Plugs containing combustion suppressant additives and their use

Abstract

The present invention relates to an article (1, 110) for use in a non-combustible aerosol delivery system, the article comprising a plug (7) containing a burn-suppressing additive. The present invention also relates to methods of making and using said article.

Description

Field

[0001] The present invention relates to an article for use in a non-flammable aerosol delivery system, the article comprising a plug containing a flame-suppressing additive. The present invention further relates to methods of making and using the article.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these items by creating products that release compounds without combustion. Examples of such products are so-called "heat-and-burn" products or tobacco heating devices or products that release compounds by heating, but not burning, smoking material. Overview

[0003] According to a first aspect disclosed herein, there is provided an article for use in a non-combustion aerosol delivery system, the article comprising: a rod including an aerosol-forming material; and a plug including a burn-suppressing additive.

[0004] In some embodiments, a plug containing a burn suppressant additive is at the distal end of the article.

[0005] In some embodiments, a plug containing a burn-suppressing additive is adjacent to the rod of aerosol-forming material.

[0006] In some embodiments, a plug containing a burn-suppressing additive is in contact with the rod of aerosol-forming material.

[0007] In some embodiments, the burn suppressant additive is an alkali metal salt optionally selected from the group consisting of: sodium chloride, potassium chloride, sodium bromide, potassium bromide, and combinations thereof.

[0008] In some embodiments, the plug is formed from a sheet material, hi some embodiments, the sheet material is paper or a paper-like material.

[0009] In some embodiments, the sheet material comprises an amorphous solid material.

[0010] In some embodiments, the burn suppressant additive is incorporated into the sheet material.

[0011] In some embodiments, the burn suppressant additive is applied in a coating on the surface of the sheet material.

[0012] In some embodiments, the plug comprises a mass of amorphous solid material.

[0013] In some embodiments, the burn suppressant additive is incorporated into the amorphous solid material. In some embodiments, the amorphous solid material comprises about 3 wt % to about 60 wt % of the burn suppressant salt (on a dry weight basis).

[0014] In some embodiments, the burn suppressant additive is applied to a coating on the surface of the plug.

[0015] In some embodiments, the coating comprises from about 3 wt % to about 70 wt % (dry weight basis) of at least one burn suppressant additive.

[0016] In some embodiments, the coating comprises a binder selected from one or more of the group consisting of polyvinyl alcohol (PVA), gelatin, gums, gum acacia, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0017] In some embodiments, the coating comprises from about 10 wt% to about 97 wt% of at least one binder.

[0018] In some embodiments, the article comprises a heating material.

[0019] In some embodiments, the heating material is heatable by immersion using a fluctuating magnetic field to heat the aerosol-forming material.

[0020] In some embodiments, the heating material is in contact with the aerosol-forming material.

[0021] In some embodiments, the heating material is in contact with a plug that includes a burn suppressing additive.

[0022] In some embodiments, the aerosol-forming material comprises one or more of tobacco itself, a tobacco derivative, expanded tobacco, reconstituted tobacco, a tobacco extract, homogenized tobacco, or a tobacco substitute.

[0023] In some embodiments, the aerosol-forming material is in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted smoking material, a liquid, a gel, a gelled sheet, a powder, or a chunk.

[0024] In some embodiments, the aerosol-forming material comprises a non-tobacco material.

[0025] In some embodiments, plugs containing burn-suppressing additives exhibit a pressure drop of about 5 to about 40 mmWG.

[0026] In some embodiments, the plug containing the burn-suppressing additive has a concentration of about 0.1 to about 0.3 mg / mm 3 It has a bulk density between .

[0027] According to a second aspect disclosed herein, there is provided a non-combustible aerosol delivery system comprising an article according to the first aspect.

[0028] According to a third aspect disclosed herein, there is provided a method of making an article according to the first aspect, wherein a burn suppressant additive is incorporated into or applied to a surface of a plug, and the plug is incorporated into the article having a rod of aerosol-forming material.

[0029] In some embodiments, a plug is incorporated into the distal end of the article.

[0030] In some embodiments, the method includes collecting one or more sheets into a rod, wrapping the rod, and cutting it into separate sections to form plugs.

[0031] In some embodiments, the method includes the step of crimping the sheet before collecting it on the rod.

[0032] In some embodiments, the method includes gathering the sheet around a former and forming a hole through the plug.

[0033] In some embodiments, the method includes applying to a surface of the sheet material a coating that includes a burn suppressing additive.

[0034] In some embodiments, the method includes applying a coating to a surface of the plug that includes a burn-suppressing additive.

[0035] In some embodiments, the coating is formed by applying a precursor material, including a binder and a burn-suppressing additive, to a surface.

[0036] In some embodiments, the coating is applied to the surface using one or more processes selected from the group consisting of: spraying, painting, or printing.

[0037] According to a fourth aspect of the present disclosure, there is provided the use of a burn suppressant additive to suppress the burning of a plug in an article for use in a non-burning aerosol delivery system.

[0038] According to a fifth aspect disclosed herein, there is provided a plug for use in an article for use in a non-flammable aerosol delivery system, the plug comprising a flame-suppressing additive.

[0039] In some embodiments, the plug comprises a combustible material.

[0040] In some embodiments, the plug comprises one or more sheets of paper or paper-like material.

[0041] In some embodiments, the plug comprises a body of amorphous solid material.

[0042] In some embodiments, the plug is resistant to combustion when exposed to temperatures up to 300°C.

[0043] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures. [Brief explanation of the drawings]

[0044] [Figure 1] 1 is a cross-sectional side view of a first embodiment of an article comprising a plug containing a burn suppressing additive. [Figure 2] FIG. 2 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the aerosol-forming material of the article of FIG. 1. Detailed Description

[0045] The present invention seeks to provide an article for use in a non-combustible aerosol delivery system, the article comprising a rod of aerosol-forming material and a plug containing a fire-suppressing additive.

[0046] In some embodiments, the article has a downstream end that typically connects to or includes a mouthpiece and / or a filter, and an upstream end, also referred to as the distal end. In some embodiments, the article includes a plug containing a burn-suppressing additive at the distal end of the article. Alternatively or additionally, the plug containing the burn-suppressing additive may be located at a different location in the article.

