Aerosol-generating substrate

Abstract

The present invention provides a consumable for use with a non-combustion aerosol delivery system, the consumable comprising a plurality of separate portions of an aerosol-forming material, each of the separate portions comprising less than about 15 mg of water.

Description

[Technical Field]

[0001] The present invention relates to consumables for use in non-combustion aerosol delivery systems, non-combustion aerosol delivery systems, and methods for generating aerosols.

[0002] Smoking consumables, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of consumables 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 consumables or aerosol-generating assemblies.

[0003] One example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosol-forming material. The solid aerosol-forming material may, in some instances, include a plant-based 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 aerosol-forming material.

[0004] Another example is a hybrid device, which includes a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-forming material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation vehicle.

[0005] According to a first aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol delivery system, the consumable comprising a plurality of separate portions of aerosol-forming material, each of the separate portions comprising less than about 15 mg of water.

[0006] A further aspect of the present invention provides a method of generating an aerosol from an aerosol-forming material, the method comprising heating a portion of the aerosol-forming material to a temperature of at least 120° C. to generate an aerosol comprising no more than about 15 mg of water.

[0007] A further aspect of the present invention provides an aerosol-forming material for use in a consumable product, the aerosol-forming material comprising an amorphous solid, wherein less than about 15 mg of water is aerosolized when the aerosol-forming material is heated to a temperature of at least 120° C.

[0008] Also provided by the present invention is a non-combustion aerosol delivery system comprising a consumable according to the first aspect of the present invention and a non-combustion aerosol delivery device comprising an aerosol generation device for generating an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0009] The present invention also relates to the use of a consumable as described herein in a non-combustion aerosol delivery device comprising an aerosol generation device for generating an aerosol from the consumable when the consumable is used in the non-combustion aerosol delivery device.

[0010] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which description is given by way of example only with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 2 is a cross-sectional view of an example of a consumable item. [Figure 2] FIG. 2 is a perspective view of the consumable item of FIG. 1. [Figure 3] FIG. 1 is a cross-sectional elevation view of an example consumable item. [Figure 4] FIG. 4 is a perspective view of the consumable item of FIG. 3. [Figure 5] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 6] FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 8] 1 is an example of a consumable product comprising multiple separate portions of aerosol-forming material, the separate portions being provided such that each separate portion may be heated and aerosolized separately. Detailed Description

[0012] As noted above, the present invention provides a consumable for use in a non-combustion aerosol delivery system, the consumable comprising a plurality of separate portions of an aerosol-forming material, each of the separate portions comprising less than about 15 mg of water.

[0013] The inventors have found that when each puff of aerosol from an aerosol delivery device contains less than about 15 mg of water, the user does not perceive the temperature of the puff as too high. Accordingly, it is contemplated that consumables of the present invention are configured so that less than about 15 mg of water is aerosolized during each puff inhaled by the user. Thus, each distinct portion of aerosol-generating material in the consumable contains less than about 15 mg of water. For example, in some embodiments, each distinct portion of aerosol-generating material contains 14 mg, 13 mg, 12 mg, 11 mg, 10 mg, 9 mg, 8 mg, 7 mg, 6 mg, 5 mg, 4 mg, 3 mg, or 2 mg or less of water. In certain embodiments, each distinct portion of aerosol-generating material contains less than about 5 mg of water, e.g., less than about 4 mg, 3 mg, or 2 mg of water. Exemplary ranges of water in each separate portion of aerosol-generating material in a consumable include 0.5-15 mg, 1-15 mg, 2-15 mg, 2-10 mg, 2-5 mg, 2-4 mg, 2-3 mg, 5-15 mg, 5-12 mg, and 10-15 mg. In certain embodiments, each separate portion of aerosol-generating material contains a minimal amount of water, e.g., at least about 0.1 mg, 0.25 mg, 0.5 mg, 1.0 mg, 1.5 mg, or 2 mg of water. The water content of the aerosol-generating material is determined by standard procedures known in the art, such as Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0014] A low water content in the discrete portion of the aerosol-forming material also allows for more rapid heating and aerosolization of the aerosol-forming material due to reduced heat absorption by the water.

[0015] Preferably, the size of each separate portion of aerosol-generating material is selected to provide a constant aerosol over a certain number of puffs. For example, each separate portion has a mass of aerosol-generating material sufficient to generate aerosol for inhalation of about four puffs, three puffs, two puffs, or one puff. In certain embodiments, the size of each separate portion of aerosol-generating material is less than about 60 mg, e.g., less than about 50 mg, less than about 40 mg, less than about 30 mg, less than about 20 mg, or less than about 10 mg. Exemplary weight ranges for each separate portion of aerosol-generating material include 10-60 mg, 20-40 mg, 15-30 mg, or 5-20 mg. In some embodiments, the separate portions of aerosol-generating material are provided such that each separate portion may be heated and aerosolized separately. The inventors have discovered that a consumable product having such a configuration allows a consistent aerosol to be delivered to a user with each puff.

[0016] FIG. 8 shows an example of a consumable (401) in which separate portions (403) of aerosol-forming material are provided such that each separate portion may be heated and aerosolized separately.

