Nicotine and binder-containing sheet

Abstract

To provide an aerosol-generating article that provides nicotine delivery similar to conventional cigarettes and that does not require a user to handle a liquid formulation.SOLUTION: A sheet (2) includes a fibrous material, one or more nicotine salts, and a binder, where at least about 20 wt.% of the one or more nicotine salts are monoprotic.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a nicotine-containing sheet. The present invention also relates to an aerosol-generating rod comprising an assembly of nicotine-containing sheets, and an aerosol-generating article comprising an aerosol-forming substrate comprising such a rod. [Background technology]

[0002] Electronic cigarettes (so-called "e-cigarettes") and other electrically operated smoking devices that vaporize a nicotine-containing liquid formulation to form a nicotine-containing aerosol that is inhaled by a user are known in the art. For example, WO 2009 / 132793 A1 discloses an electrically heated smoking system including a shell and a replaceable mouthpiece, where the shell includes a power source and an electrical circuit. The mouthpiece includes a liquid reservoir, a capillary wick having a first end extending into the liquid reservoir for contact with the liquid therein, and a heating element for heating the second end of the capillary wick. During use, the liquid is transported from the liquid reservoir toward the heating element by capillary action within the wick. The liquid is vaporized by the heating element at the second end of the wick.

[0003] Handling the liquid formulations used in e-cigarettes can be cumbersome or undesirable for users. It is desirable to provide an aerosol-generating article that provides nicotine delivery similar to that of traditional cigarettes and does not require user handling of the liquid formulation. Summary of the Invention

[0004] In accordance with the present invention, there is provided a sheet comprising a fibrous material, one or more nicotine salts, and a binder.

[0005] The present invention also provides an aerosol-generating rod comprising an assembly of sheets according to the present invention surrounded by a wrapper.

[0006] According to the present invention there is further provided an aerosol-generating article comprising an aerosol-forming substrate, wherein the aerosol-forming substrate comprises an aerosol-generating rod according to the present invention.

[0007] The term "sheet" as used herein in connection with the present invention means a laminar element having a width and length that is substantially greater than its thickness.

[0008] As used herein in connection with the present invention, the term "rod" is used to describe a generally cylindrical element of substantially circular, oval or elliptical cross section.

[0009] The term "assembled" as used herein in connection with the present invention means that the sheet is rolled, folded, or otherwise compressed or contracted substantially transverse to the cylindrical axial direction of the rod.

[0010] The sheets according to the present invention do not contain flowable liquids, so that users of the aerosol-generating rods and aerosol-generating articles according to the present invention advantageously do not have to handle liquid agents.

[0011] Electronic cigarettes generally use liquid formulations containing free nicotine base. Nicotine salts may be more stable than free nicotine base. As a result, the sheet according to the present invention and the aerosol-generating rod according to the present invention may advantageously have a longer shelf life than the liquid formulations commonly used in electronic cigarettes.

[0012] Aerosol-generating rods according to the present invention may generate nicotine-containing aerosols when heated to temperatures below about 300°C. For example, aerosol-generating rods according to the present invention may generate nicotine-containing aerosols when heated to temperatures below about 250°C or below about 220°C. Aerosol-generating rods according to the present invention may generate aerosols when heated to temperatures between about 120°C and about 140°C. Advantageously, this may eliminate the need to use large-scale equipment with high battery power to generate aerosols having high levels of nicotine from aerosol-generating rods according to the present invention.

[0013] The sheet includes one or more nicotine salts.

[0014] For example, the sheet may include one or more salts of an acid selected from the group consisting of acetic acid, benzoic acid, carbonic acid, citric acid, gallic acid, hydrochloric acid, lactic acid, lauric acid, levulinic acid, malic acid, malonic acid, oxalic acid, oxaloacetic acid, palmitic acid, pyruvic acid, phosphoric acid, salicylic acid, sorbic acid, stearic acid, sulfuric acid, and tartaric acid.

[0015] Advantageously, the sheet may comprise one or more nicotine salts of a carboxylic acid.

[0016] Advantageously, the sheet may include one or more monobasic nicotine salts.

[0017] As used herein, the term "monobasic nicotine salt" is used to describe a nicotine salt of a monobasic acid.

[0018] Advantageously, the sheet may comprise one or more nicotine salts of monobasic carboxylic acids.

[0019] Advantageously, the sheet may comprise one or more nicotine salts of a monobasic carboxylic acid selected from the group consisting of acetic acid, benzoic acid, gallic acid, lactic acid, lauric acid, levulinic acid, palmitic acid, pyruvic acid, sorbic acid, and stearic acid.

[0020] The sheet may include one or more polybasic nicotine salts.

[0021] As used herein, the term "polybasic nicotine salt" is used to describe nicotine salts of polybasic acids.

[0022] For example, the sheet may include one or more nicotine salts of dibasic carboxylic acids, such as malic acid, oxalic acid, and tartaric acid.

[0023] For example, the sheet may further include a nicotine salt of a tribasic carboxylic acid, such as citric acid.

[0024] Advantageously, at least about 20% by weight of the one or more nicotine salts in the sheet are monobasic.

[0025] For example, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight of the one or more nicotine salts in the sheet can be monobasic.

[0026] Advantageously, the sheet may contain up to five nicotine salts.

[0027] The sheet may include no more than four nicotine salts, no more than three nicotine salts, or no more than two nicotine salts.

[0028] Advantageously, the weight ratio of the primary nicotine salt to the total nicotine salt in the sheet on a dry weight basis may be at least about 2:3.

[0029] As used herein in connection with the present invention, the term "primary nicotine salt" is used to describe the nicotine salt that is present in the greatest amount, on a dry weight basis, in the sheet.