[0047] The distal end plug can help prevent aerosol-forming material from being lost from the distal end of the article.

[0048] In some embodiments, the plug containing the burn-suppressing additive is adjacent to the rod of aerosol-forming material. In some embodiments, the plug containing the burn-suppressing additive is in contact with the aerosol-forming material.

[0049] In some embodiments, when the article is in a non-combustion aerosol delivery system during use, the heating element or heating material may contact the article or may be embedded within the article. In some configurations, the heating element or heating material may expose the plug containing the burn-suppressing additive to high temperatures. In some embodiments, the plug containing the burn-suppressing additive is adjacent to the heating element or heating material. In some embodiments, the plug containing the burn-suppressing additive is in contact with the heating element or heating material.

[0050] Therefore, it is desirable to ensure that the plug can resist combustion. If the plug is made of a material that can burn or deteriorate when exposed to high temperatures, one or more burn-suppressing additives are added to prevent such burning and / or deterioration.

[0051] Advantageously, the plug containing the burn suppressant additive may be formed from a non-plastic material, for example a cellulosic material such as paper or a sheet material containing an amorphous solid.

[0052] The inventors have discovered that adding at least one burn-suppressing additive to a plug provides burn-suppressing properties, making it much more difficult to ignite an item and preventing the item from burning due to the presence of the plug containing the burn-suppressing additive.

[0053] The present invention enjoys the advantage that the article may be able to withstand higher temperatures without burning, which in turn may allow it to emit more volatile material, which is desirable for end users of non-flammable aerosol delivery systems. Additionally, the present invention has the added advantage of being safer if a consumer attempts to ignite the article, as the present invention reduces the article's combustion.

[0054] Additionally, the plugs disclosed herein provide an environmentally friendly alternative to other plugs currently in use, which may include, for example, cellulose acetate or other plastic materials.

[0055] As described herein, the fire suppression properties can be achieved using salts such as NaCl, which are sustainable and available resources. Additionally, the plug can include paper or paper-like materials, or amorphous solid materials, as described herein. These materials can be sustainably sourced and are biodegradable. The biodegradability of the packaging is environmentally friendly and an attractive feature for consumers.

[0056] The plug can have an axial length of, for example, about 5 mm to about 20 mm, such as about 5 mm to about 15 mm or about 5 mm to about 12 mm.

[0057] The plug can have a circumference of about 17 mm to about 25 mm, for example, about 19 mm to about 24 mm or about 20 mm to about 23 mm.

[0058] The pressure drop across the plug can be at least about 5 mmWG, at least about 7 mmWG, at least about 10 mmWG, at least about 12 mmWG, or at least about 15 mmWG. Alternatively or additionally, the pressure drop across the plug can be less than about 60 mmWG, less than about 50 mmWG, or less than about 40 mmWG. For example, the pressure drop across the plug can be in the range of 10 to 50 mmWG, e.g., 12 to 40 mmWG or 15 to 30 mmWG. In some embodiments, a plug including a burn suppressing additive can exhibit a pressure drop of about 12 to about 40 mmWG.

[0059] In some embodiments, the pressure drop across the plug is at least about 1 mmWG per mm of axial length of the plug, e.g., at least about 1.2, 1.5, 1.8, or 2 mmWG per mm of axial length of the plug. In some embodiments, the pressure drop across the plug is less than about 4 mmWG per mm of axial length of the plug, e.g., less than about 3.5, 3.2, 3, or 2.5 mmWG per mm of axial length of the plug. For example, the pressure drop across the plug can be in the range of 1.0 to 4.0, or 1.5 to 3.5, or 2.0 to 3.0 mmWG per mm of axial length of the plug.

[0060] The plug should contain at least about 0.05 mg / mm 3 a bulk density of, for example, at least about 0.07 mg / mm 3 , at least about 0.1 mg / mm 3 or at least about 0.12 mg / mm 3 Alternatively or additionally, the plug may have a bulk density of about 0.3 mg / mm 3 Less than 0.27 mg / mm 3 Less than or about 0.25 mg / mm 3 For example, the plug may have a bulk density of about 0.05 to about 0.35 mg / mm 3 Between about 0.1 and about 0.3 mg / mm 3 Between about 0.15 and about 0.25 mg / mm 3 The plug may have a bulk density of between about 0.2 mg / mm 3 The bulk density may be

[0061] Plug body In some embodiments, the plug is formed from a biodegradable and sustainable material. In some embodiments, the plug containing the burn suppressant additive does not include materials that are considered to be plastic materials, including bioplastics such as cellulose acetate.

[0062] In some embodiments, the plug containing the burn suppressant additive is formed from sheet material. In particular, the plug may be at least partially formed from a gathered sheet or a gathered and crimped sheet. The plug containing the burn suppressant additive may also be formed by cutting the sheet material into longitudinal strips and gathering them into a rod.

[0063] In some embodiments, the plug may be formed from a combination of sheet material that includes a burn suppressing additive and sheet material that does not include the additive.

[0064] In some embodiments, the sheet material comprises a cellulosic material, hi some embodiments, the cellulosic material comprises at least 20%, 30%, 40%, or 50% of the sheet material.

[0065] In some embodiments, the sheet may comprise or consist essentially of paper or paper-like material. The paper or paper-like material may be between about 20 gsm and about 150 gsm, or between about 20 gsm and about 120 gsm. In some embodiments, the paper or paper-like material may be between about 25 gsm and about 35 gsm, or between about 55 gsm and 65 gsm.

[0066] In some embodiments, the sheet material may be formed from plant materials, including tobacco material, for example, the sheet material may be reconstituted tobacco material or similar material formed from other types of plants or plant materials.

[0067] In some embodiments, the plug containing the burn suppressant additive is formed from a fibrous material. In some embodiments, the fibrous material is a non-plastic material, e.g., the plug is not formed from cellulose acetate. The burn suppressant additive may be added to the fibrous material before it is formed into the plug. Alternatively or additionally, the burn suppressant additive may be added to the fibrous material after it is formed into the plug. For example, the burn suppressant additive may be added to one or more surfaces of the plug.