[0017] A further aspect of the present invention provides an aerosol-generating material for use in a consumable product. The aerosol-generating material comprises an amorphous solid, and when the aerosol-generating material is heated to a temperature of at least 120°C, less than about 15 mg of water is aerosolized. In some embodiments, the aerosol-generating material comprises less than about 15 mg of water. For example, the aerosol-generating material comprises less than about 15 mg of water, such as less than about 14 mg, 13 mg, 12 mg, 11 mg, 10 mg, 9 mg, 8 mg, 7 mg, 6 mg, 5 mg, 4 mg, 3 mg, or 2 mg of water. Exemplary weight ranges of water in the aerosol-generating material include 0.5 to 15 mg, 1 to 15 mg, 2 to 15 mg, 2 to 10 mg, 2 to 5 mg, 2 to 4 mg, 2 to 3 mg, 5 to 15 mg, 5 to 12 mg, and 10 to 15 mg. In certain embodiments, each of the discrete portions of the aerosol-forming material contains less than about 5 mg of water, e.g., less than about 4 mg, 3 mg, or 2 mg of water. In certain embodiments, the aerosol-forming material contains a minimal amount of water, e.g., at least about 0.1 mg, 0.25 mg, 0.5 mg, 1.0 mg, 1.5 mg, or 2 mg of water. The water content of the aerosol-forming material is determined by standard procedures known in the art, such as Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0018] Preferably, the aerosol-generating material used in the consumable product has a size selected to provide an aerosol over a fixed number of puffs. For example, the aerosol-generating material has a mass sufficient to generate an aerosol for inhalation of about four puffs, three puffs, two puffs, or one puff. Thus, in certain embodiments, the aerosol-generating material has a mass of less than about 60 mg, e.g., less than about 50 mg, less than about 40 mg, less than about 30 mg, less than about 20 mg, or less than about 10 mg. Exemplary ranges for the mass of the aerosol-generating material include 10-60 mg, 20-40 mg, 15-30 mg, or 5-20 mg. In some embodiments, the aerosol-generating materials are provided in fixed parts by weight so that each may be heated and aerosolized separately. The inventors have discovered that this configuration allows a consistent aerosol to be delivered to the user with each puff.

[0019] In some embodiments, the aerosol-generating material of the present invention comprises an amorphous solid, which may also be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous solid is a solid material that can retain some fluid, e.g., a liquid, within it. In some instances, the aerosol-generating material comprises from about 50%, 60%, or 70% to about 90% or 95% by weight of the amorphous solid. In some instances, a distinct portion of the aerosol-generating material consists of the amorphous solid.

[0020] The amorphous solid material is formed from a dried gel. The inventors have found that using these component ratios, as the gel hardens, the flavor compounds are stabilized within the gel matrix, allowing for higher flavor loadings than non-gel compositions. The flavor (e.g., menthol) is stabilized at high concentrations, and the product has good shelf life.

[0021] 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.

[0022] 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.

[0023] The inventors have found that the thickness of the amorphous solid defined herein optimizes material properties taking into account these competing considerations.

[0024] The thicknesses specified herein are 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.

[0025] Suitably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, or 35% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50%, 5-45%, 10-40%, or 20-35% by weight of gelling agent.

[0026] In some embodiments, the gelling agent comprises one or more compounds selected from the group including hydrocolloids, e.g., alginates, cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), gums, silica or silicone compounds, clays, and combinations thereof. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectins, starches (and derivatives), cellulose (and derivatives, e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some instances, the gelling agent may comprise alginate and / or pectin, which may be combined with a hardening agent (such as a calcium source) during formation of the amorphous solid. In some instances, the amorphous solid may comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0027] 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.

[0028] In some examples, the gelling agent comprises iota- and / or kappa-carrageenan in an amount of about 2% to about 20% by weight, or about 3% to about 15% by weight, or about 4% to about 10% by weight, or about 2% to about 5% by weight, and in some examples, the gelling agent comprises kappa-carrageenan in an amount of about 2% to about 5% by weight.

[0029] The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and combinations thereof.

[0030] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxypropyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0031] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0032] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0033] In instances where the aerosol-forming material is an amorphous solid, in certain embodiments, the amorphous solid is 1 to 60 wt. % of a gelling agent; 0.1 to 50 wt. % of an aerosol-forming material; 0.1 to 80% by weight of flavorings and / or active substances; where these weights are calculated on a dry weight basis.

[0034] In some embodiments, the amorphous solid is 1 to 50 wt. % of a gelling agent; 0.1 to 50 wt. % of an aerosol-forming material; 30 to 60% by weight of flavorings and / or active substances; where these weights are calculated on a dry weight basis.

[0035] Preferably, the amorphous solid may comprise from about 0.1%, 0.5%, 1%, 3%, 5%, 7%, or 10% to about 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming agent may act as a plasticizer. For example, the amorphous solid may comprise from 0.5 to 40%, 3 to 35%, or 10 to 25% by weight of the aerosol-forming material. In some examples, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-forming material 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, resulting in a material that does not produce a satisfactory consumption experience upon use. 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 sheet to be wound onto a bobbin, which is useful for manufacturing aerosol-generating consumables.

[0036] In some embodiments, the aerosol forming agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0037] In some examples, the aerosol-forming material comprises a flavorant. Preferably, the aerosol-forming material may comprise up to about 80%, 70%, 60%, 55%, 50%, or 45% by weight of flavorant. In some examples, the aerosol-forming material may comprise at least about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavorant (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise 1-80%, 10-80%, 20-70%, 30-60%, 35-55%, or 30-45% by weight of flavorant. In some examples, the flavorant comprises, consists essentially of, or consists of menthol.

[0038] In some examples, the amorphous solid comprises a flavoring. Preferably, the amorphous solid comprises up to about 80%, 70%, 60%, 55%, 50%, or 45% by weight of flavoring. In some examples, the amorphous solid comprises at least about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-80%, 10-80%, 20-70%, 30-60%, 35-55%, or 30-45% by weight of flavoring. In some examples, the flavoring comprises, consists essentially of, or consists of menthol.

[0039] In some instances, the amorphous solids may further comprise an emulsifier, which emulsifies the molten flavoring during manufacturing. For example, the amorphous solids may comprise about 5% to about 15%, preferably about 10%, by weight of an emulsifier (calculated on a dry weight basis). The emulsifier may comprise gum acacia.

[0040] In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20% water by weight, calculated on a wet weight basis. In some instances, the hydrogel may comprise less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis. In some instances, the hydrogel may comprise at least about 1%, 2%, or at least about 5% water by weight (calculated on a wet weight basis).

