Aerosol generation

Abstract

To provide an aerosol generating article comprising an aerosol generating substrate, and an aerosol generating assembly comprising an aerosol generating substrate or aerosol generating article, and a heater which is configured to heat but not burn the aerosol generating substrate.SOLUTION: An aerosol generating substrate 103 comprises an aerosol generating material, where the aerosol generating material comprises an amorphous solid. The amorphous solid comprises an aerosol generating agent, where at least 65 wt.% of the aerosol generating agent is aerosolised when heating the aerosol generating material to 370°C for ten seconds under a 1.95 L / min airflow.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to the generation of aerosols. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release compounds from a substrate material by heating without combustion, thereby emitting an inhalable aerosol or vapor. These are sometimes referred to as non-combustion smoking articles or aerosol-generating assemblies.

[0003] One example of such a product is a heating device that releases a compound by heating, but not burning, a solid aerosolizable material. The solid aerosolizable material, in some instances, may include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of a solid aerosolizable material.

[0004] Another example is an e-cigarette / tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosolizable material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce an inhalation vehicle. Summary of the Invention

[0005] Most generally, the invention provides an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material comprises an amorphous solid, the amorphous solid comprises an aerosol-generating agent, and wherein at least 65% by weight of the aerosol-generating agent is aerosolized when the aerosol-generating material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min.

[0006] In some embodiments, the aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 1 to 60% by weight of a gelling agent, and / or 5 to 80% by weight of an aerosol-forming agent, and / or 10 to 60% by weight of an active substance, and Optionally, flavorings, where these weights are calculated on a dry weight basis.

[0007] In certain embodiments, the amorphous solid is 1 to 60% by weight of a gelling agent, and / or 5 to 80% by weight of an aerosol-forming agent, and / or 10 to 60% by weight of tobacco extract, and Optionally, flavorings, where these weights are calculated on a dry weight basis.

[0008] In some embodiments, the aerosol-generating substrate comprises about 0.1 to 80% by weight of flavoring, calculated on a dry weight basis. In particular embodiments, the aerosol-generating substrate comprises about 0.5 to 60% by weight of flavoring, calculated on a dry weight basis.

[0009] The present invention also provides an aerosol product article comprising such an aerosol-generating substrate.The present invention also provides an aerosol-generating assembly comprising such an aerosol-generating substrate or aerosol product article and a heater configured to heat but not combust the aerosol-generating substrate.

[0010] A further aspect of the invention described herein may provide for the use of an aerosol-generating substrate, an aerosol product article, or an aerosol-generating assembly in the generation of an inhalable aerosol.

[0011] Further features and advantages of the present invention will become apparent from the following description, which is given by way of example only and with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view of an example of an aerosol product. [Figure 2] FIG. 2 is a perspective view of the article of FIG. 1. [Figure 3] 1 is a cross-sectional elevation view of an example aerosol product. FIG. [Figure 4] FIG. 4 is a perspective view of the article of FIG. 3. [Figure 5] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 6] FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. [Figure 7] FIG. 1 is a perspective view of an example of an aerosol generation assembly. DETAILED DESCRIPTION OF THE INVENTION

[0013] The aerosol-forming materials described herein comprise "amorphous solids." Amorphous solids are sometimes referred to as "monolithic solids" (i.e., non-fibrous) or "dry gels." Amorphous solids are solid materials that can retain some fluid, e.g., liquid, within them. In some examples, the aerosol-forming material comprises from 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight. In some examples, the aerosol-forming material consists of an amorphous solid.

[0014] As described above, the present invention provides an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material comprises an amorphous solid, the amorphous solid comprises an aerosol-generating agent, and at least 65 wt. % of the aerosol-generating agent is aerosolized when the aerosol-generating material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min.

[0015] In some examples, at least 68%, 70%, 72%, 75%, or 78% by weight of the aerosol-forming agent is aerosolized when the aerosol-forming material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min.

[0016] The inventors have demonstrated that transfer of aerosol-forming agents from amorphous solids is more efficient than transfer from other aerosolizable materials such as tobacco.

[0017] This means that an aerosol-generating material comprising an amorphous solid can deliver the required amount of aerosol after a shorter heating period. In other words, such a material can be heated intensively for a short period of time, reducing power consumption and increasing efficiency while still delivering the required amount of aerosol per puff. Due to the high transfer rate of the aerosol-generating material from the amorphous solid to the inhaled aerosol, it is possible to heat such a material only during the puff. Optionally, different portions of such a material can be heated to provide aerosol for different puffs.

[0018] In some instances, the amorphous solid comprises an active substance. For example, in some instances, the amorphous solid comprises tobacco extract and / or nicotine. In some instances, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of the active substance. In some instances, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of the tobacco extract and / or nicotine.

[0019] In some instances, the amorphous solid comprises an active agent such as tobacco extract. In some instances, the amorphous solid may comprise 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some instances, the amorphous solid may comprise from about 5%, 10%, 15%, 20%, or 25% to about 55%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 5-60%, 10-55%, or 25-55% by weight of tobacco extract.

[0020] The tobacco extract may contain nicotine in a concentration such that the amorphous solid comprises from 1%, 1.5%, 2%, or 2.5% to about 6%, 5%, 4.5%, or 4% nicotine by weight (calculated on a dry weight basis). In some instances, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0021] In some instances, the amorphous solid does not contain tobacco material but does contain nicotine. In some such instances, the amorphous solid may comprise from about 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% by weight of nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise 1-20% or 2-5% by weight of nicotine.

