generating assembly according to claim 11, wherein the aerosol generating assembly is configured such that the heater is disposed outside the tube of the tubular substrate.

13. A method for manufacturing a tubular substrate, wherein the method comprises (a) forming a slurry containing components of a first aerosol-forming composition or a precursor thereof; (b) applying the slurry to a sheet-like carrier; (c) curing the slurry to form a gel; (d) drying to form an amorphous solid; (e) rounding to form a tube, and the amorphous solid contains 5 wt% to 80 wt% of an aerosol-generating agent, and an active substance and / or a flavoring agent. A method for manufacturing a tubular substrate.

Images