[0041] In some embodiments, the aerosol-forming material further comprises an active agent. For example, in some examples, the aerosol-forming material further comprises tobacco material and / or nicotine. In some examples, the aerosol-forming material may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some examples, the aerosol-forming material may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active agent. In some examples, the aerosol-forming material may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of botanical material. For example, the aerosol-forming material may comprise 10-50%, 15-40%, or 20-35% by weight of botanical material. In some such examples, the botanical material is tobacco. In some examples, the aerosol-forming material may comprise from about 1%, 2%, 3%, or 4% by weight to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1-20%, 2-18%, or 3-12% by weight of nicotine.

[0042] In some examples, the aerosol-forming material comprises an active agent such as tobacco extract. In some examples, the aerosol-forming material may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the aerosol-forming material may comprise from about 5%, 10%, 15%, 20%, or 25% by weight to about 60%, 50%, 45%, 40%, 35%, or 30% by weight of tobacco extract (calculated on a dry weight basis). For example, the aerosol-forming material may comprise 10 to 50%, 15 to 40%, or 20 to 35% by weight of tobacco extract. The tobacco extract may include nicotine in a concentration such that the aerosol-forming material comprises from 1%, 1.5%, 2%, or 2.5% by weight to about 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some instances, no nicotine other than that originating from the tobacco extract may be present in the aerosol-forming material.

[0043] In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0044] The active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0045] The active substance may comprise cannabidiol (CBD).

[0046] The active substances may comprise nicotine and cannabidiol (CBD).

[0047] The active substances may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0048] In some embodiments, the aerosol-forming material does not comprise tobacco material but does comprise nicotine. In some such examples, the aerosol-forming material may comprise from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% nicotine by weight (calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1 to 20%, 2 to 18%, or 3 to 12% nicotine by weight.

[0049] In some instances, the total active and / or flavor content may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, while the total active and / or flavor content may be less than about 90%, 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0050] In some examples, the total content of botanical material, nicotine, and flavorings may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, hi some examples, the total content of actives and / or flavorings may be less than about 90%, 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0051] The amorphous solid may be made from a gel, which may further comprise a solvent present at 0.1 to 50% by weight. However, the present inventors have found that the inclusion of a solvent in which the flavoring agent can dissolve reduces gel stability and may cause the flavoring agent to leave the gel and crystallize. Therefore, in some examples, the gel does not include a solvent in which the flavoring agent can dissolve.

[0052] The aerosol-generating material or the amorphous solid may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0053] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0054] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0055] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material or amorphous solid comprises nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material or amorphous solid is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacturing.

[0056] In certain embodiments, the aerosol-forming material or amorphous solid comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid.

[0057] In some instances, the amorphous solid comprises 1-60 wt% filler, e.g., 5-50 wt%, 10-40 wt%, or 15-30 wt% filler. In some such instances, the amorphous solid comprises at least 1 wt% filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler.

[0058] 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.

[0059] 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.

[0060] 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 comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0061] 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 (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). 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, such as when the amorphous solid sheet surrounds a rod of aerosol-forming material. In some instances, the aerosol-forming material may be formed as a sheet and then cut into multiple discrete portions for incorporation into the consumables of the present invention.

[0062] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0063] In some embodiments, the aerosol-forming material does not comprise tobacco fiber. In certain embodiments, the aerosol-forming material does not comprise fibrous material.

[0064] In some embodiments, the consumable product does not comprise tobacco fiber. In certain embodiments, the consumable product does not comprise fibrous material.

[0065] In some embodiments, the amorphous solid may comprise 10-35% by weight of gelling agent, 25-50% by weight of aerosol-forming material, and 30-55% by weight of an active agent (calculated on a dry weight basis). In some examples, the amorphous solid may comprise 20-30% by weight of gelling agent, 30-40% by weight of aerosol-forming material, and 35-50% by weight of an active agent (calculated on a dry weight basis). For example, the amorphous solid may comprise about 22% by weight of gelling agent, about 36% by weight of aerosol-forming material, and about 42% by weight of an active agent (calculated on a dry weight basis).

[0066] In some embodiments, the amorphous solid may comprise 10-35% by weight alginate, 25-50% by weight glycerol, and 30-55% by weight tobacco extract (calculated on a dry weight basis). In some examples, the amorphous solid may comprise 20-30% by weight alginate, 30-40% by weight glycerol, and 35-50% by weight tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may comprise about 22% by weight alginate, about 36% by weight glycerol, and about 42% by weight tobacco extract (calculated on a dry weight basis).

[0067] 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-generating material is formed as a sheet, then shredded, and incorporated into an aerosol-generating consumable 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-generating material is included in an aerosol-generating consumable product / assembly as a rolled sheet, preferably in the form of a tube.

[0068] The amorphous solid may comprise a colorant. The addition of a colorant can change the visual appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the visual appearance of the amorphous solid and the aerosol-forming material. By adding a colorant to the amorphous solid, the amorphous solid can match the color of other components of the aerosol-forming material or other components of an article comprising the amorphous solid.

[0069] Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) in the aerosol-forming material that comprises the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid renders the amorphous solid visually indistinguishable from other components in the aerosol-forming material. The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry with the materials that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0070] In some instances, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol-forming material, a flavoring, and optionally an active agent. In such instances, the water content of each discrete portion of the amorphous solid is less than about 15 mg, for example, less than about 14 mg, 13 mg, 12 mg, 11 mg, 10 mg, 9 mg, 8 mg, 7 mg, 6 mg, or 5 mg. The water content of the amorphous solid should be determined by standard procedures known in the art, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0071] In some instances, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, a flavoring agent, and optionally a tobacco material and / or a nicotine source.

[0072] In some instances, the amorphous solid has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm, or 0.05 mm to about 1.0 mm. Preferably, the thickness may range from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable.

[0073] The inventors have found that if the aerosol-generating material is too thick, heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; very thin materials are more difficult to cast, are more prone to breaking, and can impair aerosol formation during use. The inventors have found that the thickness of the aerosol-generating material defined herein optimizes material properties by taking into account these competing considerations.