[0068] In some embodiments, for example, when the plug is formed from a sheet material, such as a cellulose-based material such as paper, an aerosol modifier described herein and / or an aerosol-forming material described herein is included in the plug. In some embodiments, the aerosol modifier and / or aerosol-forming material may be applied to the material forming the plug before it is formed. Alternatively or additionally, the aerosol modifier and / or aerosol-forming material may be applied to the formed plug.

[0069] The aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. At least 0.02 mg of aerosol-forming material may be applied to the plug per mm of axial length, e.g., at least 0.03, 0.04, or 0.05 mg of aerosol-forming material per mm of axial length. Less than 0.5 mg, e.g., less than 0.4 mg, less than 0.3 mg, less than 0.2 mg, or less than 0.1 mg of aerosol-forming material may be applied to the plug per mm of axial length. For example, about 0.02 to 0.5 mg, or about 0.05 to 0.4 mg of aerosol-forming material per mm of axial length of the plug can be applied to the plug. For example, about 0.02 to 0.5 mg, or about 0.05 to 0.4 mg of glycerin or propylene glycol per mm of axial length of the plug can be applied to the plug.

[0070] In some embodiments, the plug containing the burn suppressant additive is formed from an "amorphous solid material," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid material may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it.

[0071] The amorphous solid material can comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise 1-50 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid.

[0072] In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of polysaccharides such as alginate, pectin, starch (and derivatives), and cellulose (and derivatives); gums, silica or silicone compounds; clay; polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, chitosan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0073] In some embodiments, the gelling agent comprises alginate. In one embodiment, the alginate is present in the amorphous solid in an amount of 1-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0074] In some embodiments, the plug containing the burn suppressant additive may comprise an amorphous solid, which may include a gelling agent including carrageenan.

[0075] Suitably, the amorphous solid may comprise at least about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, or 40 wt%, and / or up to about 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, or 50 wt% of the aerosol-forming material (all calculated on a dry weight basis). For example, the amorphous solid may comprise 5-10 wt%, 20-70 wt%, 40-60 wt%, or 50-60 wt% of the aerosol-forming material.

[0076] As used herein, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0077] In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerin (VG), triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0078] The aerosol-forming material may act as a plasticizer. For example, the amorphous solid material may comprise 0.5-40 wt%, 3-35 wt%, or 10-25 wt% of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. The plasticizer content specified herein provides flexibility to the amorphous solid, allowing the amorphous solid sheet to be wound onto a bobbin, which is useful in the manufacture of plugs included in aerosol products.

[0079] In some embodiments, the amorphous solid material 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%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0080] In some embodiments, the plug containing the burn suppressant additive is formed from a sheet of amorphous solid material. In particular, the plug can be formed from a collected sheet containing the amorphous solid material, or from collected and crimped sheets. The plug can also be formed by cutting one or more sheets of the amorphous solid material into longitudinal strips and collecting them into a rod.

[0081] In other embodiments, the plug containing the burn suppressant additive may be formed as a solid mass comprising an amorphous solid material. For example, the plug may be a cylindrical mass or portion of an amorphous solid material.

[0082] In some situations, particularly if the plug is made of a relatively dense material, or is tightly compressed, or collected into a rod, the plug may restrict airflow therethrough. To alleviate this, perforations or holes can be provided. In some embodiments, perforations or holes are provided in the article downstream of the plug containing the burn-suppressing additive so that air can be drawn through the perforations into the consumable and into the aerosol-forming material. Alternatively or additionally, the holes or perforations can be provided to allow air to be drawn through the plug containing the burn-suppressing additive and into the consumable.

[0083] Combustion retardant additives Burn suppressing additives are additives that, when added to or incorporated into the plug, can reduce the tendency of the plug to burn when exposed to high temperatures.

[0084] The burn suppressing additive may be added to the plug before, during, or after the plug is formed or assembled. Thus, for example, the burn suppressing additive may be added to or incorporated into the material from which the plug is formed.

[0085] In some embodiments, the burn suppressing additive is added to or applied to the sheet material used to form the plug. The burn suppressing additive may be incorporated into the sheet material, for example, during its manufacture. Alternatively or additionally, the burn suppressing additive may be applied to the sheet material, for example, in the form of a coating containing the additive, as discussed in more detail below.

[0086] In some embodiments, the burn suppressant additive is added to or applied to the amorphous solid material used to form the plug. The burn suppressant additive may be incorporated into the amorphous solid material, for example, during the manufacturing of the amorphous solid material. Alternatively or additionally, the burn suppressant additive may be applied to the amorphous solid material, whether in sheet or bulk form. For example, the burn suppressant additive may be added to a coating applied to the surface of the amorphous solid material, as discussed in more detail below.

[0087] In some embodiments, the plug containing the burn suppressing additive comprises one or more burn suppressing additives in a total amount of at least about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt%, about 50 wt%, about 60 wt%, about 70 wt%, about 65 wt%, about 60 wt%, about 55 wt%, or about 50 wt% or less (all calculated on a dry weight basis) of the plug. The amount of the burn suppressing additive is selected to provide the desired burn suppressing effect.

[0088] In some embodiments, the coating on or in the plug that includes a burn suppressant additive comprises one or more burn suppressant additives in a total amount of at least about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt%, about 50 wt%, about 60 wt%, about 70 wt%, about 65 wt%, about 60 wt%, about 55 wt%, or about 50 wt% or less of the coating (all calculated on a dry weight basis). The amount of burn suppressant additive is selected to provide the desired burn suppression effect.

[0089] For the avoidance of doubt, any reference to the amount of burn-suppressing salt in the plug is a reference to the amount of salt added and does not include salt that may be present in the plug without the addition of the burn-suppressing salt described herein.

[0090] As used herein, a fire-suppressing salt is a compound consisting of an ionic assembly of a cation and an anion. As used herein, a salt is a salt whose anion and / or whose cation can be effective in suppressing fire. In some embodiments, the salt is an inorganic salt.

[0091] In some embodiments, the salt is a halide salt, i.e., has a halide anion. In some embodiments, the salt is a chloride salt or a bromide salt. The presence of high concentrations of chloride or bromide has been shown to inhibit combustion, as discussed further below.