[0030] The weight ratio of the primary nicotine salt to the total nicotine salt in the sheet on a dry weight basis may advantageously be at least about 3:4, at least about 4:5, or at least about 5:6.

[0031] Advantageously, the sheet may contain a single nicotine salt.

[0032] More advantageously, the sheet may include a single monobasic nicotine salt.

[0033] Most advantageously, the sheet may comprise a single nicotine salt of a monobasic carboxylic acid.

[0034] The inclusion of a single nicotine salt may advantageously allow for better control of the aerosol formed by heating the aerosol-generating rod containing the sheet at a particular temperature and over time.

[0035] Advantageously, the sheet may comprise one or more nicotine salts of an acid having an atmospheric boiling point of about 150°C to about 350°C.

[0036] Advantageously, the sheet may comprise one or more nicotine salts of an acid having an atmospheric boiling point of about 230°C to about 270°C.

[0037] Advantageously, the total nicotine salt content of the sheet may be at least about 1% by weight on a dry weight basis.

[0038] Advantageously, the total nicotine salt content of the sheet may be at least about 2% by weight on a dry weight basis, or at least about 3% by weight on a dry weight basis.

[0039] Advantageously, the total nicotine salt content of the sheet may be less than about 30% by weight on a dry weight basis.

[0040] The total nicotine salt content of the sheet may advantageously be less than about 30% by weight on a dry weight basis, less than about 20% by weight on a dry weight basis, less than about 10% by weight on a dry weight basis, or less than about 6% by weight on a dry weight basis.

[0041] The total nicotine salt content of the sheet may be less than about 5% by weight on a dry weight basis, or less than about 4% by weight on a dry weight basis.

[0042] The total nicotine salt content of the sheet can be between about 1% and about 30% by weight on a dry weight basis, between about 1% and about 20% by weight on a dry weight basis, between about 1% and about 10% by weight on a dry weight basis, between about 1% and about 6% by weight on a dry weight basis, between about 1% and about 5% by weight on a dry weight basis, or between about 1% and about 4% by weight on a dry weight basis.

[0043] The total nicotine salt content of the sheet can be between about 2% and about 30% by weight on a dry weight basis, between about 2% and about 20% by weight on a dry weight basis, between about 2% and about 10% by weight on a dry weight basis, between about 2% and about 6% by weight on a dry weight basis, between about 2% and about 5% by weight on a dry weight basis, or between about 2% and about 4% by weight on a dry weight basis.

[0044] The total nicotine salt content of the sheet can be between about 3% and about 30% by weight on a dry weight basis, between about 3% and about 20% by weight on a dry weight basis, between about 3% and about 10% by weight on a dry weight basis, between about 3% and about 6% by weight on a dry weight basis, between about 3% and about 5% by weight on a dry weight basis, or between about 3% and about 4% by weight on a dry weight basis.

[0045] Advantageously, the tobacco nicotine salt content of the sheet can be less than about 0.5% by weight on a dry weight basis.

[0046] As used herein in connection with the present invention, the term "tobacco nicotine salt" is used to describe the natural nicotine salt of any tobacco material in the sheet.

[0047] The tobacco nicotine salt content of the sheet can be less than about 0.4% by weight on a dry weight basis, less than about 0.3% by weight on a dry weight basis, less than about 0.2% by weight on a dry weight basis, or less than about 0.1% by weight on a dry weight basis.

[0048] Advantageously, the weight ratio of tobacco nicotine salt to total nicotine salt in the sheet on a dry weight basis can be less than about 1:5.

[0049] The weight ratio of tobacco nicotine salt to total nicotine salt in the sheet on a dry weight basis can advantageously be less than about 1:10, less than about 1:15, or less than about 1:25.

[0050] The sheet may be substantially free of tobacco nicotine salts.

[0051] The weight percentages and weight ratios of nicotine salts listed herein are as determined by liquid chromatography.

[0052] The sheet includes a binder.

[0053] The inclusion of a binder can advantageously facilitate the manufacture of the sheet.

[0054] The inclusion of a binder may advantageously improve the uniformity of the sheet compared to a sheet that does not contain a binder.

[0055] The sheet may include a gum binder.

[0056] Advantageously, the sheet may include a natural gum binder.

[0057] Advantageously, the sheet may include one or more natural gum binders selected from the group consisting of guar gum, xanthan gum and gum arabic.

[0058] Advantageously, the binder content of the sheet may be at least about 1% by weight on a dry weight basis.

[0059] The binder content of the sheet may be at least about 2% by weight on a dry weight basis.

[0060] Advantageously, the binder content of the sheet can be less than about 10% by weight on a dry weight basis.

[0061] The binder content of the sheet can be less than about 8% by weight on a dry weight basis, less than about 6% by weight on a dry weight basis, or less than about 4% by weight on a dry weight basis.

[0062] The binder content of the sheet can be between about 1% and about 10% by weight on a dry weight basis, between about 1% and about 8% by weight on a dry weight basis, between about 1% and about 6% by weight on a dry weight basis, or between about 1% and about 4% by weight on a dry weight basis.

[0063] The binder content of the sheet can be between about 2% and about 10% by weight on a dry weight basis, between about 2% and about 8% by weight on a dry weight basis, between about 2% and about 6% by weight on a dry weight basis, or between about 2% and about 4% by weight on a dry weight basis.

[0064] Advantageously, the weight ratio of binder to nicotine salt in the sheet on a dry weight basis can be between about 2:1 and about 1:2, or between about 3:2 and about 2:3.

[0065] The sheet comprises a fibrous material.

[0066] Advantageously, the fibrous material may comprise cellulose fibers or nylon.

[0067] More preferably, the fibrous material may include cellulosic fibers.

[0068] Advantageously, the total fibrous material content of the sheet may be at least about 1% by weight on a dry weight basis.