[0074] The thicknesses specified herein are average values ​​for the thickness in question. In some instances, the thickness may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0075] The thicknesses specified herein for aerosol-forming materials also apply to amorphous solids.

[0076] In some embodiments, the aerosol-generating material is formed as a sheet. In some instances, the sheet of aerosol-generating material may be incorporated into a sheet-form assembly or consumable; for example, multiple separate portions may be multiple sheets. The sheet of aerosol-generating material may be incorporated as a flat sheet, a gathered or pleated sheet, a corrugated sheet, or a rolled sheet (i.e., in the form of a tube). In some such instances, the aerosol-generating material of these embodiments may be included in the aerosol-generating consumable / assembly as a sheet, for example, a sheet surrounding a rod of aerosol-generating material (such as tobacco). For example, the sheet of aerosol-generating material may be formed on a wrapping paper that surrounds the aerosol-generating material, such as tobacco. In other instances, the sheet may be shredded and then incorporated into an assembly, preferably mixed into aerosol-generating material, such as cut rag tobacco. In such instances, the consumable of the present invention retains the ability to aerosolize 15 mg or less of water per inhalation by a user when the aerosol-generating material is heated to a temperature of at least 120° C.

[0077] The aerosol-forming material may be of any suitable areal density, for example 30 g / m 2 ~120g / m 2 In some examples, the sheet may have a density of 80 to 120 g / m 2 , or approximately 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 , or preferably about 100 g / m 2 (So ​​that the sheet has a density similar to that of cut rag tobacco, and mixtures of these materials do not easily separate.) Such areal densities may be particularly suitable when the aerosol-forming material is included in the aerosol-generating consumable / assembly in sheet form or as shredded sheets (discussed further below). In some examples, the sheet has a mass per unit area of ​​about 30-70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2and may be used to surround an aerosol-forming material such as tobacco.

[0078] The consumable product may include a support on which the aerosol-generating material is provided. The support functions as a support on which the aerosol-generating material is formed, facilitating manufacturing. The support may provide tensile strength to the aerosol-generating material, facilitating handling. In some examples, multiple separate portions of the aerosol-generating material are deposited on such a support. In some examples, multiple separate portions of an amorphous material are deposited on such a support. In some examples, separate portions of the aerosol-generating material are deposited on such a support such that each separate portion may be heated and aerosolized separately. In an exemplary embodiment, the consumable product includes multiple separate portions of an aerosol-generating material comprising an amorphous solid, the separate portions being provided on a support, and each separate portion comprising less than 15 mg of water. Preferably, the separate portions of aerosol-generating material are provided on a support such that each separate portion may be heated and aerosolized separately. The inventors have found that a consumable product having such a structure allows a consistent aerosol to be delivered to a user with each puff.

[0079] In some examples, the substrate 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 substrate may comprise or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the substrate may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the substrate itself is a laminated structure comprising multiple layers of materials selected from the foregoing list. In some examples, the substrate may also function as a flavor carrier. For example, the substrate may be impregnated with flavor or tobacco extract.

[0080] In some instances, the support may be non-magnetic.

[0081] In some instances, the support may be magnetic. This feature may be used to secure the support to an assembly during use or to generate a particular amorphous solid form. In some instances, the aerosol-generating material may include one or more magnets that can be used to secure the material to an induction heater during use.

[0082] In some instances, the support may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the support layer, thereby controlling the flow and ensuring delivery of the aerosol or gas to the user. This can also be used to prevent condensation or other deposition of the gas / aerosol during use, for example, on the surface of a heater provided in the aerosol generation assembly. In this way, consumption efficiency and hygiene can be improved in some instances.

[0083] In some instances, the surface of the support that contacts the aerosol-generating material may be porous. For example, in one instance, the support comprises paper. The inventors have found that porous supports, such as paper, are particularly suited to the present invention, with the porous (e.g., paper) layer contacting the aerosol-generating material and forming a strong bond. The aerosol-generating material is formed by drying a gel, and, without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous support (e.g., paper), such that the support is partially bonded to the gel as the gel cures and forms crosslinks. This results in a strong bond between the gel and the support (and between the dried gel and the support).

[0084] Additionally, surface roughness can contribute to the strength of the bond between the aerosol-generating material and the substrate. The inventors have found that the roughness of paper (the surface that abuts the substrate) can preferably be 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.")

[0085] Conversely, the surface of the substrate that does not face the aerosol-forming material may be placed in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some instances, the substrate is positioned to have a rougher side that faces the aerosol-forming material and a smoother side that does not face the aerosol-forming material.

[0086] In one particular example, the support may be a paper-backed foil, where the paper layer abuts the aerosol-generating material, providing the properties discussed in the previous paragraph. The foil backing is substantially impermeable and provides aerosol flow path control. The metal foil backing may also act to transfer heat to the aerosol-generating material.

[0087] In another example, a foil layer of a paper-backed foil abuts the aerosol-forming material, and the foil is substantially impermeable to prevent moisture provided in the aerosol-forming material from being absorbed into the paper, which could weaken the structural integrity of the paper.

[0088] In some examples, the support is formed from or comprises a metal foil (e.g., aluminum foil). A metal support 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 support 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.

[0089] In some examples, the support may have a thickness of from about 0.010 mm to about 2.0 mm, preferably from about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0090] The aerosol-generating material for use in the consumable of the first aspect forms a further aspect of the present invention. Preferably, the aerosol-generating material comprises an amorphous solid, less than about 15 mg of water is aerosolized in each puff, and the aerosol-generating material is heated to a temperature of at least 120°C in the aerosol delivery device. Certain features discussed above in relation to the aerosol-generating material when present in a consumable apply equally to the aerosol-generating material when obtained in isolation and form part of the present invention.

[0091] Manufacturing method A further aspect of the present invention provides a method of making a consumable product of the present invention, comprising making an aerosol-forming material and incorporating the aerosol-forming material into the consumable product. Preferably, the aerosol-forming material is an amorphous solid.