[0092] In some embodiments, the salt may be an alkali metal salt, i.e., have an alkali metal cation. In some embodiments, the salt has an alkaline earth metal cation. In some embodiments, the salt has a zinc cation or an iron cation, such as a ferric or ferrous cation. In some embodiments, the salt has an ammonium cation or a phosphonium cation.

[0093] In some embodiments, the salt may be an alkali metal halide such as sodium chloride or potassium chloride. The salt may be an alkaline earth metal halide such as magnesium chloride, calcium chloride, etc. The salt may be another metal halide such as zinc chloride or sodium bromide.

[0094] In some embodiments, the salt has a carboxylate anion, for example, the salt may be an alkali metal carboxylate, such as potassium citrate, potassium succinate, potassium malate, potassium acetate, potassium tartrate, potassium oxalate, sodium citrate, sodium succinate, sodium acetate, or sodium malate.

[0095] In other embodiments, the salt has an anion selected from: borate, carbonate, phosphate, sulfate, or sulfamate.

[0096] Factors that may influence the selection of the salt include, for example, the melting point, which is preferably at least 450°C. In some embodiments, the salt is soluble in water. In some embodiments, the salt is selected to provide a desired pH in the material to which it is added. In some embodiments, the salt does not significantly change the pH of the material.

[0097] In some embodiments, sodium chloride (NaCl) is the salt used. Packaging with a high chloride content has proven difficult to burn. Additionally, sodium chloride is neutral, highly soluble, and does not affect the pH of the packaging.

[0098] The fire-suppressing salt may be one salt disclosed herein or known in the art, or a combination of any number of salts, referred to herein as "fire-suppressing salts." The fire-suppressing salt(s) may be advantageously selected to impart desired characteristics to the fire-suppressing material.

[0099] In some embodiments, the fire suppressant salt comprises, consists essentially of, or consists of sodium chloride, potassium chloride, sodium bromide and / or potassium bromide.

[0100] Depending on the desired burn suppression properties or other physical properties, the salt components may be in free base form, salt form, or as a complex or solvate. The burn suppression salts may be of any density and any crystalline structure.

[0101] Binder In some embodiments, the burn suppressing additive is added to the plug in the form of a coating comprising the burn suppressing additive and a binder. The coating may be applied to a sheet material used to form the body of the plug. In some embodiments, the coating is applied to the sheet before it is gathered to form the plug. In other embodiments, the coating is applied to the formed plug.

[0102] The binder may be a film-forming material that forms the base of a coating that includes the burn-suppressing additive. The burn-suppressing additive may be disposed in or on a film formed from the binder. In some embodiments, a salt is mixed with the binder and applied to the package, as discussed in more detail below.

[0103] The binder may adhere the fire suppressant additive to the sheet material or plug. The binder may also be used to adhere the sheet or plug to itself and / or other components of the article.

[0104] Suitable binders include, for example, film-forming agents such as polyvinyl alcohol (PVA), gelatin, gums such as acacia gum, starch and its derivatives, polysaccharides, pectin, alginate, wood pulp, cellulose, cellulose derivatives such as carboxymethylcellulose, silica or silicone compounds, clay, and combinations thereof. Suitable binders include, for example, one or more gelling agents such as alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, chitosan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder may include alginate and / or pectin, and the precursor material may further include a hardening agent (such as a calcium source) that can assist in the formation of an amorphous solid. In some cases, the binder may include calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0105] In some embodiments, the coating comprises at least about 0.1 wt%, about 0.2 wt%, about 0.3 wt%, about 0.4 wt%, about 0.5 wt%, about 0.6 wt%, about 0.7 wt%, about 0.8 wt%, about 0.9 wt%, about 1 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, or at least about 50 wt% binder (all calculated on a dry weight basis). In some cases, the coating comprises no more than about 70 wt%, about 65 wt%, about 60 wt%, about 55 wt%, about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, or about 30 wt% binder (all calculated on a dry weight basis).

[0106] precursor material In some embodiments, the burn suppressant additive is incorporated into or added to the precursor material used to form the coating.

[0107] In some embodiments, the burn suppressant additive is suspended in the precursor material. In some embodiments, the burn suppressant additive is dissolved in the precursor material, optionally in the presence of a solvent. The solvent may be an aqueous or organic liquid, and may be polar or non-polar, depending on the material to be dissolved and the degree to which it is dissolved.

[0108] The precursor material can include about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt%, or about 50 wt% of the burn suppressant additive (all calculated on a dry weight basis).

[0109] The precursor material can include about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt%, or about 50 wt% of a fire-suppressing salt (all calculated on a dry weight basis).

[0110] In some embodiments, a precursor material containing the burn suppressant additive is applied to the surface of the sheet or plug, which deposits the burn suppressant additive on the surface of the sheet or plug, resulting in a coating on the surface of the sheet or plug.

[0111] In some embodiments, the sheet or plug is contacted with a precursor material, such as a solution or suspension containing the burn-suppressing additive. This technique can be used to form a coating containing the burn-suppressing additive on a surface or portion of a surface of the sheet or plug. In some embodiments, the precursor material may be sprayed, printed, painted, or otherwise applied locally to the sheet or plug. This is advantageous because it can result in the formation of a coating of the burn-suppressing additive that is uniformly distributed across the sheet or plug. Some application methods, such as spraying, printing, and painting, can be more precise and result in a localized coating, or can apply a higher concentration of the burn-suppressing additive to the sheet or plug.

[0112] The sheet or wrapper can be contacted multiple times with a precursor material containing the burn suppressant additive to form one or more layers containing the burn suppressant additive. In some embodiments, one layer can be allowed to dry before the next layer is applied. In some embodiments, the layers can have different compositions, including different burn suppressant additives and / or other components, such as binders. This can result in specific burn suppression profiles or can take advantage of different adhesive properties of binders. This process can also be repeated to provide a desired thickness of the layer of burn suppressant additive and / or a desired amount or concentration of the burn suppressant additive, which is an added benefit. The additional thickness, when applied to the sheet or plug, can improve structural rigidity or increase its tensile strength.