[0069] Advantageously, the total fibrous material content of the sheet may be less than about 70% by weight on a dry weight basis.

[0070] The total fibrous material content of the sheet can be less than about 60% by weight on a dry weight basis, less than about 50% by weight on a dry weight basis, less than about 40% by weight on a dry weight basis, less than about 30% by weight on a dry weight basis, less than about 20% by weight on a dry weight basis, or less than about 10% by weight on a dry weight basis.

[0071] The total fibrous material content of the sheet can be between about 1% and about 70% by weight on a dry weight basis, between about 1% and about 60% by weight on a dry weight basis, between about 1% and about 50% by weight on a dry weight basis, between about 1% and about 40% by weight on a dry weight basis, between about 1% and about 30% by weight on a dry weight basis, between about 1% and about 20% by weight on a dry weight basis, or between about 30% and about 10% by weight on a dry weight basis.

[0072] Advantageously, the weight ratio of fibrous material to nicotine salt in the sheet on a dry weight basis may be between about 30:1 and about 1:5, or between about 15:1 and about 1:3.

[0073] Advantageously, the weight ratio of fibrous material to binder in the sheet on a dry weight basis can be between about 25:1 and about 1:3, or between about 10:1 and about 1:2.

[0074] Advantageously, the sheet may further comprise cellulose powder.

[0075] Advantageously, the cellulose powder may have an average particle size of less than about 60 microns. The inclusion of a cellulose powder having an average particle size of less than about 60 microns may facilitate sheet formation.

[0076] Advantageously, the weight ratio of cellulose powder to total cellulosic material in the sheet on a dry weight basis may be greater than about 1:2.

[0077] The weight ratio of cellulose powder to total cellulosic material in the sheet on a dry weight basis may advantageously be greater than about 2:3, greater than about 3:4, greater than about 4:5, or greater than about 5:6.

[0078] Advantageously, the weight ratio of cellulose powder to nicotine salt in the sheet on a dry weight basis can be between about 18:1 and about 5:1, or between about 16:1 and about 8:1.

[0079] Advantageously, the weight ratio of cellulose powder to binder in the sheet on a dry weight basis can be between about 20:1 and about 10:1, or between about 18:1 and about 12:1.

[0080] Advantageously, the weight ratio of cellulose powder to fibrous material in the sheet on a dry weight basis can be between about 30:1 and about 10:1, or between about 25:1 and about 15:1.

[0081] Advantageously, the total cellulosic content of the sheet can be at least about 30% by weight on a dry weight basis.

[0082] The total cellulosic content of the sheet can be at least about 35% by weight on a dry weight basis, or at least about 40% by weight on a dry weight basis.

[0083] Advantageously, the total cellulosic content of the sheet can be less than about 60% by weight on a dry weight basis.

[0084] The total cellulosic content of the sheet can be less than about 55% by weight on a dry weight basis, or less than about 50% by weight on a dry weight basis.

[0085] The total cellulosic material content of the sheet can be between about 30% and about 60% by weight on a dry weight basis, between about 30% and about 55% by weight on a dry weight basis, or between about 30% and about 50% by weight on a dry weight basis.

[0086] The total cellulosic material content of the sheet can be between about 35% and about 60% by weight on a dry weight basis, between about 35% and about 55% by weight on a dry weight basis, or between about 35% and about 50% by weight on a dry weight basis.

[0087] The total cellulosic material content of the sheet can be between about 40% and about 60% by weight on a dry weight basis, between about 40% and about 55% by weight on a dry weight basis, or between about 40% and about 50% by weight on a dry weight basis.

[0088] Advantageously, the sheet may further comprise a sugar.

[0089] As used herein in connection with the present invention, the term "sugar" is used to describe monosaccharides, disaccharides, oligosaccharides containing 3 to 10 monosaccharide units and sugar alcohols.

[0090] The inclusion of sugar may advantageously improve the malleability and flexibility of the sheets compared to sheets that do not contain sugar, which may facilitate assembly of the sheets to form rods.

[0091] The sheets may advantageously comprise one or more sugars selected from the group consisting of disaccharides and sugar alcohols.

[0092] For example, the sheet may comprise one or more disaccharides, such as lactose, sucrose, and trehalose, one or more sugar alcohols, such as mannitol and sorbitol, or a combination of one or more disaccharides and one or more sugar alcohols.

[0093] Advantageously, the weight ratio of reducing sugars to total sugars in the sheet on a dry weight basis may be less than about 1:2.

[0094] The weight percentages and weight ratios of sugars listed herein are as determined by liquid chromatography.

[0095] The weight ratio of reducing sugars to total sugars in the sheet on a dry weight basis may advantageously be less than about 1:4, less than about 1:6, less than about 1:8, or less than about 1:10.

[0096] The sheet may be substantially free of reducing sugars.

[0097] Advantageously, the weight ratio of cyclic sugars to total sugars in the sheet on a dry weight basis may be less than about 1:3.

[0098] The weight ratio of cyclic sugars to total sugars in the sheet on a dry weight basis may advantageously be less than about 1:4, less than about 1:6, less than about 1:8, or less than about 1:10.

[0099] The sheets may be substantially free of cyclic sugars.

[0100] Advantageously, the weight ratio of formaldehyde-producing sugars to total sugars in the sheet on a dry weight basis can be less than about 1:3.

[0101] As used herein in connection with the present invention, the term "formaldehyde-generating sugars" is used to describe sugars whose thermal decomposition can lead to the formation of formaldehyde.

[0102] The weight ratio of formaldehyde-producing sugars to total sugars in the sheet on a dry weight basis can advantageously be less than about 1:4, less than about 1:6, less than about 1:8, or less than about 1:10.

[0103] The sheet may be substantially free of formaldehyde-generating sugars.