[0092] The method may include the steps of: (a) forming a slurry comprising components of an amorphous solid or precursors thereof; (b) forming a layer of the slurry; (c) setting the slurry to form a gel; (d) drying the gel to form an amorphous solid; (e) dividing the amorphous solid into separate portions, each portion comprising 15 mg or less of water; and (f) incorporating the separate portions of the amorphous solid into a consumable product.

[0093] Block (b) of the step of forming the layer of slurry may include spraying, casting, or extruding the slurry. In some examples, the layer of slurry is formed by electrostatically spraying the slurry. In some examples, the layer of slurry is formed by casting the slurry.

[0094] In some instances, (b) and / or (c) and / or (d) may occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (b) through (d) may occur sequentially.

[0095] In some instances, a hardening agent (such as a calcium source) may be added to the slurry before or during (b). This may be appropriate when gelation occurs relatively slowly (e.g., with an alginate gelling agent), and therefore the slurry may be cast, for example, after the hardening agent has been added.

[0096] In another example, step (c) of hardening the slurry as a gel may comprise adding a hardener to the slurry layer, which may be, for example, sprayed onto the gel or pre-loaded onto the surface onto which the slurry will be deposited.

[0097] For example, a stiffening agent comprising a calcium source (such as calcium chloride or calcium citrate) may be added to a slurry containing alginate and / or pectin to form a calcium cross-linked alginate / pectin gel. In some instances where gelation occurs rapidly (such as when a pectin gelling agent is used), calcium should be added after casting (because the gel will be too viscous to cast).

[0098] In examples, the hardening agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the hardening agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the hardening agent comprises or consists of calcium formate. The inventors have determined that the use of calcium formate as a hardening agent typically results in an amorphous solid having higher tensile strength and higher elongation resistance.

[0099] The total amount of stiffening agent, e.g., calcium source, may be 0.5 to 5% by weight (calculated on a dry weight basis). Preferably, the total amount may be about 1%, 2.5%, or 4% to about 4.8% or 4.5% by weight. The inventors have found that adding too little stiffening agent may result in a gel that does not stabilize the flavoring, causing the flavoring to fall out of the gel. The inventors have found that adding too much stiffening agent results in a gel that is very sticky and therefore difficult to handle.

[0100] When the amorphous solid does not contain tobacco, a larger amount of hardener may need to be applied. In some instances, therefore, the total amount of hardener may be 0.5 to 12% by weight, e.g., 5 to 10% by weight, calculated on a dry weight basis. Preferably, the total amount may be about 5%, 6%, or 7% by weight to about 12% by weight or 10% by weight. In this instance, the amorphous solid generally does not contain tobacco.

[0101] 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.

[0102] In some instances, the slurry may be warmed before and during casting. This can result in slower gelation, which improves handling and facilitates the casting process. Additionally, warming the slurry can melt flavoring ingredients (e.g., menthol), facilitating handling.

[0103] In some instances, the menthol (or other flavoring) may be distributed throughout the slurry in powder form. In some instances, the menthol (or other flavoring) may be melted into the slurry (which may be heated). In such instances, an emulsifier such as gum acacia may be added to disperse the molten menthol throughout the slurry.

[0104] In some instances, the slurry may be cast as a band cast sheet. The sheet may be loaded with a release agent, such as lecithin, which may aid in the separation of the band cast from the amorphous solid.

[0105] In some embodiments, the slurry comprises: 1 to 60 wt. % of a gelling agent; 0.1 to 50 wt. % of an aerosol-forming material; 0.1 to 80% by weight of menthol (Weights are calculated on a dry basis), A solvent; Equipped with.

[0106] In instances where the solvent comprises water, the dry weight content of the slurry will match the dry weight content of the amorphous solids. Thus, any discussion herein regarding the composition of solids is expressly disclosed in combination with any slurry embodiment of the invention.

[0107] Consumable and non-combustible aerosol delivery systems As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user; Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning the aerosol-forming material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; a consumable comprising an aerosol-generating material and configured for use in one of these non-combustion aerosol delivery systems; and Aerosol-free delivery systems that deliver one or more substances (which may or may not comprise nicotine) to a user orally, nasally, transdermally, or otherwise without forming an aerosol (including, but not limited to, oral products such as lozenges, gums, patches, articles comprising inhalable powders, and oral tobacco, including snus or moist snuff). Includes.

[0108] According to this disclosure, a "combustion-type" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery to the user.

[0109] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are not combusted or burned during use to facilitate delivery to the user.

[0110] In some embodiments, the delivery system is a combustion-type aerosol delivery system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0111] In some embodiments, the present disclosure relates to components used in combustion-based aerosol delivery systems, for example, additive release components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper.

[0112] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example, a powdered non-combustion aerosol delivery system.

[0113] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0114] In some embodiments, the non-combustion aerosol delivery system is a tobacco heating system, also known as a non-combustion heating system.

[0115] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, comprise a tobacco or non-tobacco product.

[0116] Typically, a non-combustion aerosol delivery system may comprise a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device, however, it is contemplated that a consumable that itself comprises a means for powering an aerosol generating component may itself form a non-combustion aerosol delivery system.

[0117] In some embodiments, the non-combustion aerosol delivery device may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source comprises a carbon substrate or a heat conducting material in proximity to the heat generating power source, which may be energized to distribute power in the form of heat to the aerosol-generating material. In some embodiments, the power source, such as a heat generating power source, is provided in the consumable to form the non-combustion aerosol delivery.

[0118] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol-forming material, an aerosol-forming component, an aerosol-forming region, a mouthpiece, and / or a region for receiving the aerosol-forming material.

[0119] In some embodiments, the non-combustion aerosol delivery system is a heater capable of interacting with an aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol-generating component is capable of generating an aerosol from the aerosol-generating material without the application of heat. For example, the aerosol-generating component may be capable of generating an aerosol from the aerosol-generating material without the application of heat, for example, via one or more of vibrational, mechanical, pressurized, or electrostatic means.