[0113] In some embodiments, the precursor material and / or subsequent coating comprises or is in the form of an amorphous solid, which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the precursor material or coating may be in the form of a dried gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. A precursor material or coating in the form of an amorphous solid may include a binder comprised of at least one gelling agent as described herein. A precursor material or coating comprising an amorphous solid enjoys the advantage of providing increased tensile strength and stiffness to the sheet or plug.

[0114] In some embodiments, the precursor material used to form one layer may be in liquid form, while the precursor material used to form another layer may be in solid or amorphous solid form. In an exemplary embodiment, a precursor material in liquid form and including a binder such as PVA may provide the first layer. A precursor material in amorphous solid form may provide the second layer. The second layer may be in the form of a sheet. Such an embodiment provides a sheet or plug to which the amorphous solid sheet is adhered via the first layer. The layer(s) may be positioned in specific portions of the sheet or plug, thus providing the benefits of the amorphous solid form locally. The amorphous solid may include additional components described herein, advantageously providing the additional components locally to portions of the sheet or plug.

[0115] The layers may contain the same or different burn suppressant additives. Additionally, the ratio of the burn suppressant additives in the precursor material may be varied to provide desired properties for the layer(s) on the sheet or plug.

[0116] In some embodiments, the coating containing the burn suppressant additive is applied to a portion of the sheet or plug, such as a patch or section of the sheet or plug. The coating may be applied to the interior and / or exterior surfaces of the wrapper.

[0117] In some embodiments, the coating is on a surface of a plug located adjacent to the aerosol-forming material in the article.

[0118] In another embodiment of the present invention, the precursor material may be applied in the form of a printed patch. In this embodiment, the precursor material may have properties tailored to this application method, for example, the precursor material may have a suitable viscosity or may contain a higher concentration of burn-suppressing additive. An advantage of this application method is that the printed patch can be precisely sized, shaped, and positioned on the sheet or plug, providing a more controlled application of salt to the sheet or plug. The printed patch may be placed on part or the entire sheet of the plug.

[0119] Precursor material components In some embodiments, the precursor material includes a binder and a fire-suppressing additive.

[0120] In some cases, the precursor material comprises at least about 0.1 wt%, about 1 wt%, about 10 wt%, about 20 wt%, about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, or at least about 50 wt% binder (all calculated on a dry weight basis). In some cases, the precursor material comprises no more than about 70 wt%, about 65 wt%, about 60 wt%, about 55 wt%, about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, or about 30 wt% binder (all calculated on a dry weight basis).

[0121] The precursor material may include an appropriate amount of binder to provide an advantageous viscosity. For example, the precursor material must be viscous enough to form a film and provide a coating with a desired thickness or other physical characteristics. However, if the precursor material is too viscous, the material may be difficult to apply to a sheet or plug.

[0122] In some embodiments, precursor materials that include a binder provide adhesive qualities to the precursor material. The precursor material can be a viscous composition that has an adhesive or "glue-like" quality. In some embodiments, the precursor material, and subsequent coating, can be advantageously used to adhere sheets or plugs in place.

[0123] In some embodiments, the precursor material includes one or more solvents. The solvent may be included to dissolve one or more components of the precursor material. Additionally or alternatively, the solvent may be included to control the properties of the precursor material, such as its viscosity or drying behavior under certain conditions. The viscosity of the precursor material may be reduced, for example, to facilitate its application to a package while maintaining a desired binder and additive content.

[0124] The solvent may include one or more liquids, including aqueous and non-aqueous liquids. For example, the solvent may be selected from the group consisting of: water (such as distilled water), benzyl alcohol, ethanol, methanol, triacetin, glycerol, propylene glycol, or combinations thereof. In some embodiments, the solvent is distilled water.

[0125] The solvent may be advantageously selected to be easily removed after application of the precursor material to the sheet or plug to form a (dry) coating containing the fire-suppressing salt on the surface of the sheet or plug. In some embodiments, the solvent may be removed as a result of a processing step, as discussed in more detail below. In some embodiments, the liquid carrier is advantageously a volatile solvent that can be removed by evaporation.

[0126] Precursor material processing The precursor material can be optionally treated to provide a coating when applied to the surface of the sheet or plug. Treatment can include steps such as drying, curing, crosslinking, heating, or any other suitable treatment of the alginate or polymer. This provides the advantage that the coating can have different properties than the precursor material. For example, the precursor material can be liquid, but harden on the sheet or plug during the treatment step, imparting suitable rigidity to the coating. In a further example, the precursor material can be "sticky" before treatment and not sticky after treatment to prevent unintended adhesion of the sheet or plug to the surface.

[0127] The precursor material may be treated differently at different locations on the seat or plug, which provides the advantage that burn suppressant additives and properties can be imparted to different sections of the seat or plug.

[0128] In some embodiments, some components of the precursor material are removed, for example via evaporation, while the burn suppressant additive (and other non-volatile components) remain deposited on the sheet or plug in a coating.

[0129] In some embodiments, the precursor material or components of the precursor material may remain in the coating formed on the sheet or plug and may impart additional burn suppression, flavor, fragrance, and / or physical characteristics to the coating.

[0130] In some embodiments, the precursor material is not treated to form the coating without further processing.

[0131] coating In some embodiments, the coating may have a thickness of about 0.2 μm to about 50 μm. The coating may have a thickness of at least about 0.2 μm, about 0.3 μm, about 0.4 μm, about 0.5 μm, about 0.6 μm, about 0.7 μm, about 0.8 μm, about 0.9 μm, about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, or about 30 μm. The coating may have a thickness of about 50 μm, about 45 μm, about 40 μm, about 35 μm, about 30 μm, about 25 μm, about 20 μm, about 15 μm, about 10 μm, or about 5 μm or less.

[0132] The burn suppressant additive coating may include two or more layers, and the coating thickness described herein refers to the total thickness of these layers. The coating may also contain other additives in addition to the burn suppressant additive(s) disclosed herein. The coating may also be very thin and may not be consistent across the surface of the sheet or plug. The coating thickness may be selected to provide the desired burn suppression characteristics and to impart satisfactory rigidity and structural integrity to the coated sheet.

[0133] The thickness of the coating of the burn-suppressing salt may be measured using a microscope, such as a scanning electron microscope (SEM), known to those skilled in the art, or any other suitable technique known to those skilled in the art.