[0104] Advantageously, the sheet may comprise one or more sugar alcohols.

[0105] Advantageously, the sugar alcohol content of the sheet may be at least about 10% by weight on a dry weight basis.

[0106] The sugar alcohol content of the sheet can be at least about 15% by weight on a dry weight basis, at least about 20% by weight on a dry weight basis, or at least about 25% by weight on a dry weight basis.

[0107] Advantageously, the sugar alcohol content of the sheet may be less than about 40% by weight on a dry weight basis.

[0108] The sugar alcohol content of the sheet may be less than about 35% by weight on a dry weight basis, or less than about 30% by weight on a dry weight basis.

[0109] The sugar alcohol content of the sheet can be between about 10% and about 40% by weight on a dry weight basis, between about 10% and about 35% by weight on a dry weight basis, or between about 10% and about 30% by weight on a dry weight basis.

[0110] The sugar alcohol content of the sheet can be between about 15% and about 40% by weight on a dry weight basis, between about 15% and about 35% by weight on a dry weight basis, or between about 15% and about 30% by weight on a dry weight basis.

[0111] The sugar alcohol content of the sheet can be between about 20% and about 40% by weight on a dry weight basis, between about 20% and about 35% by weight on a dry weight basis, or between about 20% and about 30% by weight on a dry weight basis.

[0112] The sugar alcohol content of the sheet can be between about 25% and about 40% by weight on a dry weight basis, between about 25% and about 35% by weight on a dry weight basis, or between about 25% and about 30% by weight on a dry weight basis.

[0113] Advantageously, the sheet may comprise mannitol, sorbitol, or a combination thereof.

[0114] More advantageously, the sheet may contain mannitol.

[0115] The thermal decomposition of sorbitol and mannitol advantageously does not lead to the formation of formaldehyde.

[0116] Advantageously, the weight ratio of sugar alcohol to total sugars in the sheet may be at least about 2:3.

[0117] The weight ratio of sugar alcohols to total sugars in the sheet on a dry weight basis can advantageously be at least about 3:4, at least about 4:5, or at least about 5:6.

[0118] Advantageously, the total sugar content of the sheet may be at least about 15% by weight on a dry weight basis.

[0119] The total sugar content of the sheet can be at least about 20% by weight on a dry weight basis, at least about 25% by weight on a dry weight basis, or at least about 30% by weight on a dry weight basis.

[0120] Advantageously, the total sugar content of the sheet may be less than about 45% by weight on a dry weight basis.

[0121] The total sugar content of the sheet can be less than about 40% by weight on a dry weight basis, less than about 35% by weight on a dry weight basis, or less than about 30% by weight on a dry weight basis.

[0122] The total sugar content of the sheet can be between about 15% and about 45% by weight on a dry weight basis, between about 15% and about 40% by weight on a dry weight basis, between about 15% and about 35% by weight on a dry weight basis, or between about 15% and about 30% by weight on a dry weight basis.

[0123] The total sugar content of the sheet can be between about 20% and about 45% by weight on a dry weight basis, between about 20% and about 40% by weight on a dry weight basis, between about 20% and about 35% by weight on a dry weight basis, or between about 20% and about 30% by weight on a dry weight basis.

[0124] The total sugar content of the sheet can be between about 25% and about 45% by weight on a dry weight basis, between about 25% and about 40% by weight on a dry weight basis, between about 25% and about 35% by weight on a dry weight basis, or between about 25% and about 30% by weight on a dry weight basis.

[0125] Advantageously, the combined fructose and glucose content of the sheets may be less than about 5% by weight on a dry weight basis.

[0126] As used herein in connection with the present invention, the term "combined fructose and glucose content" is used to describe the weight percentage of fructose and glucose in the sheet.

[0127] The sheets may have a combined fructose and glucose content of less than about 3% by weight on a dry weight basis, less than about 2% by weight on a dry weight basis, or less than about 1% by weight on a dry weight basis.

[0128] Advantageously, the weight ratio of fructose and glucose to total sugars in the sheet on a dry weight basis may be less than about 1:5.

[0129] Advantageously, the weight ratio of fructose and glucose to total sugars in the sheet on a dry weight basis can be less than about 1:10, less than about 1:15, or less than about 1:25.

[0130] The sheet may be substantially free of fructose or glucose.

[0131] Advantageously, the weight ratio of sugar to nicotine salt in the sheet on a dry weight basis can be between about 12:1 and about 5:2, or between about 10:1 and about 5:1.

[0132] Advantageously, the weight ratio of sugar to binder in the sheet on a dry weight basis can be between about 15:1 and about 5:1, or between about 12:1 and about 8:1.

[0133] Advantageously, the weight ratio of sugar to fibrous material in the sheet on a dry weight basis can be between about 25:1 and about 1:3, or between about 20:1 and about 1:2.

[0134] Advantageously, the weight ratio of sugar to cellulose powder in the sheet on a dry mass basis may be between about 4:3 and about 1:2, or between about 1:1 and about 5:9.

[0135] Advantageously, the sheet may further comprise at least one aerosol former.

[0136] The inclusion of an aerosol former may advantageously facilitate the formation of a nicotine-containing aerosol upon heating on an aerosol-generating rod containing the sheet.

[0137] The at least one aerosol former may be any suitable known compound or mixture of compounds that promotes the formation of a dense, stable aerosol during use and that is substantially resistant to thermal degradation at the use temperatures of the aerosol product article, including the aerosol-forming substrate, including the sheet.

[0138] Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate).

[0139] Advantageously, the sheet may comprise one or more polyhydric alcohols.

[0140] More advantageously, the sheet may include one or more aerosol formers selected from the group consisting of triethylene glycol, 1,3-butanediol and glycerin.