[0120] The non-combustion aerosol delivery system includes a heater 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. In still further examples, the heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use.

[0121] In some examples, the heater, when in use, may heat the aerosol-forming material to between 120°C and 350°C without burning it. In some examples, the heater, when in use, may heat the aerosol-forming material to between 140°C and 250°C without burning it. 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 0.017 mm and 2.0 mm, preferably between about 0.1 mm and 1.0 mm, from the heater. These minimum distances may, in some examples, reflect the thickness of the support supporting the amorphous solid. In some examples, the surface of the amorphous solid may directly abut the heater.

[0122] In some instances, the heater may be incorporated into the aerosol-generating material. In some 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 incorporated into the aerosol-generating substrate.

[0123] The non-combustion aerosol delivery system may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components so that they condense to form the aerosol. The cooling element may also act to keep 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.

[0124] In some examples, the non-combustion aerosol delivery system may be a heat-not-burn device. That is, the aerosol generating assembly may include a solid tobacco-containing material (and not a liquid aerosol-forming 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.

[0125] In some examples, the non-combustion aerosol delivery system may be a hybrid device. That is, the non-combustion aerosol delivery system may include a solid aerosol-forming material and a liquid aerosol-forming material. In some examples, the amorphous solid may comprise nicotine. In some examples, the amorphous solid may comprise tobacco material. In some examples, the amorphous solid may comprise tobacco material and a separate nicotine source. These separate aerosol-forming materials may be heated by separate heaters or the same heater, and in some examples, the downstream aerosol-forming material may be heated by a hot aerosol generated from the upstream aerosol-forming material. Hybrid devices are disclosed in WO 2016 / 135331 A1, the entirety of which is incorporated herein by reference.

[0126] The consumable may also be referred to herein as a cartridge. The consumable may be adapted for use in a THP, a hybrid device, or another aerosol generating device. In some instances, the consumable may further comprise a filter and / or a cooling element, as previously described. In some instances, the consumable may be surrounded by a packaging material, such as paper.

[0127] The consumable may further include vent holes. These may be located in the sidewalls of the consumable. 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 consumable during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0128] Ventilation promotes the production of visible heated volatiles from the consumable when the consumable 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.

[0129] 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.

[0130] 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%.

[0131] 1 and 2, there are shown a partially cutaway cross-sectional view and a perspective view of an example aerosol-generating consumable 101. The consumable 101 is adapted for use with a device having a power source and a heater. This embodiment of the consumable 101 is particularly suited for use with the device 51 shown in FIGS. 5-7, which are described below. In use, the consumable 101 can be removably inserted into the device 51 at insertion point 20 shown in FIG. 5.

[0132] One example consumable 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.

[0133] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The consumable 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 consumable 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 consumable 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.

[0134] 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.

[0135] In one example, the overall length of the consumable 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and more preferably 83 mm.

[0136] One axial end of the body 103 of aerosol-generating material is visible at the distal end 115 of the consumable 101. However, in other embodiments, the distal end 115 of the consumable 101 may include an end piece (not shown) that covers one axial end of the body 103 of aerosol-generating material.

[0137] The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the periphery of 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.

[0138] In one example, the 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 the body of aerosol-generating material 103 flow. The 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 the consumable 101 during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of consumable 101 during insertion into device 51.

[0143] 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.

[0144] 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.

[0145] 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 consumable 101. Therefore, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the consumable 101. Additionally, the filter segment performs a filtration function in the consumable 101.

[0146] 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.

[0147] 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.

[0148] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0149] The oral end segment 111 is an annular tube that surrounds and defines a cavity within the oral end segment 111. This cavity provides a chamber for heated volatile components flowing from the filter segment 109. The oral 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 consumable during manufacturing and insertion into the device 51. In one example, the wall thickness of the oral end segment 111 is approximately 0.29 mm. In one example, the length of the oral end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0150] 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.

[0151] 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.

[0152] 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.

[0153] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example consumable 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.

[0154] 3 and 4, a ventilation region 317 is provided in the consumable 301 to allow air to flow from the exterior of the consumable 301 to the interior of the consumable 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through an outer layer of the consumable 301. The ventilation holes may be located in the cooling segment 307 to aid in cooling the consumable 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 consumable 301 in a cross section substantially perpendicular to the longitudinal axis of the consumable 301.

[0155] In one example, there are 1 to 4 rows of vent holes to provide ventilation to the consumable 301. Each row of vent holes may have 12 to 36 vent holes 317. The diameter of the 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.

[0156] 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 consumable 301. The vent holes 317 are positioned to effectively cool the consumable 301.

[0157] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the consumable, and preferably 17 mm to 20 mm from the proximal end 313 of the consumable 301. The location of the vent holes 317 is determined so that the user will not block the vent holes 317 when the consumable 301 is in use.

[0158] By providing a row of vent holes 17-20 mm from the proximal end 313 of the consumable 301, the vent holes 317 can be positioned on the outside of the device 51 when the consumable 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 consumable 301 from outside the device 51 through the vent holes to help cool the consumable 301.

[0159] The length of the cooling segment 307 is such that when the consumable 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 serves two functions: first, to provide a physical gap between the heating apparatus and the heat-sensitive filter apparatus 309 of the device 51; and second, to allow the vent hole 317 to be positioned within the cooling segment while also being positioned outside the device 51 when the consumable 301 is fully inserted into the device 51. As can be seen in FIGS. 6 and 7 , the majority of the cooling element 307 is positioned within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 51.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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 consumables 101, 301 containing aerosol-generating materials into and from the device 51 during use.

[0165] 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.

[0166] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol-generating material within the consumable 101, 301, as discussed further below.

[0167] 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 consumable (to volatilize the aerosol-forming material without burning it, as described above).

[0168] 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.

[0169] 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 consumable 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.