[0134] In some cases, the coating thickness may vary by about 25%, about 20%, about 15%, about 10%, about 5%, or about 1% or less over its area, which has the advantage that the coated sheet has a consistent thickness and / or that a plug formed from the coated sheet or bearing the coating has consistent dimensions, so that the plug can fit with other components of the article and therefore the article can fit more easily into a non-combustion aerosol delivery system.

[0135] In some embodiments of the present invention, only a portion of the total area of the surface of the seat contained in the plug includes a coating containing the burn-suppressing additive, while in other embodiments, the entire surface of the seat includes a coating containing the burn-suppressing additive.

[0136] In articles including the coatings described herein, the portion of the plug facing or adjacent to the end of the rod of aerosol-forming material may include a coating including a burn-suppressing additive. This embodiment has the advantage of preventing the plug from burning if the aerosol-forming or heating material disposed thereon is heated to a high temperature.

[0137] method The articles described herein may be manufactured by a process in which the burn suppressant additive is incorporated into or applied to the surface of a plug, and the plug is then incorporated into the article with the rod of aerosol-forming material.

[0138] In some embodiments, a plug is incorporated into the distal end of the article.

[0139] In some embodiments, the method includes collecting one or more sheets into a rod, wrapping the rod, and cutting it into separate sections to form plugs. The method may include crimping the sheets before collecting them into the rod.

[0140] The method may include gathering the sheet around a former and forming a hole through the plug.

[0141] In some embodiments where the plug is formed from a sheet, the burn suppressant additive is included when the sheet material is made.

[0142] In some embodiments where the plug is formed from a sheet, the burn suppressant additive is incorporated into a coating that is applied to the surface of the sheet material.

[0143] In some embodiments, the burn suppressing additive is applied to at least a portion of the surface of the formed plug. In some embodiments, the burn suppressing additive is incorporated into a coating that is applied to the surface of the plug.

[0144] In some embodiments, the coating is formed by applying a precursor material, including a binder and a burn-suppressing additive, to a surface.

[0145] consumables As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including non-combustion aerosol delivery systems, such as e-cigarettes and tobacco heating products, that release compounds from an aerosol-forming material without burning the aerosol-forming material, and hybrid systems that generate an aerosol using a combination of aerosol-forming materials.

[0146] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0147] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0148] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0149] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0150] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-forming materials, one or more of which may be heated. Each aerosol-forming material may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

[0151] Typically, a non-combustible aerosol delivery system may include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0152] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-generating materials and are designed for use with non-combustible aerosol delivery devices.

[0153] A consumable is an article containing an aerosol-forming material, some or all of which is intended to be consumed during use by a user, and also includes a plug containing the burn-suppressing additive described herein. The article typically has a downstream end that connects to or includes a mouthpiece and / or filter, and an upstream end, also referred to as the distal end. In some embodiments, the article includes a plug containing the burn-suppressing additive at the distal end of the article.

[0154] The consumable may further include one or more other components, such as a storage area for the aerosol-generating material, a transfer component for the aerosol-generating material, an aerosol-generating area, a container, a packaging, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0155] A susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, and penetration with a varying magnetic field results in induction heating of the heating material. The heating material may be a magnetic material, and penetration with a varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, and the susceptor can be heated by both heating mechanisms. A device designed to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0156] In some embodiments, the heating material may comprise a metal or metal alloy. In some embodiments, the heating material may comprise one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. Other heating material(s) may be used in other embodiments. In some embodiments, the heating material may be magnetic. It has also been found that when a magnetic, electrically conductive material is used as the heating material, the magnetic coupling between the magnetic, electrically conductive material and the electromagnet of the device can be enhanced during use. In addition to potentially enabling magnetic hysteresis heating, this can result in greater or improved Joule heating of the heating material and, therefore, greater or improved heating of the smokable material.

[0157] In some embodiments, the heating material comprises a plate or strip or ribbon, hi some embodiments, the heating material comprises a mesh or expanded metal.

[0158] In some embodiments, the heating material is in contact with the aerosol-generating material when the article is in use. In some embodiments, the heating material is incorporated into the article. In other embodiments, the heating material is inserted into the article when the article is inserted into the non-combustion aerosol delivery device.

[0159] When the article includes a heating material, such as a susceptor, the heating material may be included in the rod of aerosol-generating material. In some embodiments, the heating material is distributed within the aerosol-generating material. In some embodiments, a sheet or mesh of heating material extends through the rod of aerosol-generating material. In some embodiments, the heating material extends to the end of the rod of aerosol-generating material that is in contact with the plug containing the burn-suppressing additive. In some embodiments, the plug containing the burn-suppressing additive is in contact with the upstream end of the rod of aerosol-generating material, optionally at the distal end of the article.

[0160] The heating material may be in contact with a plug containing the burn-suppressing additive. In some embodiments, the heating material may extend through the plug containing the burn-suppressing additive and into the aerosol-forming material. In such embodiments, the plug containing the burn-suppressing additive may be upstream of the rod of aerosol-forming material, optionally at the distal end of the article.

[0161] An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or any other means. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and / or a flavoring. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, from about 50 wt%, about 60 wt%, or about 70 wt% amorphous solid, up to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0162] In some embodiments, the article comprises a package enclosing the rod and plug of aerosol-forming material, at least a portion of the package including a burn-suppressing additive, hi some embodiments, the burn-suppressing additive is provided in the form of a coating on a surface of at least a portion of the package.

[0163] The wrapper may include a burn suppressant additive, and a coating containing same, as described herein for the plug. The burn suppressant additive may be incorporated into the wrapper in the manner described herein for the plug.

[0164] The inventors have discovered that the addition of at least one fire-retardant additive to a coating applied to the surface of a package imparts fire-retardant properties, and the presence of a coating containing a fire-retardant salt makes it much more difficult to ignite the item, preventing it from burning.

[0165] Additionally, the packaging provides an environmentally friendly alternative to other known packaging that acts as a fire suppressant. For example, it is common to use aluminum as a packaging material to suppress fire in aerosol products. Because aluminum is energy intensive to manufacture and difficult to recycle after use, the packaging described herein is a more sustainable alternative.