[0022] In some instances, the total active and / or fragrance content may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, while in some instances the total active and / or fragrance content may be less than about 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0023] In some examples, the total content of tobacco extract, nicotine, and flavorings may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, and in some examples, the total content of tobacco material, nicotine, and flavorings may be less than about 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0024] In some instances, the amorphous solid comprises 5-80% by weight of the aerosol generating agent. 1 to 60% by weight of a gelling agent, and / or 5 to 80% by weight of an aerosol-forming agent, and / or 0.1 to 60% by weight of active substances and / or flavorings, where these weights are calculated on a dry weight basis (DWB).

[0025] In some instances, the amorphous solid comprises 5-80% by weight of the aerosol generating agent. 1 to 60% by weight of a gelling agent, and / or 5 to 80% by weight of an aerosol-forming agent, and / or 10 to 60% by weight of tobacco extract and / or nicotine and / or flavoring; where these weights are calculated on a dry weight basis (DWB).

[0026] The inventors have found that amorphous solids having this composition can be efficiently heated to produce inhalable aerosols.

[0027] Furthermore, the inventors have found that transfer of the active agent from such amorphous solids is more efficient than transfer from other aerosolizable materials, such as tobacco. In some instances, at least 70%, 72%, 75%, 78%, or 80% by weight of the active agent is aerosolized when the aerosol-forming material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min. In some instances, at least 70%, 72%, 75%, 78%, or 80% by weight of the total active ingredient is aerosolized when the aerosol-forming material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min.

[0028] As used herein, "active ingredient," which may alternatively be referred to as "volatile ingredient" or "volatile material," refers to a component of the amorphous solid that has a physiological or sensory effect on the human body. Specifically, the active ingredient can therefore comprise nicotine or a derivative thereof, a scent, and a high vapor pressure flavoring. In some instances, the amorphous solid comprises nicotine. In some instances, the amorphous solid comprises a flavoring. In some instances, the flavoring comprises or consists of menthol.

[0029] The amorphous solid may, in some instances, be a hydrogel and may comprise less than about 20%, 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). In some instances, the amorphous solid may comprise at least about 1%, 2%, or 5% water by weight (WWB). In some instances, the amorphous solid comprises from about 1% to about 15%, or from about 5% to about 15% water by weight, calculated on a wet weight basis. Preferably, the water content of the amorphous solid may be from about 5%, 7%, or 9% to about 15%, 13%, or 11% (WWB), most preferably about 10%.

[0030] In some instances, the amorphous solid may comprise 1-60% by weight of gelling agent, where these weights are calculated on a dry weight basis. Preferably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, 35%, 30%, or 27% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50%, 5-40%, 10-30%, or 15-27% by weight of gelling agent.

[0031] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), 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, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginate and / or pectin, which may be combined with a setting agent (such as a calcium source) during the formation of the amorphous solid. In some examples, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0032] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30% by weight (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.

[0033] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0034] The amorphous solid may comprise from about 5%, 10%, 20%, 25%, 27%, or 30% to about 60%, 55%, 50%, 45%, 40%, or 35% by weight of an aerosol generating agent (DWB). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise 10-60%, 20-50%, 25-40%, or 30-35% by weight of an aerosol generating agent. In some examples, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol generating agent comprises, consists essentially of, or consists of glycerol. The inventors have found that if the plasticizer content is too high, the amorphous solid may absorb water (because the aerosol generating agent is hygroscopic), resulting in a material that does not produce a suitable consumption experience when used. The inventors have found that if the plasticizer content is too low, the amorphous solid may become brittle and easily break. The plasticizer content specified herein provides the amorphous solid with flexibility that allows the amorphous solid sheet to be wound onto a bobbin, which is useful for producing aerosol products.

[0035] The amorphous solid may comprise from about 10%, 20%, 30%, 40%, or 45% by weight to about 50%, 55%, or 60% (DWB) tobacco extract. For example, the amorphous solid may comprise 20-60%, 40-55%, or 45-50% tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises from about 1%, 1.5%, or 2% by weight to about 6%, 5%, 4%, or 3% (DWB) nicotine. In some instances, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0036] In some instances, the tobacco extract may be an aqueous extract obtained by extraction with water. The tobacco extract may be an extract from any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. It may also be an extract from tobacco particle "fines" or dust, expanded tobacco, petioles, expanded petioles, and other processed petiole materials (such as rolled cut petioles). The extract may be obtained from ground tobacco or reconstituted tobacco material.

[0037] In some examples, the amorphous solid may comprise a flavoring. Preferably, the amorphous solid may comprise up to about 60%, 50%, 40%, 30%, 20%, 10%, or 5% by weight of flavoring. In some examples, the amorphous solid may comprise at least about 0.1%, 0.5%, 1%, 2%, 5%, 10%, 20%, or 30% by weight of flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60%, 1-60%, 5-60%, 10-60%, 20-50%, or 30-40% by weight of flavoring. In some examples, the flavoring (if present) comprises, consists essentially of, or consists of menthol. In some examples, the amorphous solid is free of flavoring.

[0038] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, for example, between 1% and 60% by weight, or between 5% and 50% by weight, or between 5% and 30% by weight, or between 10% and 20% by weight of filler.

[0039] In other embodiments, the amorphous solid comprises less than 20% by weight of filler, preferably less than 10% by weight or less than 5% by weight, hi some instances, the amorphous solid comprises less than 1% by weight of filler, and in some instances, no filler.

[0040] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). The filler may also comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0041] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that including a fibrous filler in an amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in instances where the amorphous solid is provided as a sheet, for example, when the amorphous solid sheet surrounds a rod of aerosolizable material.

[0042] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0043] In some embodiments, the aerosol-forming material does not comprise tobacco fiber. In certain embodiments, the aerosol-forming material does not comprise fibrous material.