[0170] 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 such that when the consumable 101, 301 is inserted into the device 51, substantially the entire body of the aerosol-forming material 103, 303 of the consumable 101, 301 is inserted into the heating device 23.

[0171] 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.

[0172] 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.

[0173] The housing 59 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23 .

[0174] 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 consumable 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 consumable 101, 301. The gap 36 surrounds the entire periphery of the consumable 101, 301 over at least a portion of the cooling segment 307.

[0175] 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 the consumable 101, 301 inserted within the device 51 to help secure it therein. Open spaces (not shown) defined by adjacent pairs of the ridges 60 and the consumable 101, 301 form ventilation paths around the outer surface of the consumable 101, 301. These ventilation paths allow hot steam escaping from the consumable 101, 301 to exit the device 51 and allow cooling air to flow within the gap 36 around the consumable 101, 301 and into the device 51.

[0176] In operation, the consumable 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. Referring particularly 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 consumable 101, 301) is completely contained within the heating assembly 23 of the device 51. The proximal end 113, 313 of the consumable 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

[0177] During operation, the heating device 23 heats the consumable 101, 301 to volatilize at least one component of the aerosol-forming material from the body 103, 303 of aerosol-forming material.

[0178] The primary flow path for heated volatiles from the body of aerosol-generating material 103, 303 is axially through the consumable 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.

[0179] 3 and 4, cool air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0180] Illustrative Embodiments In some embodiments, the amorphous solid comprises menthol.

[0181] Certain embodiments comprising a menthol-containing amorphous solid may be particularly suitable for inclusion as shredded sheets in an aerosol-generating consumable / assembly. In these embodiments, the amorphous solid may have the following composition (calculated on a dry weight basis) calculated as percentages on a dry weight basis: 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; menthol in an amount of about 35% to about 60%, or about 40% to 55% by weight; and aerosol-generating material (preferably comprising glycerol) in an amount of about 10% to about 30%, or about 15% to about 25% by weight (calculated on a dry weight basis).

[0182] In one embodiment, the amorphous solid comprises 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 material (calculated on a dry weight basis).

[0183] As noted above, the amorphous solid of these embodiments may be included in the aerosol-generating consumable / assembly as a shredded sheet. The shredded sheet may be blended with cut tobacco and provided in the consumable / 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.

[0184] Certain embodiments of the menthol-containing amorphous solid may be particularly suitable for inclusion in an aerosol-generating consumable / assembly as a sheet, such as a sheet surrounding a rod of aerosol-generating material (such as tobacco). In these embodiments, the amorphous solid may have the following composition (calculated on a dry weight basis): gelling agent (preferably comprising alginate, more preferably a combination of alginate and pectin) in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight; menthol in an amount of about 10% to about 50% by weight, or about 15% to about 40% by weight; aerosol-forming material (preferably comprising glycerol) in an amount of about 5% to about 40% by weight, or about 10% to about 35% by weight; and optionally, a filler in an amount up to 60% by weight (e.g., 5% to 20% by weight, or 40% to 60% by weight).

[0185] In one of these embodiments, the amorphous solid comprises about 11% by weight of an alginate / pectin gelling agent blend, about 56% by weight of a wood pulp filler, about 18% by weight of a menthol flavoring, and about 15% by weight of glycerol (calculated on a dry weight basis).

[0186] In another of these embodiments, the amorphous solid comprises about 22% by weight of an alginate / pectin gelling agent blend, about 12% by weight of a wood pulp filler, about 36% by weight of a menthol flavoring, and about 30% by weight of glycerol (calculated on a dry weight basis).

[0187] As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is disposed on a support comprising paper. In one embodiment, the sheet is disposed on a support comprising metal foil, preferably aluminum foil. In this embodiment, the amorphous solid may abut against the metal foil.

[0188] 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.

[0189] 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 (calculated on a dry weight basis): 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%, flavoring 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%, aerosol-forming material (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 does not comprise a filler).

[0190] In one of these embodiments, the amorphous solid comprises about 27% by weight alginate gelling agent, about 14% by weight flavoring, and about 57% by weight glycerol aerosol-forming material (calculated on a dry weight basis).

[0191] In another of these embodiments, the amorphous solid comprises about 29% by weight alginate gelling agent, about 9% by weight flavoring, and about 60% by weight glycerol (calculated on a dry weight basis).

[0192] The amorphous solid of these embodiments may be included in the aerosol-generating consumable / assembly as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in the aerosol-generating consumable / assembly as a sheet, for example, a sheet surrounding a rod of aerosol-generating material (such as tobacco). Alternatively, the amorphous solid of these embodiments may be included in the aerosol-generating consumable / assembly as a layer portion disposed on a support.

[0193] definition

[0194] active substance In some embodiments, the substance to be delivered comprises an active agent.

[0195] 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.

[0196] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0197] In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0198] The active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0199] The active substance may comprise cannabidiol (CBD).

[0200] The active substances may comprise nicotine and cannabidiol (CBD).

[0201] The active substances may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0202] plant matter 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 (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0203] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0204] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0205] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0206] fragrance In some embodiments, the substance delivered comprises a fragrance.

[0207] 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 sugars, maltodextrins, cellulose, cellulose gums, cellulose acetates, cellulose syrups, cellulose gums, cellulose acetates, cellulose gum ...

[0208] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavoring components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring components extracted from tobacco. In some embodiments, the flavoring comprises flavoring components extracted from cannabis.

[0209] 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.

[0210] Aerosol-Generating Materials An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, e.g., a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight to about 90%, 95%, or 100% amorphous solid by weight.

[0211] The aerosol-generating material may comprise one or more active agents and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0212] Aerosol-forming materials The aerosol-forming material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0213] In some embodiments, the aerosol-forming material comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0214] functional materials The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0215] base body The material may be on or in a support to form a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is incorporated within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0216] consumables A consumable is an article comprising or consisting of an aerosol-generating material intended to be consumed, in part or in whole, during use by a user. A consumable may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that generates heat upon use to cause the generation of an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0217] Susceptor A susceptor is a material that can be heated by the penetration of a varying magnetic field, for example, an alternating magnetic field. The susceptor may be an electrically conductive material, in which case penetration with a varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, in which case penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, in which case the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0218] Aerosol Generator An aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibrational, high pressure, or electrostatic energy. 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.