[0166] As used herein, packaging is an integral part of an article or consumable, and the term is not used to refer to packaging for an article that is removed prior to use of the article.

[0167] In some embodiments, a non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat-generating power source.

[0168] In some embodiments, the non-combustible aerosol delivery system may include a consumable receiving area, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0169] In some embodiments, the article, packaging, carrier, amorphous solid, aerosol-generating material, or any component of the article may further comprise one or more of aerosol-forming material(s), functional material(s), fragrance(s), botanical(s), active material(s), or aerosol modifier(s).

[0170] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0171] The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0172] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0173] As used herein, the terms "flavoring" and "flavoring agent" refer to materials that can be used, where local regulations permit, to create a desired flavor, aroma, or other somatosensory stimulus in products intended for adult consumers. They include naturally occurring flavor materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, maize, etc.). Ruby, citrus fruits, Drambuie, bourbon, Scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgobiloba), hazel, hibiscus, bay leaf, mate tea tree, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, peppermint, perilla, curcuma, coriander leaves, myrtle, black currant, valerian, mustard, nutmeg flower, damien, marjoram, olive, lemon balm, lemon basil, chives, and bayberry. The compositions may contain other additives such as ginseng, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural sources, or blends thereof. They may be in any suitable form, for example, liquids such as oils and fats, solids such as powders, or gases.

[0174] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

[0175] In some embodiments, the flavorings may include those perceived by the five senses, typically intended to achieve chemically induced and sensed somatosensory stimulation through stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or flavor nerves, and may include agents that produce heat, cooling, tingling, and numbing effects. Suitable heat effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0176] In some embodiments, the substance delivered comprises a fragrance.

[0177] As used herein, an active substance can be a physiologically active material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive drugs. The active substance may be of natural origin or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other botanical substances. In some embodiments, the substance to be delivered includes an active substance.

[0178] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0179] As provided herein, the active substance may include one or more of the components, derivatives or extracts of cannabis, such as one or more of the cannabinoids or terpenes.

[0180] As used herein, the active substance may comprise or be derived from one or more of botanical matter or its components, derivatives, or extracts. As used herein, the term "botanical matter" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, pods, husks, and the like. Alternatively, the material may comprise active compounds naturally present in the botanical matter or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, powder, ground particles, granules, pellets, shreds, strips, sheets, and the like. Examples of plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, mate tea, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, and rosemary. , saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, coriander leaf, bergamot, orange blossom, myrtle, blackcurrant, valerian, mustard, nutmeg flower, damien, marjoram, olive, lemon balm, lemon basil, chive, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0181] In some embodiments, the active substance comprises or is derived from one or more of a botanical material or a component, derivative, or extract thereof, and the botanical material is tobacco.

[0182] In some embodiments, the active agent comprises or is derived from one or more of a botanical material or a component, derivative, or extract thereof, wherein the botanical material is selected from eucalyptus, star anise, cocoa, and hemp.

[0183] In some embodiments, the active substance comprises or is derived from one or more of a botanical substance or a component, derivative, or extract thereof, wherein the botanical substance is selected from rooibos and fennel.

[0184] Aerosol modifiers are substances that are typically placed downstream of the aerosol-generation region and are designed to modify the generated aerosol, for example, by altering the flavor, fragrance, acidity, or other characteristics of the aerosol. Aerosol modifiers can be provided in the aerosol modifier's release components that can selectively manipulate the release of the aerosol modifier.

[0185] The aerosol modifier may be, for example, an additive or an absorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may be free of filtration materials.

[0186] In some embodiments, the article comprises a substrate. A material may be present on or in a support to form the substrate. The support may be or include, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0187] In some embodiments, the non-combustible aerosol delivery system includes an aerosol generator. The aerosol generator is a device designed to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater designed to apply thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is designed to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be designed to apply one or more of vibration, pressure increase, or electrostatic energy to the aerosol-generating material.

[0188] 1 is a side cross-sectional view of a consumable product or article 1 for use in an aerosol delivery system. Article 1 comprises a mouthpiece section 2 and an aerosol-generation section 3.

[0189] The aerosol-generating zone 3 is in the form of a cylindrical rod and contains an aerosol-forming material 4, which in this example comprises reconstituted cut rag tobacco. The aerosol-forming material can be any suitable material.

[0190] The mouthpiece section 2, in an exemplary embodiment, comprises a body of material 5 such as collected paper or fibrous or filamentary tow.

[0191] The rod-shaped consumable 1 further comprises a wrapper 6, such as a paper wrapper, that encloses the mouthpiece region 2 and the aerosol-generation region 3. The consumable 1 also comprises a plug 7 at its distal end that contains a burn-suppressing additive.

[0192] 2 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material of a consumable item 110, as described herein. In general, device 100 can be used to heat a replaceable item 110 containing an aerosol-generating medium, such as item 1 illustrated in FIG. 1 or described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable item 110 together form a system.

[0193] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by the heating assembly. In use, the article 110 can be fully or partially inserted into the heating assembly and heated by one or more components of the heater assembly.

[0194] The device 100 in this example includes a first end 106 with a lid 108 that is movable relative to the first end 106 to close the opening 104 when no item 110 is placed therein. In FIG. 2, the lid 108 is shown in an open position, but the lid 108 may be moved to a closed position. For example, a user may slide the lid 108 in the direction of arrow "B."

[0195] Device 100 may also include a user-operable control element 112, such as a button or switch, that, when pressed, activates device 100. For example, a user can turn device 100 on by operating switch 112.

[0196] Device 100 may also include an electrical component, such as a socket / port 114, that can receive a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port. [Example]

[0197] Sheets containing fire-retardant salts were tested to assess their flame resistance. For testing, the sheets were exposed to an open flame to see if they would burn.

[0198] Example 1 In the first example, various coatings were prepared on paper sheets by applying two layers of precursor material. Different concentrations of fire-suppressing salt and binder were used in the different tests, as shown in Table 1. The fire-suppressing salt was NaCl, and the binder was PVA glue. None of the treated sheets ignited during the burn test.