[0141] The aerosol former content of the sheet may advantageously be at least about 5% by weight on a dry weight basis.

[0142] The aerosol former content of the sheet can be at least about 10% by weight on a dry weight basis, or at least about 15% by weight on a dry weight basis.

[0143] The aerosol former content of the sheet may advantageously be less than about 35% by weight on a dry weight basis.

[0144] The aerosol former content of the sheet can be less than about 30% by weight on a dry weight basis, or less than about 25% by weight on a dry weight basis.

[0145] The aerosol former content of the sheet can be between about 5% and about 35% by weight on a dry weight basis, between about 5% and about 30% by weight on a dry weight basis, or between about 5% and about 25% by weight on a dry weight basis.

[0146] The aerosol former content of the sheet can be between about 10% and about 35% by weight on a dry weight basis, between about 10% and about 30% by weight on a dry weight basis, or between about 10% and about 25% by weight on a dry weight basis.

[0147] The aerosol former content of the sheet can be between about 15% and about 35% by weight on a dry weight basis, between about 15% and about 30% by weight on a dry weight basis, or between about 15% and about 25% by weight on a dry weight basis.

[0148] Advantageously, the weight ratio of aerosol former to nicotine salt in the sheet on a dry weight basis can be between about 15:1 and about 3:1, or between about 10:1 and about 4:1.

[0149] Advantageously, the weight ratio of aerosol former to binder in the sheet on a dry weight basis can be between about 15:1 and about 1:4, or between about 10:1 and about 1:3.

[0150] Advantageously, the weight ratio of aerosol former to fibrous material in the sheet on a dry weight basis can be between about 15:1 and about 1:4, or between about 8:1 and about 1:2.

[0151] Advantageously, the weight ratio of aerosol former to cellulose powder in the sheet on a dry weight basis can be between about 2:3 and about 1:3, or between about 1:2 and about 2:5.

[0152] Advantageously, the weight ratio of aerosol former to sugar in the sheet on a dry weight basis can be between about 2:3 and about 1:3, or between about 1:2 and about 2:5.

[0153] Advantageously, the weight ratio of aerosol former to total nicotine in the sheet on a dry weight basis may be less than about 15:1.

[0154] The weight ratio of aerosol former to total nicotine in the sheet on a dry weight basis can advantageously be between about 3:1 and about 10:1, or between about 4:1 and about 8:1.

[0155] As used herein in connection with the present invention, the term "total nicotine" is used to describe nicotine, nicotine base, and nicotine salts in the sheet.

[0156] Electronic cigarettes typically use liquid formulations with aerosol-former to nicotine weight ratios ranging from about 20:1 to about 100:1 on a dry weight basis. Heating such liquid formulations can produce aerosols with lower nicotine concentrations. As a result, users may take deeper, longer puffs to provide the desired nicotine intake.

[0157] The sheet may further include one or more flavoring agents.

[0158] As used herein with respect to the present invention, the term "flavoring agent" is used to describe any agent that, in use, imparts taste or fragrance or both to the aerosol generated by the aerosol-forming substrate, including the sheet.

[0159] The sheet may further include one or more natural flavors, one or more artificial flavors, or a combination of one or more natural flavors and one or more artificial flavors.

[0160] For example, the sheet may include one or more flavoring agents that provide a flavor selected from the group consisting of menthol, lemon, vanilla, orange, wintergreen, cherry, and cinnamon.

[0161] The sheet may further include one or more chemosensory agents.

[0162] As used herein in connection with the present invention, the term "chemosensory agent" is used to describe any agent that, when used, is perceived in the user's mouth or olfactory cavity by means other than, or in addition to, perception via taste or olfactory receptor cells. Perception of chemosensory agents is via either the trigeminal nerve, glossopharyngeal nerve, vagus nerve, or some combination thereof, typically via a "trigeminal response." Typically, chemosensory agents are perceived as hot, spicy, cooling, or soothing sensations.

[0163] The sheet may include one or more agents that are both flavoring and chemosensory agents. For example, the sheet may include menthol or another flavoring agent that provides a cooling chemosensory effect.

[0164] As used herein in connection with the present invention, the term "menthol" is used to describe the compound 2-isopropyl-5-methylcyclohexanol in any of its isomeric forms.

[0165] Advantageously, the sheet may contain less than about 15% by weight tobacco material on a dry weight basis.

[0166] Advantageously, the tobacco material content of the sheet may be less than about 10% by weight on a dry weight basis, less than about 5% by weight on a dry weight basis, less than about 3% by weight on a dry weight basis, less than about 2% by weight on a dry weight basis, or less than about 3% by weight on a dry weight basis. The sheet may be substantially free of tobacco material.

[0167] The sheet may have a width of at least about 20 mm.

[0168] Advantageously, the width of the sheet can be at least about 40 mm, at least about 60 mm, or at least about 80 mm.

[0169] The width of the sheet can be between about 20 mm and about 300 mm, between about 40 mm and about 300 mm, between about 60 mm and about 300 mm, or between about 80 mm and about 300 mm.

[0170] The sheet may have a thickness of at least about 50 microns.

[0171] Advantageously, the thickness of the sheet can be at least about 75 microns, at least about 100 microns, or at least about 125 microns.

[0172] The thickness of the sheet can be between about 50 microns and about 300 microns, between about 75 microns and about 300 microns, between about 100 microns and about 300 microns, or between about 125 microns and about 300 microns.

[0173] The sheet may be formed by applying one or more nicotine salts and sugar to a layered substrate comprising a fibrous material and a binder. For example, the sheet may be formed by applying a liquid formulation comprising one or more nicotine salts to a sheet of fibrous material comprising a binder.