[0044] In some embodiments, the aerosol-generating substrate does not comprise tobacco fibers. In certain embodiments, the aerosol-generating substrate does not comprise fibrous material.

[0045] In some embodiments, the aerosol product does not comprise tobacco fiber. In certain embodiments, the aerosol product does not comprise fibrous material.

[0046] In some instances, the amorphous solid may consist essentially of or consist of a gelling agent, an aerosol generating agent, an active agent, water, and optionally a flavoring. In some instances, the amorphous solid may consist essentially of or consist of glycerol, alginate and / or pectin, an active agent, and water.

[0047] In some instances, the amorphous solid may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, a tobacco extract, water, and optionally a flavoring. In some instances, the amorphous solid may consist essentially of, or consist of, glycerol, alginate and / or pectin, a tobacco extract, and water.

[0048] In some instances, the aerosol-generating substrate may further comprise a carrier onto which the amorphous solid is disposed, which may facilitate manufacturing and / or handling by, for example, (a) providing a surface onto which the slurry can be applied (and from which the slurry does not have to be subsequently separated), (b) providing a non-stick surface for the aerosol-generating material, and (c) providing some rigidity to the substrate.

[0049] In some examples, the aerosol-generating substrate comprises a carrier on which the amorphous solid is disposed. In some examples, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some examples, the carrier may comprise or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the carrier comprises paper. In some examples, the carrier itself is a laminated structure comprising multiple layers of materials selected from the foregoing list. In some examples, the carrier may be impregnated with flavorings or tobacco extract.

[0050] In some instances, the carrier may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the carrier layer during use, thereby controlling the flow and ensuring delivery of the aerosol or gas to the user. This may also be utilized to prevent condensation or other deposition of the gas / aerosol during use, for example, on the surface of a heater provided within the aerosol generating assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

[0051] In some instances, the carrier in the aerosol product may comprise or consist of a porous layer in contact with the amorphous solid. For example, the porous layer may be a paper layer. In some specific instances, the amorphous solid is placed in direct contact with the porous layer, and the porous layer forms a strong bond with the amorphous solid. Without being limited by theory, it is believed that the amorphous solid is formed by drying a gel, and the slurry from which the gel is formed partially impregnates the porous layer (e.g., paper) so that the porous layer partially bonds to the gel when the gel hardens and forms crosslinks. This provides a strong bond between the gel and the porous layer (and between the dried gel and the porous layer).

[0052] In addition, surface roughness can contribute to the strength of the bond between the amorphous material and the carrier. The inventors have found that the roughness of the paper (the roughness of the surface in contact with the carrier) can be preferably in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, and preferably 100 Bekk seconds (measured over an air pressure range of 50.66 to 48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specific pressure is forced between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness.")

[0053] Conversely, the surface of the carrier not facing the amorphous solid may be placed in contact with the heater, and a smoother surface may provide more efficient heat transfer, so in some instances the carrier is positioned with a rougher side abutting the amorphous material and a smoother side opposite the amorphous material.

[0054] In one particular example, the carrier may be a paper-backed foil, where the paper layer abuts the amorphous solid layer, providing the properties discussed in the previous paragraphs. The foil backing is substantially impermeable and provides aerosol flow path control. The metal foil backing may also act to transfer heat to the amorphous solid.

[0055] In another example, a foil layer of a paper-backed foil abuts the amorphous solid, and the foil is substantially impermeable to prevent moisture provided in the amorphous solid from being absorbed into the paper, which could weaken the structural integrity of the paper.

[0056] In some examples, the carrier is formed from or comprises a metal foil (e.g., aluminum foil). A metallic carrier may allow for better transfer of thermal energy to the amorphous solid. Additionally, or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (e.g., cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0057] In some instances, the carrier may be magnetic. This feature may be used to secure the carrier to an assembly during use or to generate a particular amorphous solid form. In some instances, the aerosol-generating substrate may include one or more magnets that can be used to secure the substrate to an induction heater during use.

[0058] In some instances, the aerosol-forming material may comprise a heating means, such as a resistive or inductive heating element, embedded in the amorphous solid.

[0059] In some instances, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials having a thickness of 0.2 mm are particularly suitable. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0060] The inventors have found that if the amorphous solid is too thick, heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. That is, very thin materials are more difficult to cast and are prone to breakage, which can impair aerosol formation during use.

[0061] The inventors have found that the thickness of the amorphous solid defined herein optimizes material properties taking into account these competing considerations. The thickness defined herein is the average thickness of the material. In some instances, the thickness of the amorphous solid may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0062] The aerosol-forming material comprising an amorphous solid may have any suitable areal density, for example, 30 g / m 2 ~120g / m 2 In some embodiments, the aerosol-forming material may have a density of about 30 to 70 g / m 2 , or about 40 to 60 g / m 2 In some embodiments, the amorphous solid may have an areal density of about 80-120 g / m 2 , or approximately 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2Such areal densities may be particularly suitable when the aerosol-forming material is included in the aerosol product article / assembly in sheet form or as chopped sheets (discussed further below).

[0063] The amorphous solid may be formed as a sheet. It may be incorporated into an article in sheet form. In some examples, the aerosol-forming material may be included as a flat sheet, a pleated or gathered sheet, a corrugated sheet, or a rolled sheet (i.e., in the form of a tube). In some such examples, the amorphous solid of these embodiments may be included in an aerosol product article / assembly as a sheet, for example, as a sheet surrounding a rod of aerosolizable material (such as tobacco). In other examples, the aerosol-forming material may be formed as a sheet and then shredded and incorporated into an article. In some examples, the shredded sheet may be mixed with cut rag tobacco and incorporated into an article. In such cases, the aerosol-forming material may be formed in a thickness of 80 to 120 g / m 2 (thus it has a density comparable to cut rag tobacco and therefore the mixture components do not separate).

