Aerosol generation

Abstract

Disclosed herein is a layered aerosol-generating material, the material comprising an aerosol-forming layer attached to a carrier layer, the aerosol-forming layer comprising an amorphous solid, and the carrier layer having a thickness of from about 10 μm to about 2.5 mm. [Selected Figure] Figure 1

Description

Technical Field

[0001] The present invention relates to aerosol generation.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to generate tobacco smoke. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a base material through heating without burning. These are sometimes referred to as non-combustible smoking articles or aerosol-generating assemblies.

[0003] An example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some examples, comprise tobacco material. Heating volatilizes at least one component of the material to typically form an inhalable aerosol. These products are sometimes referred to as heat-not-burn devices, tobacco heating devices, or tobacco heating products. Various different configurations for volatilizing at least one component of a solid aerosolizable material are known.

[0004] As another example, there are electronic cigarette / tobacco heating product hybrid devices, also known as electronic cigarette hybrid devices. These hybrid devices comprise a liquid source (which may or may not contain nicotine) that is vaporized by heating to generate an inhalable vapor or aerosol. The device further comprises a solid aerosolizable material (which may or may not contain tobacco material), and components of this material are entrained in the inhalable vapor or aerosol to produce an inhalation medium.

Summary of the Invention

[0005] A first aspect of the present invention provides a laminated aerosol generating material comprising an aerosol-forming layer attached to a carrier layer, wherein the aerosol-forming layer comprises an amorphous solid, and the carrier layer has a thickness ranging from about 10 μm to about 2.5 mm.

[0006] A second aspect of the present invention provides an aerosol product used in an aerosol generating assembly. This aerosol product comprises a laminated aerosol generating material according to the first aspect.

[0007] A third aspect of the present invention provides an aerosol generating assembly comprising an aerosol generating material and a heater configured to heat the aerosol generating material without combustion, wherein the aerosol generating material comprises an aerosol forming layer comprising an amorphous solid, and substantially the entire aerosol forming layer is located within the aerosol generating assembly at a distance from the heater in the range of 10 μm to about 4 mm.

[0008] A fourth aspect of the present invention provides an aerosol product for use in an aerosol generating assembly, comprising an aerosol generating material, the aerosol generating material comprising an aerosol forming layer comprising an amorphous solid, and the aerosol product is configured for use in the aerosol generating assembly such that substantially all of the aerosol forming layer is located within the aerosol generating assembly at a distance of less than about 4 mm from the heater. In some embodiments, substantially all of the aerosol forming layer is located within the aerosol generating assembly at a distance ranging from 10 μm to about 4 mm from the heater.

[0009] A fifth aspect of the present invention provides a method for producing a layered aerosol generating material according to the first aspect.

[0010] Further aspects of the present invention described herein may provide the use of aerosol-generating materials, aerosol products, or aerosol-generating assemblies in the generation of inhalable aerosols.

[0011] Further features and advantages of the present invention will become apparent from the following description, which is provided for illustrative purposes only with reference to the accompanying drawings. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic diagram of the breakdown of a layered aerosol-generating material. [Figure 2] This is a cross-sectional view of an example of an aerosol product. [Figure 3] Figure 2 is a perspective view of the item. [Figure 4] This is a cross-sectional elevation view of an example of an aerosol product. [Figure 5] Figure 4 is a perspective view of the item. [Figure 6] This is a perspective view of an example of an aerosol generation assembly. [Figure 7] This is a cross-sectional view of an example of an aerosol generation assembly. [Figure 8] This is a perspective view of an example of an aerosol generation assembly. [Modes for carrying out the invention]

[0013] The aerosol-forming layers described herein comprise an "amorphous solid." Amorphous solids are sometimes referred to as "monolithic solids" (i.e., non-fibrous materials) or "dry gels." An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within itself. In some examples, the aerosol-forming layer comprises an amorphous solid ranging from about 50% by weight, 60% by weight, or 70% by weight to about 90% by weight, 95% by weight, or 100% by weight. In some examples, the aerosol-forming layer consists of an amorphous solid.

[0014] As described above, the present invention provides a laminated aerosol generating material comprising an aerosol-forming layer attached to a carrier layer, wherein the aerosol-forming layer comprises an amorphous solid, and the carrier layer has a thickness ranging from approximately 10 μm to approximately 2.5 mm. Figure 1 is a schematic diagram of such a laminated material, and the laminated structure (shown by the dotted line) includes a carrier layer 4 and an amorphous solid layer 2.