[0174] The sheet may be formed by casting a slurry containing a fibrous material, one or more nicotine salts, and a binder onto a support surface, drying the cast slurry to form a sheet, and removing the sheet from the support surface.

[0175] The aerosol-generating rod comprises an assembly of sheets according to the invention surrounded by a wrapper.

[0176] Preferably, the collection of sheets extends along substantially the entire length of the aerosol-generating rod and across substantially the entire cross-sectional area of ​​the aerosol-generating rod.

[0177] Advantageously, the sheets may be textured, which facilitates assembly of the sheets to form the aerosol-generating rod.

[0178] As used herein in connection with the present invention, the term "textured sheet" is used to describe a sheet that has been crimped, embossed, debossed, perforated, or otherwise modified. The textured sheet may include a plurality of spaced indentations, protrusions, perforations, or a combination thereof.

[0179] More advantageously, the sheet may be crimped.

[0180] The term "crimped sheet" as used herein in connection with the present invention is intended to be synonymous with the term "creased sheet" and is used to describe a sheet having a plurality of substantially parallel ridges or corrugations.

[0181] Advantageously, the crimped sheet may have a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the aerosol-generating rod, which facilitates assembly of the crimped sheet to form the aerosol-generating rod.

[0182] The sheet may be textured using suitable known machinery for texturing filter tow, paper and other materials.

[0183] The sheet may be crimped using a crimping unit of the type described in CH-A-691156 which includes a pair of rotatable crimping rollers, although it will be appreciated that the sheet may also be textured using other suitable machinery and processes which deform or perforate the sheet.

[0184] The inclusion of sugar in the sheet may advantageously facilitate the application of texture to the sheet.

[0185] The aerosol-generating rods can be manufactured using conventional cigarette filter manufacturing machinery.

[0186] For example, aerosol-generating rods comprising an assembly of sheets according to the present invention surrounded by a wrapper can be produced using machinery for forming filter rods comprising an assembly of crimped paper sheets of the type described in CH-A-691156.

[0187] A method of forming an aerosol-generating rod may include the steps of providing a continuous sheet according to the present invention, gathering the continuous sheet transversely to its longitudinal axis, surrounding the gathered continuous sheet with a wrapper to form a continuous rod, and cutting the continuous rod into a plurality of individual aerosol-generating rods.

[0188] Advantageously, the aerosol-generating rod may be of substantially uniform cross section.

[0189] The rod length of the aerosol-generating rod may advantageously be between about 5 mm and about 25 mm, between about 5 mm and about 20 mm, or between about 5 mm and about 15 mm.

[0190] As used herein in connection with the present invention, the term "rod length" is used to describe the maximum dimension in the direction of the cylindrical axis of the aerosol-generating rod.

[0191] The rod diameter of the aerosol-generating rod may advantageously be between about 6 mm and about 10 mm, between about 6 mm and about 9 mm, or between about 6 mm and about 8 mm.

[0192] As used herein in connection with the present invention, the term "rod diameter" is used to describe the largest dimension of the aerosol-generating rod in a direction substantially perpendicular to the cylindrical axis.

[0193] The aerosol-generating rod may comprise an assembly of sheets according to the present invention surrounded by a porous wrapper.

[0194] The aerosol-generating rod may comprise an assembly of sheets according to the present invention surrounded by a non-porous wrapper.

[0195] The aerosol-generating rod may be used as a component of an aerosol-generating article.

[0196] The aerosol-generating rod may be advantageously used as the aerosol-generating substrate in an aerosol-generating article.

[0197] Aerosol-generating rods may be used particularly advantageously as aerosol-generating substrates in heated aerosol-generating articles.

[0198] As used herein, the term "aerosol-generating substrate" is used to describe a material that has the ability to release volatile compounds upon heating to produce an aerosol.

[0199] An inhalable nicotine-containing aerosol is produced upon heating of the aerosol-generating substrate, including the aerosol-generating rod.

[0200] Many aerosol-generating articles have been proposed in the art in which the aerosol-forming substrate is heated rather than combusted. In heated aerosol-generating articles, the aerosol is typically generated by heat transfer from a heat source, e.g., a chemical, electrical, or combustible heat source, to a physically separated aerosol-generating substrate that may be located within, around, or downstream from the heat source.

[0201] The aerosol-generating rod may be used as the aerosol-generating substrate in a heated aerosol-generating article that includes a combustible heat source and an aerosol-generating substrate downstream of the combustible heat source.

[0202] For example, an aerosol-generating rod may be used as an aerosol-generating substrate in a heated aerosol-generating article of the type disclosed in WO 2009 / 022232 A2, which comprises a combustible carbon-based heat source, an aerosol-generating substrate downstream of the combustible heat source, and a thermally conductive element surrounding and in contact with a rear portion of the combustible carbon-based heat source and an adjacent front portion of the aerosol-generating substrate. Of course, an aerosol-generating rod may also be used as an aerosol-generating substrate in heated aerosol-generating articles comprising combustible heat sources having other configurations.

[0203] The aerosol-generating rod may be used as an aerosol-generating substrate in a heated aerosol-generating article for use in an electrically operated aerosol-generating system in which the aerosol-generating substrate of the heated aerosol-generating article is heated by an electrical heat source.

[0204] For example, an aerosol-generating rod may be used as the aerosol-generating substrate in an aerosol-generating article of the type disclosed in EP 0 822 760 A2.

[0205] The aerosol-generating article may comprise an aerosol-forming substrate including an aerosol-generating rod and one or more other elements.

[0206] The one or more other elements may include one or more of a support element, a spacer element, an aerosol cooling element, and a mouthpiece.

[0207] example Sheets according to the present invention are prepared having the compositions shown in Table 1.