[0064] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-forming material is formed as a sheet, then shredded, and incorporated into an aerosol product. In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-forming material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0065] In some examples, at least a portion of the aerosol-generating material is included as a rolled sheet, forming a tubular rod of aerosol-generating material. The tubular nature of the aerosol-generating material in such cases can be adapted for use in many ways. In some examples, the aerosol product article is configured for use with an aerosol-generating assembly having a heater disposed inside the tube during use. In other examples, the aerosol product article is configured for use with an aerosol-generating assembly having a heater disposed outside the tube during use. In such cases, no components of the aerosol-generating assembly may be disposed within the tube during use; rather, the tube provides a flow path for the aerosol or vapor during use, which can reduce or prevent condensation of the aerosol or vapor on reusable components of the aerosol-generating assembly, thereby improving consumption efficiency and hygiene. In some such examples, the outer wall of the tube is substantially or completely impermeable to the gas / aerosol and can further control the flow path.

[0066] Other aspects of the invention include aerosol product articles comprising the aerosol-forming materials described herein, and aerosol-generating assemblies comprising such aerosol-generating substrates or articles.

[0067] In some examples, the article or assembly may further comprise a filter and / or a cooling element. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some examples, the cooling element may act to cool the gaseous components so that they condense to form an aerosol. The cooling element may also act to move hot portions of the device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0068] The heater in the assembly is configured to heat but not combust the aerosol-generating material. In some examples, the heater may be a thin-film electrical resistance heater. In other examples, the heater may include an induction heater or other heater. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol-generating assembly may include multiple heaters. The heaters may be powered by a battery.

[0069] In some examples, the heater, when in use, may heat the aerosolizable material to between 120°C and 350°C without burning the aerosolizable material. In some examples, the heater, when in use, may heat the aerosolizable material to between 140°C and 250°C without burning the aerosolizable material. In some examples, when in use, substantially the entire amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some examples, the solid is positioned between about 0.010 mm and 2.0 mm, preferably between about 0.02 mm, 0.05 mm, 0.1 mm and 1.0 mm, or 0.5 mm from the heater. These minimum distances may, in some examples, reflect the thickness of the carrier supporting the amorphous solid. In some examples, the surface of the amorphous solid may directly abut the heater.

[0070] In some instances, the heater may be embedded in the aerosol-generating substrate. In such instances, the heater may be an electrical resistance heater (with exposed contacts for connection to an electrical circuit). In other such instances, the heater may be an inductively heated susceptor embedded in the aerosol-generating substrate.

[0071] In some examples, the aerosol-generating assembly may be a heat-not-burn device. That is, the aerosol-generating assembly may include a solid tobacco-containing material (and not a liquid aerosolizable material). In some examples, the amorphous solid may comprise a tobacco material. A heat-not-burn device is disclosed in WO 2015 / 062983 A2, the entirety of which is incorporated herein by reference.

[0072] In some examples, the aerosol-generating assembly may be an e-cigarette hybrid device. That is, the aerosol-generating assembly may include a solid aerosolizable material and a liquid aerosolizable material. In some examples, the amorphous solid may comprise nicotine. In some examples, the amorphous solid may comprise a tobacco material. In some examples, the amorphous solid may comprise a tobacco material and a separate nicotine source. These separate aerosolizable materials may be heated by separate heaters or the same heater, and in some examples, the downstream aerosolizable material may be heated by a hot aerosol generated from the upstream aerosolizable material. An e-cigarette hybrid device is disclosed in WO 2016 / 135331 A1, the entirety of which is incorporated herein by reference.

[0073] The aerosol production article or assembly may further include vent holes. These may be located in the sidewalls of the article. In some instances, the vent holes may be located in the filter and / or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0074] Ventilation promotes the production of visible heated volatiles from the article when the article is heated during use. The heated volatiles are made visible by cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation), and ultimately, the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and coalescence of newly formed droplets from the heated volatiles.

[0075] In some instances, the ratio of cool air to the sum of heated volatiles and cool air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0076] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0077] The assembly may comprise an integrated aerosol production article and heater, or may comprise a heating device into which the article is inserted during use.

[0078] 1 and 2, there is shown a partially cutaway cross-sectional view and a perspective view of an example aerosol production article 101. Article 101 is adapted for use with a device having a power source and a heater. This embodiment of article 101 is particularly suited for use with device 51, described below, and shown in FIGS. 5-7. In use, article 101 can be removably inserted into device 51 at insertion point 20, shown in FIG. 5.

[0079] The example article 101 is in the form of a generally cylindrical rod including a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol-generating material as described herein may be incorporated in both sheet and chopped form.

[0080] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The body of aerosol-generating material 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the body of aerosol-generating material 103, between the body of aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in abutting relationship with the aerosol-generating material 103 and the filter segment 109. In another example, there may be separations between the body of aerosol-generating material 103 and the cooling segment 107 and between the body of aerosol-generating material 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed at proximal end 113 of article 101 and is adjacent to filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0081] In one example, the rod of aerosol-forming material 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably 42 mm.

[0082] In one example, the overall length of the article 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0083] One axial end of the body of aerosol-generating material 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers one axial end of the body of aerosol-generating material 103.

[0084] The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is positioned substantially around the filter assembly 105 to surround it and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0085] In one example, cooling segment 107 is an annular tube that surrounds and defines a cavity within the cooling segment. This cavity provides a chamber through which heated volatile components generated from body 103 of aerosol-generating material flow. Cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into device 51. In one example, the wall thickness of cooling segment 107 is approximately 0.29 mm.

[0086] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperatures of the aerosol-generating material 103 when the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the aerosol-generating material body 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and may no longer be able to effectively perform its required function.