[0219] 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.

[0220] The above-described embodiments should be understood as illustrative of the present invention. Further embodiments of the present invention are contemplated. 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. [Example]

[0221] In a first example, a slurry having the following composition was formed in a high shear mixer: Water and glycerol were mixed first, then alginate and ground menthol powder were added. After the alginate was fully hydrated, calcium citrate was added. The slurry was cast at room temperature to a thickness of 2 mm and allowed to harden as a gel. The gel was then dried in an oven (60°C for 1-3 hours).

[0222] [Table 1]

[0223] In a second example, a slurry having the following composition was formed in a high shear mixer: Water and glycerol were mixed first, then pectin and ground menthol powder were added. The slurry was heated to 50-80°C with mixing to melt the menthol and reduce the viscosity of the slurry.

[0224] The warmed slurry was cast to a thickness of 2 mm. An aqueous solution of calcium chloride (2.1 g of calcium chloride dissolved in water) was sprayed onto the cast to gel it. The gel was then dried in an oven (60°C for 1-3 hours).

[0225] [Table 2]

[0226] In this second example, the calcium source was added after casting due to the rate of gelation of the pectin gelling agent: if calcium was added before casting, gelation would occur too quickly and the material would not be as easily castable.

[0227] In this second embodiment, the slurry may comprise molten menthol, since the pectin gelling agent has groups along the polysaccharide chain that emulsify the menthol in the slurry. In the first embodiment, the alginate gelling agent does not have these emulsifying properties, so the menthol is used in dry powder form.

[0228] The composition of the aerosol-forming material of the third example and the corresponding slurry from which it is formed are set forth in the table below.

[0229] [Table 3]

Claims

1. 1. A consumable for use with a non-combustion aerosol delivery system, the consumable comprising a plurality of separate portions of an aerosol-generating material, each of the separate portions comprising less than 15 mg of water, the separate portions of the aerosol-generating material being arranged such that each separate portion may be heated and aerosolized separately.

2. The consumable product of claim 1 , wherein the aerosol-forming material comprises an amorphous solid.

3. The amorphous solid is 1 to 60 wt. % of a gelling agent; 0.1 to 50% by weight of an aerosol-forming material; 0.1 to 80% by weight of flavorings and / or active substances; 3. The consumable of claim 2, wherein these percentages are calculated on a dry weight basis.

4. The amorphous solid is 1 to 50 wt. % of a gelling agent; 0.1 to 50% by weight of an aerosol-forming material; 30-60% by weight of flavorings and / or active substances; 4. The consumable of claim 2 or claim 3, wherein the percentages are calculated on a dry weight basis.

5. 5. The consumable product of claim 3 or claim 4, wherein the gelling agent comprises a hydrocolloid.

6. The consumable product of claim 5 , wherein the hydrocolloid comprises one or more compounds selected from the group including alginates, cellulose derivatives, gums, silica or silicone compounds, clays, and combinations thereof.

7. The consumable product of claim 6 , wherein the gelling agent comprises calcium cross-linked alginate and / or calcium cross-linked pectin.

8. The consumable product of any preceding claim, wherein the aerosol-forming material comprises powdered botanical material and / or nicotine and / or tobacco extract.

9. The consumable product of any one of claims 1 to 8, wherein the aerosol-forming material comprises an acid.

10. The consumable product of any one of claims 1 to 9, wherein the aerosol-forming material comprises benzoic acid.

11. The consumable product of any one of claims 1 to 10, wherein the aerosol-forming material comprises menthol.

12. The consumable product of any one of claims 1 to 11, wherein each of the discrete portions of aerosol-forming material has a mass of between 5 and 30 mg.

13. The consumable product of any one of claims 1 to 12, wherein each of the discrete portions of aerosol-forming material has a mass of between 10 and 20 mg.

14. The consumable product of any one of claims 1 to 13, wherein each of the separate portions comprises less than 5 mg of water.

15. 1. A method of generating an aerosol from an aerosol-forming material, the method comprising: heating at least a portion of the aerosol-forming material to a temperature of at least 120° C. to generate an aerosol comprising less than 15 mg of water.

16. 16. The method of claim 15, comprising heating a plurality of separate portions of aerosol-forming material to a temperature of at least 120°C to generate an aerosol comprising a total of less than 15 mg of water.

17. 17. The method of claim 15 or claim 16, wherein the aerosol comprises less than 5 mg of water.

18. 18. The method of any one of claims 15 to 17, wherein the aerosol-forming material has a mass of 5 to 30 mg.

19. 19. The method of any one of claims 15 to 18, wherein the aerosol-forming material comprises less than 15 mg of water.

20. 20. The method of any one of claims 15 to 19, wherein the aerosol-forming material comprises less than 5 mg of water.

21. 1. An aerosol-generating material for use in a non-combustion aerosol delivery system, the aerosol-generating material comprising an amorphous solid, wherein, when the aerosol-generating material is used in the non-combustion aerosol delivery system, less than 15 mg of water is aerosolized when the aerosol-generating material is heated to a temperature of at least 120°C.

22. 22. The aerosol-forming material of claim 21, having a mass of 20 to 60 mg.

23. 23. The aerosol-forming material of claim 21 or claim 22, wherein less than 5 mg of water is aerosolized.

24. 15. A non-combustion aerosol delivery system comprising the consumable product of any one of claims 1 to 14 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device for generating an aerosol from the consumable product when the consumable product is used with the non-combustion aerosol delivery device.

25. 15. Use of the consumable product of any one of claims 1 to 14 in a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generation device for generating an aerosol from the consumable product when the consumable product is used with the non-combustion aerosol delivery device.

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