[0015] Preferably, the thickness of the carrier layer may be in the range from about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm, or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, or 0.5 mm. The carrier may comprise one or more layers, and the thickness described herein refers to the sum of the thicknesses of these layers.

[0016] The presence of a carrier layer can be advantageous because it facilitates manufacturing and handling. Furthermore, it allows for some control over the flow path, improving the user experience and hygiene in the device during use. However, the inventors have shown that if the carrier layer is too thick, heating efficiency decreases, negatively impacting power consumption during use.

[0017] The inventors have shown that the carrier thickness specified herein optimizes material properties by taking these conflicting considerations into account. Generally, carrier materials with higher thermal conductivity tend to be thicker (thicker carriers improve handling and facilitate manufacturing), while those with lower thermal conductivity tend to be thinner (to ensure efficient heating of amorphous solids).

[0018] In some examples, the laminated aerosol-forming material has a thickness of less than about 4 mm, preferably less than about 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm, or less than 0.5 mm. When in use, the carrier layer is placed between the aerosol-forming layer and the heat source. The inventors have found that by placing substantially the entire aerosol-forming layer within 4 mm of the heater, the aerosol-forming material can be heated quickly and efficiently when in use.

[0019] In some examples, the aerosol-forming layer has a thickness of from about 0.015 mm to about 1.5 mm, preferably from about 0.05 mm to about 1.0 mm. Preferably, the thickness may range from about 0.015 mm, 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 with a thickness of 0.2 mm is particularly suitable.

[0020] The inventors have found that if the aerosol-forming layer is too thick, the heating efficiency will decrease, which adversely affects power consumption during use. Conversely, if the aerosol-forming layer is too thin, manufacturing and handling become difficult; very thin materials are difficult to cast (mold), may become brittle, and can impair aerosol formation during use. The inventors have found that the thickness of the amorphous solid defined herein optimizes material properties in view of these competing considerations.

[0021] The thickness value referred to herein is an average thickness value. In some examples, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

[0022] In some examples, the carrier layer may be substantially or completely impermeable to gas and / or aerosol. This prevents aerosol or gas from passing through the carrier, thereby controlling the flow and ensuring good delivery to a user. This may also be used, for example, to prevent condensation or other deposition of gas / aerosol occurring during use on the surface of a heater provided in an aerosol-generating assembly. Therefore, in some examples, consumption efficiency and hygiene can be improved.

[0023] The carrier may be any suitable material that can be used to support the amorphous solid. In some examples, the carrier may be formed from a material selected from metal foil, paper, carbon paper, oil-resistant paper, ceramics, carbon allotropes (e.g., graphite and graphene), plastics, cardboard, wood, or a combination thereof. In some examples, the carrier may comprise or consist of tobacco material (such as a sheet of reconstituted cigarette). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the carrier itself is a laminated structure comprising layers of multiple materials selected from the above list.

[0024] In some examples, the carrier of the aerosol product may have or consist of a porous layer in contact with an amorphous solid. In some specific examples, the amorphous solid is placed in direct contact with the porous layer, and the porous layer is in contact with the amorphous solid, forming a strong bond. The amorphous solid is formed by drying a gel, and, though not limited by theory, the slurry forming the gel is thought to partially impregnate the porous layer (e.g., paper), resulting in the porous layer being partially bonded to the gel as the gel hardens and forms crosslinks. This results in a strong bond between the gel and the porous layer (and between the dried gel and the porous layer).

[0025] In addition, surface roughness can contribute to the strength of the bond between the amorphous material and the carrier. The inventors have found that the roughness of the paper (the surface in contact with the carrier) is preferably in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, and preferably 100 Bekk seconds (measured over an air pressure range of 50.66 to 48.00 kPa) (The Bekk smoothness tester is an instrument used to measure the smoothness of a paper surface. In this tester, air at a specific pressure is introduced between a smooth glass surface and a paper sample. The time (in seconds) that a fixed volume of air penetrates between these surfaces is called "Bekk smoothness").

[0026] Conversely, the carrier surfaces that do not face the amorphous solid may be placed in contact with the heater, and smoother surfaces may provide more efficient heat transfer. Therefore, in some examples, the carriers are arranged to have a rougher surface in contact with the amorphous material and a smoother surface that does not face the amorphous material.

[0027] In one particular example, the carrier may be foil backed with paper, where the paper layer is in contact with the amorphous solid layer, and the properties discussed in the previous paragraphs are brought about by this contact. The foil backing is substantially impermeable, resulting in control of the aerosol channel. Metal foil backing can also serve to transfer heat to the amorphous solid.