[0208] [Table 1] To prepare the sheets, cellulose fiber, glycerin, nicotine lactic acid (solution), and water are placed in a tank and stirred at 1000 rpm for 1 minute. In a separate container, cellulose powder, sorbitol, and guar gum are manually premixed. The premixed cellulose powder, sorbitol, and guar gum are added to the tank containing cellulose fiber, glycerin, nicotine lactic acid (solution), and water. The resulting mixture is stirred at 5000 rpm for 4 minutes under vacuum (0.8 mbar).

[0209] The resulting slurry is poured onto a support surface and then dried to form a sheet.

[0210] The sheet is approximately 175 microns thick.

[0211] The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0212] [Figure 1] FIG. 1 shows a schematic cross-section of an apparatus for forming an aerosol-generating rod according to the present invention. [Figure 2] FIG. 2 shows an embodiment of an aerosol-generating article according to the present invention. [Figure 3] FIG. 3 shows an embodiment of an aerosol-generating article according to the present invention. [Figure 4] FIG. 4 shows an embodiment of an aerosol-generating article according to the present invention. [Figure 5] FIG. 5 shows an aerosol generating system including the electrically operated aerosol generating device and aerosol-generating article shown in FIG. [Figure 6] FIG. 6 is a schematic cross-sectional view of the electrically operated aerosol generating device shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0213] 1 generally includes a feed means for providing a continuous sheet according to the present invention, a crimping means for crimping the continuous sheet, a rod-forming means for gathering the continuous crimped sheet and surrounding the gathered material with a wrapper to form a continuous rod, and a cutting means for cutting the continuous rod into a plurality of individual aerosol-generating rods. The apparatus also includes a conveying means for conveying the continuous sheet from the feed means to the rod-forming means, via the crimping means, and downstream through the apparatus.

[0214] As shown in FIG. 1, the supply means for supplying a continuous sheet comprises a continuous sheet 2 according to the present invention mounted on a bobbin 4 .

[0215] The crimping means includes a pair of rotatable crimping rollers 6. In use, a continuous sheet 2 is drawn from a first bobbin 4 and conveyed downstream by a conveying mechanism through a series of guides and tension rollers to the pair of crimping rollers 6. As the continuous sheet 2 is fed between the pair of crimping rollers 6, the crimping rollers intermesh and crimp the sheet 2 through the apparatus to form a continuous crimped sheet 8 having a plurality of spaced ridges or corrugations substantially parallel to the longitudinal axis of the sheet.

[0216] The continuously crimped sheet 8 is conveyed downstream from the pair of crimping rollers 6 to a rod forming means where it is fed through a tapered funnel or horn 10. The tapered funnel 10 causes the continuous sheet 8 to converge transversely to its longitudinal axis. The sheet of material 8 assumes a substantially cylindrical structure as it passes through the tapered funnel 10.

[0217] Upon exiting the tapered funnel 10, the assembly of sheets is wrapped in a continuous sheet of wrapper material 12. The wrapper is a paper wrapper supplied from a bobbin 14 and wrapped around the assembly of continuously crimped sheets by an endless belt conveyor or tool. As shown in Figure 1, the rod-forming means includes adhesive application means 16 for applying adhesive to one of the longitudinal ends of the wrapper so that, when the opposing longitudinal ends of the wrapper come into contact, they adhere to one another to form a continuous rod.

[0218] The rod forming means further includes drying means 18 downstream of the adhesive application means 16 which, in use, dries the adhesive applied to the joints of the continuous rod as the continuous rod is conveyed downstream from the rod forming means to the cutting means.

[0219] The cutting means includes a rotary cutter 20 that cuts the continuous rod into a plurality of individual aerosol-generating rods 22 of unit rod length or multiple unit rod lengths.

[0220] FIG. 2 shows an aerosol-generating article 1000 according to a first embodiment of the present invention. The aerosol-generating article 1000 comprises an aerosol-forming substrate 1020 including an aerosol-generating rod, a hollow cellulose acetate tube 1030, a spacer element 1040, and a mouthpiece filter 1050. The aerosol-forming substrate 1020, the hollow cellulose acetate tube 1030, the spacer element 1040, and the mouthpiece filter 1050 are coaxially arranged in order and surrounded by an outer wrapper 1060 to form the aerosol-generating article 1000. The aerosol-generating article 1000 has an oral end 1012 that a user inserts into their mouth during use, and a distal end 1013 located at the end of the aerosol-generating article 100 opposite the oral end 1012. The aerosol-generating article 1000 shown in FIG. 2 is particularly suitable for use with an electrically operated aerosol-generating device that includes a heater for heating the aerosol-forming substrate 1020.

[0221] The aerosol-forming substrate 1020 comprises an aerosol-generating rod according to the present invention, which comprises a collection of crimped sheets according to the present invention surrounded by a wrapper.

[0222] The aerosol-generating article 1000 shown in Figure 2 is designed to engage with an aerosol-generating device that includes means for heating the aerosol-forming substrate 1020 to a temperature sufficient to form an aerosol. The aerosol-generating device may comprise a heating element that surrounds the aerosol-generating article 1000 adjacent to the aerosol-forming substrate 1020, or a heating element that is inserted into the aerosol-forming substrate 1020.

[0223] Upon engagement with an aerosol-generating device, the aerosol-forming substrate 1020 is heated to a temperature of approximately 220° C. At this temperature, a nicotine-containing aerosol is generated. The user draws on the mouth end 1012 of the aerosol-generating article 1000, and the aerosol is drawn downstream through the hollow cellulose acetate tube 1030, the spacer element 1040, and the mouthpiece filter 1050 into the user's mouth.