[0087] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, even more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0088] The cooling segment 107 is made from paper, meaning that the cooling segment 107 is constructed from a material that, in use, does not produce compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0089] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into device 51.

[0090] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0091] In some embodiments, a capsule (not shown) may be provided within filter segment 109. The capsule may be located substantially in the center of filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, if a capsule is present, the capsule may contain a volatile component, such as a flavoring or an aerosol-forming agent.

[0092] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to draw of the article 101. Therefore, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the article 101. Additionally, the filter segment performs a filtration function in the article 101.

[0093] In one example, filter segment 109 is made from 8Y15 grade filter tow material, which provides filtering for the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0094] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips against the surface of filter segment 109.

[0095] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0096] The mouth end segment 111 is an annular tube that surrounds and defines a cavity within the mouth end segment 111. This cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacturing and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0097] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0098] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0099] It should be understood that in one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 positioned within the tube to separate the mouth end segment 111 and the cooling segment 107.

[0100] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0101] 3 and 4, a ventilation region 317 is provided in the article 301 to allow air to flow from the exterior of the article 301 to the interior of the article 301. In one example, the ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of the article 301. The vent holes may be located in the cooling segment 307 to aid in cooling the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of the article 301 in a cross section substantially perpendicular to the longitudinal axis of the article 301.

[0102] In one example, there are 1 to 4 rows of vent holes to provide ventilation to article 301. Each row of vent holes may have 12 to 36 vent holes 317. The diameter of vent holes 317 may be, for example, 100 to 500 μm. In one example, the axial spacing between rows of vent holes 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0103] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

[0104] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The vent holes 317 are located such that the user will not block the vent holes 317 when the article 301 is in use.

[0105] By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be positioned on the outside of the device 51 when the article 301 is fully inserted into the device 51, as seen in Figures 6 and 7. By positioning the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 51 through the vent holes to help cool the article 301.

[0106] The length of cooling segment 307 is such that when item 301 is fully inserted into device 51 , cooling segment 307 is partially inserted into device 51 . The length of this cooling segment 307 serves two functions: first, to provide a physical gap between the heating apparatus of device 51 and heat-sensitive filter apparatus 309; and second, to allow vent hole 317 to be located within the cooling segment while also being located outside device 51 when item 301 is fully inserted into device 51. As can be seen in FIGS. 6 and 7 , the majority of cooling element 307 is located within device 51. However, there is a portion of cooling element 307 that extends outside device 51. This portion of cooling element 307 that extends outside device 51 is where vent hole 317 is located.

[0107] 5-7, an example of a device 51 is shown that is configured to heat an aerosol-forming material to volatilize at least one component of the aerosol-forming material, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, but not burning, the aerosol-forming material.

[0108] The first end 53 may be referred to herein as the oral or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on / off button 57 that allows the entire device 51 to be activated and deactivated as desired by the user.

[0109] The device 51 includes a housing 59 for arranging and protecting the various internal components of the device 51. In the illustrated example, the housing 59 includes a unitary sleeve 11 that surrounds the outer edge of the device 51, the sleeve 11 being capped by a top panel 17 that generally forms the "top" of the device 51 and a bottom panel 19 that generally forms the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

[0110] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 51, or may be "permanently" secured to unitary sleeve 11, for example, to prevent a user from accessing the interior of device 51. In one example, panels 17 and 19 are made of a plastic material (including, for example, glass-filled nylon formed by injection molding) and unitary sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0111] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, through which a user can insert and remove an item 101, 301 containing an aerosol-generating material into and from the device 51 during use.

[0112] Housing 59 has disposed therein or secured thereto heating device 23, control circuitry 25, and power supply 27. In this example, heating device 23, control circuitry 25, and power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuitry 25 generally located between heating device 23 and power supply 27, although other arrangements are possible.

[0113] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol-forming material within the article 101, 301, as discussed further below.

[0114] Power source 27 may be, for example, a battery, which may be rechargeable or non-rechargeable. Suitable examples of batteries include, for example, lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and, under the control of control circuitry 25, provides power when needed to heat the aerosol-forming material within the article (to volatilize the aerosol-forming material without burning it, as described above).

[0115] An advantage of locating power supply 27 laterally adjacent to heating apparatus 23 is that a physically larger power supply 25 can be used without excessively lengthening the overall length of device 51. Of course, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore can provide a longer battery life for device 51.

[0116] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular around its circumference. In one example, the or each heating element may be a thin-film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramic and aluminum nitride ceramic, as well as silicon nitride ceramic, which may be layered and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), and resistive heating elements formed by resistive electrical windings, etc.

[0117] In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned so that when the article 101, 301 is inserted into the device 51, substantially the entire body of the article 101, 301, which is made of aerosol-forming material 103, 303, is inserted into the heating device 23.

[0118] The or each heating element may be arranged to heat selected zones (areas) of aerosol-forming material independently, for example sequentially (over time as described above) or together (simultaneously), as desired.

[0119] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps reduce heat passing from the heating device 23 to the exterior of the device 51. This generally reduces heat loss, and therefore helps keep the power requirements of the heating device 23 low. The insulation 31 also helps keep the exterior of the device 51 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low-pressure region between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of insulating materials (e.g., including suitable foam-type materials) in addition to or in place of the double-walled sleeve.

[0120] The housing 59 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23 .

[0121] The device 51 further includes a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f spaced along the exterior surface of the chamber 35, each fin circumferentially disposed about the exterior surface of the chamber 35. When the item 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the item 101, 301. The gap 36 surrounds the entire periphery of the item 101, 301 over at least a portion of the cooling segment 307.