[0028] In another example, the foil layer of a paper backing comes into contact with an amorphous solid. The foil is substantially impermeable, preventing moisture introduced into the amorphous solid from being absorbed by the paper (which could weaken the structural integrity of the paper).

[0029] In some examples, the carrier is formed from or comprises a metal foil (such as aluminum foil). The metal carrier can enable better transfer of thermal energy to the amorphous solid. In addition, or alternatively, the metal foil may function as a susceptor in the induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, about 1 μm to about 10 μm, preferably about 5 μm.

[0030] Similarly, it has been found that laminated carriers of paper and oil-resistant paper are particularly useful in the present invention. The paper layer is in contact with an amorphous solid, and the adhesive amorphous solid does not readily adhere to the backing of the oil-resistant paper carrier.

[0031] In some examples, the layered aerosol generating material may include one or more magnets that can be used to secure the material to the device during use.

[0032] In some examples, the aerosol-generating material may include embedded heating means such as resistance heating elements or induction heating elements. For example, the heating means may be embedded in an amorphous solid.

[0033] Composition of aerosol-forming materials In some examples, the amorphous solid may contain 1 to 60% by weight of a gelling agent, where these weights are calculated on a dry weight basis.

[0034] Preferably, the amorphous solid may contain a gelling agent in amounts ranging from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 27 wt% (all calculated on a dry weight basis). For example, the amorphous solid may contain a gelling agent in amounts of 1 to 50 wt%, 5 to 40 wt%, 10 to 30 wt%, or 15 to 27 wt%.

[0035] In some embodiments, the gelling agent comprises a hydrophilic colloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginates and / or pectin, which may be combined with a curing agent (such as a calcium source) during the formation of an amorphous solid. In some examples, the amorphous solid may comprise calcium crosslinked alginates and / or calcium crosslinked pectin.

[0036] In some embodiments, the gelling agent comprises an alginate, which is present in the amorphous solid in an amount of 10 to 30% by weight (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one further gelling agent, such as pectin.

[0037] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0038] Preferably, the amorphous solid may contain an aerosol-generating agent (all calculated on a dry weight basis) in amounts ranging from about 5% by weight, 10% by weight, 15% by weight, or 20% by weight to about 80% by weight, 70% by weight, 60% by weight, 55% by weight, 50% by weight, 45% by weight, 40% by weight, or 35% by weight. The aerosol-generating agent may act as a plasticizer. For example, the amorphous solid may contain 10-60% by weight, 15-50% by weight, or 20-40% by weight of the aerosol-generating agent. In some examples, the aerosol-generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-generating agent comprises glycerol, is essentially composed of glycerol, 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 during use. They have also found that if the plasticizer content is too low, the amorphous solid may become brittle and easily break. The plasticizer content specified herein results in amorphous solid flexibility that allows the amorphous solid sheet to be wound onto a bobbin, which is useful for the production of aerosol products.

[0039] In some examples, the amorphous solid may contain a fragrance. Preferably, the amorphous solid may contain up to about 60% by weight, 50% by weight, 40% by weight, 30% by weight, 20% by weight, 10% by weight, or 5% by weight of a fragrance. In some examples, the amorphous solid may contain at least about 0.1% by weight, 0.5% by weight, 1% by weight, 2% by weight, 5% by weight, 10% by weight, 20% by weight, or 30% by weight of a fragrance (all calculated on a dry weight basis). For example, the amorphous solid may contain 0.1–60% by weight, 1–60% by weight, 5–60% by weight, 10–60% by weight, 20–50% by weight, or 30–40% by weight of a fragrance. In some examples, the fragrance (if present) may contain menthol, be essentially made of menthol, or consist of menthol. In some examples, the amorphous solid does not contain a fragrance.

[0040] In some examples, the amorphous solid comprises an active substance. For example, in some examples, the amorphous solid comprises tobacco material and / or nicotine. For example, the amorphous solid may comprise powdered tobacco and / or nicotine and / or tobacco extract. In some examples, the amorphous solid may comprise an active substance in amounts ranging from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis). In some examples, the amorphous solid may comprise tobacco material and / or nicotine in amounts ranging from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, or 40 wt% (calculated on a dry weight basis).