[0199] [Table 1]

[0200] Example 2 Sheets of amorphous material containing a fire-suppressing salt were formed from a slurry having the following composition: 43g alginate (2.7%) 100g sodium chloride (6.3%) 50g glycerol (3.1%) 1400ml of water (87.9%)

[0201] The slurry was dried in an oven and the resulting sheets were tested by attempting to set the sheets on fire using an open flame. The sodium chloride content of the dried sheets was 52 wt% (dry weight basis) and the amount of alginate binder was 22.3 wt% (DWB).

[0202] Tests have shown that amorphous solid materials containing sodium chloride resist combustion well.

[0203] Additionally, additional sheets were formed from slurries having the following composition: 21.5g alginate 21.5g wood pulp 120g sodium chloride 30g glycerol 1400ml water

[0204] The slurry was dried in an oven to form a sheet. The resulting sheet also did not burn when exposed to an uncovered flame from a lighter. The sodium chloride content of the dried sheet was 62.2 wt% (dry weight basis), and the amount of alginate binder was 11.1 wt% (DWB).

[0205] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as representative examples of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limiting the scope of the invention as defined by the claims or the claimed equivalents, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims

1. 1. An article for use in a non-flammable aerosol delivery system comprising: a rod containing an aerosol-forming material; and a plug including a fire suppressant additive and configured to make it more difficult for a consumer to ignite and burn the article.

2. The article of claim 1 , wherein the plug containing the burn suppressant additive is at a distal end of the article.

3. 3. The article of claim 1 or 2, wherein the plug containing the burn suppressant additive is adjacent to the rod of aerosol-forming material.

4. The article of any one of claims 1 to 3, wherein the plug containing the burn suppressant additive is in contact with the rod of aerosol-forming material.

5. The article of any one of claims 1 to 4, wherein the burn suppressant additive is an alkali metal salt optionally selected from the group consisting of sodium chloride, potassium chloride, sodium bromide, potassium bromide, and combinations thereof.

6. The article of any one of claims 1 to 5, wherein the plug is formed from a sheet material.

7. 7. The article of claim 6, wherein the sheet material is paper or a paper-like material.

8. The article of claim 6 , wherein the sheet material comprises an amorphous solid material.

9. The article of any one of claims 6 to 8, wherein the burn suppressant additive is incorporated into the sheet material.

10. The article of any one of claims 6 to 9, wherein the burn suppressant additive is applied in a coating on the surface of the sheet material.

11. The article of any one of claims 1 to 5, wherein the plug comprises a mass of amorphous solid material.

12. 12. The article of claim 8 or 11, wherein the burn suppressant additive is incorporated into the amorphous solid material.

13. 13. The article of claim 12, wherein the amorphous solid material comprises from about 3 wt% to about 60 wt% of a fire-suppressing salt (on a dry weight basis).

14. The article of any one of claims 1 to 13, wherein the burn suppressant additive is applied to a coating on the surface of the plug.

15. 15. The article of claim 10 or 14, wherein the coating comprises from about 3 wt% to about 70 wt% (dry weight basis) of at least one burn suppressant additive.

16. 16. The article of any one of claims 10, 14 or 15, wherein the coating comprises a binder.

17. 17. The article of claim 16, wherein the binder is selected from one or more of the group consisting of polyvinyl alcohol (PVA), gelatin, gums, gum acacia, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethyl cellulose.

18. 18. The article of claim 16 or 17, wherein the coating comprises from about 10 wt% to about 97 wt% of at least one binder.

19. The article of any one of claims 1 to 18, comprising a heating material.

20. 20. The article of claim 19, wherein the heating material is invasively heatable using a fluctuating magnetic field to heat the aerosol-forming material.

21. 21. The article of claim 19 or 20, wherein the heating material is in contact with the aerosol-forming material.

22. The article of any one of claims 19 to 21, wherein the heating material is in contact with the plug containing a burn suppressing additive.

23. 23. The article of any one of claims 1-22, wherein the aerosol-forming material comprises one or more of tobacco itself, a tobacco derivative, expanded tobacco, reconstituted tobacco, a tobacco extract, homogenized tobacco, or a tobacco substitute.

24. 24. The article of any one of claims 1 to 23, wherein the aerosol-forming material is in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted smoking material, a liquid, a gel, a gelled sheet, a powder, or a block.

25. The article of any one of claims 1 to 24, wherein the aerosol-forming material comprises a non-tobacco material.

26. The article of any one of claims 1 to 25, wherein the plug containing the burn suppressant additive exhibits a pressure drop of from about 5 to about 40 mmWG.

27. The plug containing the burn-suppressing additive has a content of about 0.1 to about 0.3 mg / mm ３ 27. The article of any one of claims 1 to 26, having a bulk density between

28. A non-combustible aerosol delivery system comprising the article of any one of claims 1 to 27.

29. 28. A method of manufacturing the article of any one of claims 1 to 27, wherein a burn suppressant additive is incorporated into or applied to a plug, the plug being incorporated into an article having a rod of aerosol-forming material, the plug being configured to make it more difficult for a consumer to ignite and burn the article.

30. 30. The method of claim 29, wherein the plug is incorporated into the distal end of the article.

31. 31. A method according to claim 29 or 30, comprising the steps of collecting one or more sheets into a rod, wrapping the rod and cutting it into separate sections to form plugs.

32. 32. The method of claim 31, including the step of crimping the sheet before collecting it on a rod.

33. 33. The method of claim 31 or 32, including the step of gathering the sheet around a former and forming a hole through the plug.

34. 34. A method according to any one of claims 31 to 33, comprising applying to a surface of the sheet material a coating comprising the burn suppressing additive.

35. A method according to any one of claims 29 to 33, including the step of applying to a surface of the plug a coating comprising the burn suppressing additive.

36. 36. The method of claim 34 or 35, wherein the coating is formed by applying a precursor material comprising a binder and the burn suppressant additive to a surface.

37. 37. The method of claim 36, wherein the coating is applied to the surface using one or more processes selected from the group consisting of spraying, painting, or printing.

38. Use of a burn-suppressing additive to suppress the combustion of a plug in an article for use in a non-flammable aerosol delivery system, the plug being configured to make it more difficult for a consumer to ignite and burn the article.

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