[0122] The collar 33 includes a plurality of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage with and help secure an item 101, 301 inserted within the device 51. Open spaces (not shown) defined by adjacent pairs of the ridges 60 and the items 101, 301 form ventilation paths around the outer surfaces of the items 101, 301. These ventilation paths allow hot steam escaping from the items 101, 301 to exit the device 51 and allow cooling air to flow into the device 51 around the items 101, 301 within the gap 36.

[0123] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. Referring specifically to Figure 6, in one example, the body of aerosol-generating material 103, 303 (which is located at the distal end 115, 315 of the article 101, 301) is completely contained within the heating element 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

[0124] During operation, the heating device 23 heats the article 101, 301 to volatilize at least one component of the aerosol-forming material from the body 103, 303 of aerosol-forming material.

[0125] The primary flow path for heated volatiles from the body of aerosol-generating material 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth-end segment 111, 313 to the user. In one example, the temperature of heated volatiles generated from the body of aerosol-generating material ranges from 60°C to 250°C, which may exceed acceptable inhalation temperatures for a user. As the heated volatiles travel through the cooling segment 107, 307, they cool, causing some volatiles to condense on the interior surface of the cooling segment 107, 307.

[0126] In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0127] In some examples, a method of making an aerosol-generating material includes (a) forming a slurry comprising components of an amorphous solid material, (b) casting a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying the gel to form an amorphous solid.

[0128] Step (b) of forming the layer of slurry may comprise, for example, spraying, casting, or extruding the slurry. In some examples, the slurry layer is formed by electrostatically spraying the slurry. In some examples, the slurry layer is formed by casting the slurry.

[0129] In some instances, steps (b) and / or (c) and / or (d) may occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, these steps may occur sequentially.

[0130] Step (b) may comprise forming a layer of the slurry on the carrier.

[0131] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5°C, such as a viscosity of about 14 to about 16 Pa·s at 46.5°C.

[0132] The step (c) of hardening the gel may comprise adding a hardening agent to the slurry. For example, the slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as a gelling agent, and a hardening agent comprising a calcium source (e.g., calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0133] The total amount of hardening agent, e.g., calcium source, may be 0.5 to 5 wt. % (calculated on a dry weight basis). The inventors have found that adding too little hardening agent may result in an amorphous solid that does not stabilize the amorphous solid components, causing these components to detach from the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

[0134] In some instances, however, a stiffening agent is not necessary: ​​the tobacco extract may contain enough calcium to effect gelation.

[0135] Alginate is a derivative of alginic acid and is typically a high molecular weight polymer (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginate crosslinks to form a gel. The inventors have determined that alginate with a high G monomer content more readily forms a gel upon addition of a calcium source. Thus, in some examples, the gel precursor may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0136] The slurry itself may also form part of the present invention. In some instances, the slurry solvent may consist essentially of or consist of water. In some instances, the slurry may comprise about 50%, 60%, 70%, 80%, or 90% or more by weight (WWB) of solvent.

[0137] In instances where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the amorphous solids. Thus, discussion herein of the composition of solids is expressly disclosed in conjunction with the slurry aspect of the invention.

[0138] Illustrative Embodiments In some embodiments, the amorphous solid comprises menthol.

[0139] Certain embodiments comprising menthol-containing amorphous solids may be particularly suitable for inclusion as shredded sheets in an aerosol product / assembly. In these embodiments, the amorphous solids may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 20% to about 40%, or about 25% to 35% by weight (DWB), menthol in an amount of about 35% to about 60%, or about 40% to 55% by weight, and aerosol generating agent (preferably comprising glycerol) in an amount of about 10% to about 30%, or about 15% to about 25% by weight.

[0140] In one embodiment, the amorphous solid comprises (DWB) about 32-33% by weight of an alginate / pectin gelling agent blend, about 47-48% by weight of a menthol flavoring, and about 19-20% by weight of a glycerol aerosol forming agent.

[0141] As noted above, the amorphous solid of these embodiments may be included in the aerosol product article / assembly as a shredded sheet. The shredded sheet may be blended with cut tobacco and provided in the article / assembly. Alternatively, the amorphous solid may be provided as an unshredded sheet. Suitably, the shredded or unshredded sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0142] Certain embodiments of the menthol-containing amorphous solid may be particularly suitable for inclusion in an aerosol product / assembly as a sheet, such as a sheet surrounding a rod of aerosolizable material (such as tobacco). In these embodiments, the amorphous solid may have the following composition (DWB): (DWB) gelling agent (preferably comprising alginate, more preferably a combination of alginate and pectin) in an amount of about 5% to about 40%, or about 10% to 30% by weight; menthol in an amount of about 10% to about 50%, or about 15% to 40% by weight; aerosol-forming agent (preferably comprising glycerol) in an amount of about 5% to about 40%, or about 10% to about 35% by weight; and optionally, filler in an amount up to 60% by weight (e.g., 5% to 20%, or 40% to 60% by weight).

[0143] In one of these embodiments, the amorphous solid comprises (DWB) about 11% by weight alginate / pectin gelling agent blend, about 56% by weight wood pulp filler, about 18% menthol flavoring, and about 15% by weight glycerol.

[0144] In another of these embodiments, the amorphous solid comprises (DWB) about 22% by weight alginate / pectin gelling agent blend, about 12% by weight wood pulp filler, about 36% menthol flavoring, and about 30% by weight glycerol.

[0145] As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is disposed on a carrier comprising paper. In one embodiment, the sheet is disposed on a carrier comprising metal foil, preferably aluminum metal foil. In this embodiment, the amorphous solid may abut against the metal foil.