[0224] 3 shows an aerosol-generating article 5000 according to a second embodiment of the present invention. The aerosol-generating article 5000 comprises an aerosol-forming substrate 5020, a support element 5030, an aerosol cooling element 5040, and a mouthpiece 5050. The aerosol-forming substrate 5020, the support element 5030, the aerosol cooling element 5040, and the mouthpiece 5050 are coaxially arranged in sequence and surrounded by an outer wrapper 5060 to form the aerosol-generating article 5000. The aerosol-generating article 5000 has an oral end 5070, which a user inserts into the mouth during use, and a distal end 5080 located at the opposite end of the aerosol-generating article 5000 from the oral end 5070.

[0225] In use, volatile material emitted from the aerosol-forming substrate 5020 passes along the aerosol-cooling element 5040 towards the mouth end 5070 of the aerosol-generating article 5000. The volatile material may be cooled within the aerosol-cooling element 5040 to form an aerosol that is inhaled by the user. In the embodiment shown in Figure 5, the aerosol-cooling element comprises a collection of crimped sheets of polylactic acid surrounded by a wrapper. The aerosol-forming substrate 5020 comprises an aerosol-generating rod according to the present invention, comprising a collection of crimped sheets according to the present invention surrounded by a wrapper.

[0226] Figure 4 shows an aerosol-generating article 1001 according to a third embodiment of the present invention. Unlike the aerosol-generating articles according to the first and second embodiments of the present invention shown in Figures 2 and 3, the aerosol-generating article 1001 shown in Figure 4 includes a combustible heat source 1080 that, when ignited, transfers heat by conduction to an aerosol-forming substrate 1020 to generate an inhalable aerosol. The combustible heat source 1080 is a carbonaceous heat source located adjacent to the aerosol-forming substrate at the distal end 1013 of the aerosol-generating article 1001. Elements of the aerosol-generating article shown in Figure 4 that are essentially the same as elements of the aerosol-generating article shown in Figure 2 are numbered the same as the articles in Figure 2.

[0227] Figure 5 shows a portion of an electrically operated aerosol-generating system 2000 that uses a heating blade 2100 to heat the aerosol-generating substrate 1020 of the aerosol-generating article 1000. The heating blade is mounted within the aerosol-article receiving chamber of an electrically operated aerosol-generating device 2010. The aerosol-generating device 2010 defines a plurality of air holes 2050 that allow air to flow through the aerosol-generating article 1000. The air flow is indicated by arrows in Figure 5. The aerosol-generating device 2100 includes a power source and electronic components, which are not shown in Figure 5. The structure of the aerosol-generating article 1000 shown in Figure 5 is identical to that of the aerosol-generating article 1000 according to the first embodiment shown in Figure 2.

[0228] In Figure 6, the components of the aerosol generating device 2010 are shown in a simplified manner. The components of the aerosol generating device 2010 are not drawn to scale in Figure 6, and components that are not relevant to understanding the embodiment have been omitted to simplify Figure 6.

[0229] As shown in Figure 6, the aerosol-generating device 2010 includes a housing 6130. The heating element 6120 is mounted within an aerosol-generating article receiving chamber within the housing 6130. The aerosol-generating article 1000 (shown by a dashed line in Figure 6) is inserted into the aerosol-generating article receiving chamber within the housing 6130 of the aerosol-generating device 2010 such that the heating element 6120 is inserted directly into the aerosol-forming substrate 1020 of the aerosol-generating article 1000.

[0230] Within the housing 6130 is an electrical energy source 6140, such as a rechargeable lithium ion battery. A controller 6150 is connected to the heating element 6120, the electrical energy source 6140, and a user interface 6160, such as buttons or a display. The controller 6150 controls the power supplied to the heating element 6120 to regulate its temperature.

Claims

1. 1. An aerosol-generating article comprising an aerosol-generating substrate, the aerosol-generating substrate comprising a sheet comprising a fibrous material, one or more nicotine salts and a binder, the sheet having a total nicotine salt content of 1% to 6% by weight on a dry weight basis and a binder content of less than 8% by weight on a dry weight basis.

2. 2. The aerosol-generating article of claim 1, wherein the sheet has a binder content of from 1% to 8% by weight on a dry weight basis.

3. 3. The aerosol-generating article of claim 1 or 2, wherein the sheet comprises one or more gum binders.

4. 4. The aerosol-generating article according to claim 1, wherein the sheet comprises one or more natural gum binders selected from the group consisting of guar gum, xanthan gum, and gum arabic.

5. 5. The aerosol-generating article according to claim 1, wherein the weight ratio of binder to nicotine salt in the sheet is from 2:1 to 1:2 on a dry mass basis.

6. 6. The aerosol-generating article of claim 1, wherein the sheet comprises one or more nicotine salts selected from the group consisting of nicotine acetate, nicotine benzoate, nicotine gallate, nicotine lactate, nicotine laurate, nicotine levutate, nicotine palmitate, nicotine pyruvate, nicotine sorbate, and nicotine stearate.

7. The aerosol-generating article according to any one of claims 1 to 6, wherein the sheet further comprises sugar.

8. 8. The aerosol-generating article according to claim 1, wherein the sheet further comprises one or more aerosol formers selected from the group consisting of propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin.

9. 9. The aerosol-generating article of any one of claims 1 to 8, wherein the sheet comprises less than 2 weight percent tobacco material on a dry weight basis.

10. The aerosol-generating article according to any one of claims 1 to 9, wherein the sheet does not contain tobacco material.

11. 11. An aerosol-generating article according to any one of claims 1 to 10, wherein the sheets are gathered together and the gathered sheets are surrounded by a wrapper to form an aerosol-generating rod.

12. 12. An aerosol-generating article according to any one of claims 1 to 11, comprising a combustible heat source and the aerosol-generating substrate located downstream of the combustible heat source.

13. An aerosol-generating article according to any one of claims 1 to 12 for use in an electrically heated aerosol generating system.

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