[0041] In some examples, the amorphous solid comprises an active substance such as tobacco extract. In some examples, the amorphous solid may comprise 5–60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the amorphous solid may comprise tobacco extract in amounts ranging from about 5% by weight, 10% by weight, 15% by weight, 20% by weight, or 25% by weight to about 55% by weight, 50% by weight, 45% by weight, or 40% by weight (calculated on a dry weight basis). For example, the amorphous solid may comprise 5–60% by weight, 10–55% by weight, or 25–55% by weight of tobacco extract. The tobacco extract may contain nicotine at concentrations such that the amorphous solid comprises 1% by weight, 1.5% by weight, 2% by weight, or 2.5% by weight to about 6% by weight, 5% by weight, 4.5% by weight, or 4% by weight (calculated on a dry weight basis) of nicotine. In some cases, nicotine other than that obtained from tobacco extract may not be present in the amorphous solid.

[0042] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such examples, the amorphous solid may contain nicotine ranging from about 1% by weight, 2% by weight, 3% by weight, or 4% by weight to about 20% by weight, 15% by weight, 10% by weight, or 5% by weight (calculated on a dry weight basis). For example, the amorphous solid may contain 1 to 20% by weight or 2 to 5% by weight of nicotine.

[0043] In some examples, the total content of the active substance and / or fragrance may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight. In some examples, the total content of the active substance and / or fragrance may be less than about 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight (all calculated on a dry weight basis).

[0044] In some examples, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight. In some examples, the total content of tobacco material, nicotine, and flavorings may be less than about 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight (all calculated on a dry weight basis).

[0045] In some embodiments, the amorphous solid is a hydrogel containing less than about 20% by weight of water on a wet weight basis. In some examples, the hydrogel may contain less than 15% by weight, 12% by weight, or 10% by weight of water on a wet weight basis (WWB). In some examples, the hydrogel may contain at least about 1% by weight, 2% by weight, or at least about 5% by weight of water (WWB). In some embodiments, the amorphous solid may contain about 1% to about 15% by weight of water on a wet weight basis, or about 5% to about 15% by weight of water. The water content of the amorphous solid is preferably about 5% by weight, 7% by weight, or 9% to about 15% by weight, 13% by weight, or 11% by weight (WWB), and more preferably about 10% by weight.

[0046] The amorphous solid may be prepared from a gel, which may further contain a solvent in an amount of 0.1 to 50% by weight. However, the inventors have found that the inclusion of a solvent to which the fragrance can dissolve reduces the gel stability, and the fragrance may leave the gel and crystallize. Therefore, in some examples, the gel does not contain a solvent to which the fragrance can dissolve.

[0047] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, for example, 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight of filler.

[0048] In other embodiments, the amorphous solid comprises less than 20% by weight, preferably less than 10% by weight or less than 5% by weight of filler. In some examples, the amorphous solid comprises less than 1% by weight of filler, and in some examples, it comprises no filler.

[0049] If a filler is present, it may comprise one or more inorganic fillers, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and a suitable inorganic adsorbent (such as a molecular sieve). The filler may also comprise one or more organic fillers, such as wood pulp, cellulose, and cellulose derivatives. In certain examples, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0050] In certain embodiments including 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. While we do not wish to be bound by theory, it is thought that including a fibrous filler in an amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in examples where the amorphous solid is provided as a sheet, for example, when an amorphous solid sheet surrounds a rod of aerosolizable material.

[0051] In some embodiments, the amorphous solid does not contain tobacco fibers. In certain embodiments, the amorphous solid does not contain fibrous material.

[0052] In some embodiments, the aerosol-generating material does not include tobacco fibers. In certain embodiments, the aerosol-generating material does not include fibrous material.

[0053] In some embodiments, the aerosol-generating substrate does not include tobacco fibers. In certain embodiments, the aerosol-generating substrate does not include fibrous material.

[0054] In some embodiments, the aerosol product does not contain tobacco fibers. In certain embodiments, the aerosol product does not contain fibrous material.

[0055] In some cases, amorphous solids are 1 to 60% by weight of a gelling agent, and / or 5-80% by weight of an aerosol-generating agent, and / or 0.1 to 60% by weight of active substance, Equipped with Optional, flavorings These may be provided. Note that these weights are calculated on a dry weight basis.

[0056] In some cases, amorphous solids are 1 to 50% by weight of a gelling agent, and / or 5-80% by weight of an aerosol-generating agent, and / or 1-60% by weight of active substance, Equipped with Optional, flavorings These may be provided. Note that these weights are calculated on a dry weight basis.

[0057] In some examples, the amorphous solid consists essentially of, or may consist of, a gelling agent, an aerosol-generating agent, tobacco material and / or a nicotine source, water, and optionally a flavoring.