[0146] In one embodiment, the sheet forms part of a laminate material with layers (preferably comprising paper) attached to the top and bottom of the sheet. Suitably, the sheet of amorphous solid has a thickness of from about 0.015 mm to about 1 mm.

[0147] In some embodiments, the amorphous solid comprises a flavoring that does not comprise menthol. In these embodiments, the amorphous solid may have the following composition (DWB): a gelling agent (preferably comprising alginate) in an amount of about 5 to about 40 wt %, or about 10 to about 35 wt %, or about 20 to about 35 wt % (DWB); a flavoring agent in an amount of about 0.1 to about 40 wt %, about 1 to about 30 wt %, about 1 to about 20 wt %, or about 5 to about 20 wt %; an aerosol-forming agent (preferably comprising glycerol) in an amount of 15 to 75 wt %, about 30 to about 70 wt %, or about 50 to about 65 wt %; and optionally a filler (suitably wood pulp) in an amount of about 60 wt %, about 20 wt %, about 10 wt %, or less than about 5 wt % (preferably, the amorphous solid is filler-free).

[0148] In one of these embodiments, the amorphous solid comprises (DWB) about 27% by weight alginate gelling agent, about 14% by weight flavoring, and about 57% by weight glycerol aerosol forming agent.

[0149] In another of these embodiments, the amorphous solid comprises (DWB) about 29% by weight alginate gelling agent, about 9% by weight flavoring, and about 60% by weight glycerol.

[0150] The amorphous solids of these embodiments may be included in the aerosol product / assembly as shredded sheets, optionally blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in the aerosol product / assembly as sheets, such as sheets surrounding a rod of aerosolizable material (such as tobacco). Alternatively, the amorphous solids of these embodiments may be included in the aerosol product / assembly as a layer portion disposed on a carrier.

[0151] In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may have the following composition (DWB): a gelling agent (preferably comprising alginate) in an amount of about 5% to about 40%, about 10% to about 30%, or about 15% to about 25% by weight (DWB); a tobacco extract in an amount of about 30% to about 60%, about 40% to about 55%, or about 45% to about 50% by weight; and an aerosol-forming agent (preferably comprising glycerol) in an amount of about 10% to about 50%, about 20% to about 40%, or about 25% to about 35% by weight.

[0152] In one embodiment, the amorphous solid comprises (by weight on a DWB basis) about 20% alginate gelling agent, about 48% Virginia tobacco extract, and about 32% glycerol.

[0153] The amorphous solid of these embodiments may have any suitable water content, for example, from about 5% to about 15% by weight, or from about 7% to about 13% by weight, or about 10% by weight.

[0154] The amorphous solid of these embodiments may be included in the aerosol product / assembly as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in the aerosol product / assembly as a sheet, for example, a sheet surrounding a rod of aerosolizable material (such as tobacco). Alternatively, the amorphous solid of these embodiments may be included in the aerosol product / assembly as a layer disposed on a carrier. Preferably, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0155] The slurry for forming the amorphous solid may also form part of the present invention. In some examples, the slurry may have an elastic modulus (also called storage modulus) of about 5 to 1200 Pa, and in some examples, the slurry may have a viscous modulus (also called loss modulus) of about 5 to 600 Pa.

[0156] definition As used herein, an active substance is a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active substance may be selected from, for example, functional foods, nootropics, and psychoactive substances. The active substance may be naturally occurring or synthetically derived. The active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other botanical materials.

[0157] In some embodiments, the active substance comprises nicotine.

[0158] In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0159] As described herein, the active substance may comprise one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0160] Cannabinoids are a class of natural or synthetic compounds that act on intracellular cannabinoid receptors (i.e., CB1 and CB2) that inhibit neurotransmitter release in the brain. Cannabinoids can be found naturally in plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis species exhibit at least 85 different phytocannabinoids, divided into several subcategories. These subcategories include cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol, and cannabinodiol, as well as other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0161] As described herein, the active agent may comprise or be derived from one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, peels, etc. Alternatively, the material may comprise an active compound naturally occurring in the plant material or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, shreds, sheets, etc. Examples of botanical ingredients include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, Calvi, 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: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Menthapiperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Menthapulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0162] In some embodiments, the plant material is selected from eucalyptus, star anise, cocoa, and hemp.

[0163] In some embodiments, the plant material is selected from rooibos and fennel.

[0164] As used herein, the terms "flavoring" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sheesh Shisha, pineapple, honey essence, 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 from any species of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai citric acid, citric acid, citric acid, citric acid salts ...They may contain artificial, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, for example, liquid (such as an oil), solid (such as a powder), or gas.

[0165] The flavoring may suitably comprise one or more mint flavors, suitably mint oil from any species of the mint genus. The flavoring may suitably comprise, consist essentially of, or consist of menthol.

[0166] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint.

[0167] In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components.

[0168] In some embodiments, the fragrance comprises eugenol.

[0169] In some embodiments, the flavoring comprises flavor components extracted from tobacco.

[0170] In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0171] In some embodiments, the flavoring agent may comprise a sensory agent intended to achieve somatic sensations typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and these may include agents that provide a heating, cooling, tingling, or numbing effect. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol or WS-3.

[0172] As used herein, the term "aerosol-generating agent" refers to an agent that facilitates the generation of an aerosol. The aerosol-generating agent may facilitate the generation of an aerosol by facilitating the initial volatilization and / or condensation of a gas into an inhalable solid and / or liquid aerosol.

[0173] Suitable aerosol generating agents include, but are not limited to, polyols, such as erythritol, sorbitol, glycerol, and glycols such as propylene glycol and triethylene glycol, as well as non-polyols, such as monohydric alcohols, high-boiling hydrocarbons, acids (such as lactic acid), glycerol derivatives, esters (such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristates (including ethyl myristate and isopropyl myristate)), and aliphatic carboxylic acid esters (such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate). The aerosol generating agent may preferably have a composition that does not dissolve menthol. The aerosol generating agent may preferably comprise, consist essentially of, or consist of glycerol.

[0174] As used herein, the term "tobacco material" refers to any material comprising tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract.

[0175] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag, or whole leaf, including Virginia and / or Burley and / or Oriental. It may also be tobacco particle "fines" or dust, expanded tobacco, petioles, expanded petioles, and other processed petiole materials (such as rolled cut petioles). The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fiber and may be formed by casting, a Fourdrinier approach with back-addition of tobacco extract, or extrusion.

[0176] All weight percentages (indicated as wt. %) described herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights indicated on a dry weight basis refer to the total extract, slurry, or material except for water, and may include components that are liquids themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages indicated on a wet weight basis refer to all components, including water.

[0177] For the avoidance of doubt, where the term "comprising" is used herein in defining the invention or features of the invention, embodiments are also disclosed in which the invention or features may be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material "comprising" certain features means that those features are contained in, contained in, or retained within the material.

[0178] The above-described embodiments should be understood as illustrative of the present invention. It should be understood that any feature described in connection with any one embodiment may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other embodiment or any combination of any other embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, as defined in the appended claims.

Claims

1. an aerosol-generating substrate comprising an aerosol-generating material, the aerosol-generating material comprising an amorphous solid, the amorphous solid comprising an aerosol-generating agent, at least 65 wt.% of the aerosol-generating agent being aerosolized when the aerosol-generating material is heated to 370°C for 10 seconds under an airflow of 1.95 L / min; The aerosol-forming material comprising the amorphous solid has a density of 30 g / m ２ ~120g / m ２ an aerosol-generating substrate having a surface density of

2. 2. The aerosol-generating substrate according to claim 1, wherein the amorphous solid comprises 20 to 80% by weight of the aerosol-generating agent, calculated on a dry weight basis.

3. 2. The aerosol-generating substrate according to claim 1, wherein the amorphous solid comprises 20 to 50% by weight of the aerosol-generating agent, calculated on a dry weight basis.

4. 4. The aerosol-generating substrate according to claim 1, wherein the amorphous solid comprises less than 20% by weight of filler.

5. 5. The aerosol-generating substrate according to claim 1, wherein the amorphous solid comprises less than 5% by weight of calcium carbonate.

6. 5. The aerosol-generating substrate according to claim 1, wherein the amorphous solid does not comprise calcium carbonate.

7. 6. An aerosol-generating substrate according to claim 1, wherein the amorphous solid comprises 20 to 50% by weight of flavoring agent, calculated on a dry weight basis.

8. 8. The aerosol-generating substrate of claim 7, wherein the flavoring comprises menthol.

9. 8. An aerosol-generating substrate according to any one of claims 1 to 7, wherein the amorphous solid comprises 25 to 55% by weight of tobacco extract, calculated on a dry weight basis.

10. 10. The aerosol-generating substrate according to any one of claims 1 to 9, wherein the amorphous solid does not comprise tobacco material.

11. 11. An aerosol-generating substrate according to any preceding claim, wherein the amorphous solid comprises 10 to 30% by weight of gelling agent, calculated on a dry weight basis.

12. 12. The aerosol-generating substrate of claim 11, wherein the gelling agent comprises calcium cross-linked alginate and / or calcium cross-linked pectin.

13. 12. The aerosol-generating substrate of claim 11, wherein the gelling agent comprises alginate and at least one further gelling agent.

14. 12. The aerosol-generating substrate of claim 11, wherein the gelling agent comprises carboxymethyl cellulose.

15. An aerosol-generating substrate according to any preceding claim, wherein the optional filler is a fibrous organic filler material.

16. 16. An aerosol-generating substrate according to any preceding claim, wherein the amorphous solid does not comprise tobacco fibres.

17. The aerosol-forming material comprising the amorphous solid has a density of 80 g / m ２ ~120g / m ２ 17. The aerosol-generating substrate according to claim 1, having a surface density of

18. 16. The aerosol-generating substrate according to any one of claims 1 to 15, further comprising a carrier on which the amorphous solid is disposed, the carrier being a paper-backed foil.

19. 19. The aerosol-generating substrate of claim 18, wherein the paper layer abuts the amorphous solid layer.

20. 20. An aerosol-generating substrate according to claim 18 or 19, wherein the foil layer is substantially impermeable.

21. 21. An aerosol-generating substrate according to any one of claims 18 to 20, wherein the foil layer has a thickness of less than 20 μm.

22. 22. An aerosol-generating substrate according to any one of claims 18 to 21, wherein the foil layer has a thickness of from 1 μm to 10 μm.

23. 23. The aerosol-generating substrate according to any one of claims 18 to 22, wherein the carrier is impregnated with a flavoring or a tobacco extract.

24. An aerosol-producing article comprising an aerosol-generating substrate according to any one of claims 1 to 23.

25. 25. The aerosol product of claim 24, wherein the amorphous solid is included in the aerosol product as a sheet surrounding a rod of aerosolizable material.

26. 26. The aerosol product of claim 25, wherein the rod of aerosolizable material is tobacco.

27. 25. The aerosol product of claim 24, wherein the aerosol-forming material is included in the aerosol product as shredded sheets.

28. 28. The aerosol product of claim 27, wherein the aerosol-forming material is included in the aerosol product as shredded sheets mixed with cut rag tobacco.

29. An aerosol-generating assembly comprising an aerosol-generating substrate according to any one of claims 1 to 23 or an article according to any one of claims 25 to 28, and a heater configured to heat but not combust the aerosol-generating substrate.

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