[0058] Aerosol products and assemblies Further aspects of the present invention provide the following: • Aerosol products used in aerosol generation assemblies. This article includes a laminated aerosol generation material according to the first embodiment. Aerosol product used in an aerosol generation assembly, comprising a generating material. The aerosol generating material comprises an aerosol-forming layer comprising an amorphous solid, and the aerosol product is configured for use in an aerosol generation assembly such that substantially all of the aerosol-forming layer is located within the aerosol generation assembly at a distance of approximately 10 μm to 4 mm from the heater. An aerosol generating assembly comprising an aerosol generating material and a heater configured to heat the aerosol generating material without combustion. The aerosol generating material comprises an aerosol-forming layer comprising an amorphous solid, and substantially the entire aerosol-forming layer is located within the aerosol generating assembly at a distance of less than approximately 4 mm from the heater.

[0059] In some examples, the assembly may comprise a laminated aerosol-generating material according to the first aspect of the present invention.

[0060] The inventors have found that minimizing the distance between the aerosol layer and the heater improves the user experience. This reduces the formation of undesirable residues on the heater, thereby improving hygiene. Furthermore, contact between the aerosol-forming layer and the heater (or between residues and the heater) can lead to carbonization, which may impair fragrance delivery.

[0061] The maximum distance between the aerosol-forming layer and the heater ensures efficient heating.

[0062] In some cases, the heater may heat the aerosolizable material between 120°C and 350°C during use without combustion. In some cases, the heater may heat the aerosolizable material between 140°C and 250°C during use without combustion.

[0063] In some examples, substantially all of the aerosol-forming layer is located within the assembly at a distance of less than approximately 4 mm, less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2.0 mm, less than 1.5 mm, less than 1.0 mm, less than 0.5 mm, or less than 0.3 mm from the heater. In some examples, the surface of the amorphous solid may be in direct contact with the heater.

[0064] In some examples, substantially all of the aerosol-forming layer is located within the assembly at distances from the heater ranging from 0.010 mm, 0.015 mm, 0.017 mm, 0.020 mm, 0.023 mm, 0.025 mm, 0.05 mm, 0.075 mm, 0.1 mm to approximately 4 mm, 3.5 mm, 3 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, 0.5 mm, or 0.3 mm.

[0065] In some cases, there may be a minimum gap of at least about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm, or 0.1 mm between the aerosol-forming layer in the assembly and the heater.

[0066] In some examples, the aerosol-generating material is provided as a flat sheet with a carrier layer in contact with a flat heater surface. In some examples, the aerosol-generating material is provided as a rolled sheet for use in an oven-type heater (i.e., a heater surrounding a tube) (i.e., in the form of a tube with a carrier on its outer surface). In some such examples, the amorphous solid of these embodiments may be included in the aerosol product / assembly as a sheet surrounding a rod of aerosolizable material (e.g., tobacco).

[0067] In some examples, a sheet-like amorphous solid may have a tensile strength of about 200 N / m to about 900 N / m. In some examples where the amorphous solid does not contain fillers, 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. In some examples where the amorphous solid contains fillers, 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 are particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol product / assembly as a wound sheet, preferably in the form of a tube.

[0068] Aerosol-generating materials comprising amorphous solids can have any suitable surface density, for example, 30 g / m². 2 ~120g / m 2 It may have the following properties. In some embodiments, the aerosol-generating material is about 30-70 g / m². 2 , or approximately 40-60 g / m 2 It may have a surface density of about 80-120 g / m². In some embodiments, the amorphous solid has a surface density of about 80-120 g / m². 2 , or approximately 70-110 g / m 2 , or especially about 90-110 g / m² 2 It may have a surface density. Such a surface density is particularly suitable when the aerosol-generating material is included in the aerosol product / assembly in sheet form.

[0069] The heater is configured to heat the aerosol-generating material without causing combustion. In some examples, the heater may be a thin-film electrical resistance heater. In other examples, the heater may be an induction heater or other type of heater. The heater may be a flammable heat source or a chemical heat source that generates heat by causing an exothermic reaction during use. The aerosol-generating assembly may include multiple heaters. These heaters may be powered by batteries.

[0070] The aerosol generating assembly may further comprise a cooling element and / or a filter. If a cooling element is present, it may act or function to cool the gaseous component or the aerosol component. In some examples, the cooling element may act to cool the gaseous component so that it condenses to form an aerosol. The cooling element may also act to keep the very hot parts of the device away from the user. If a filter is present, it may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0071] In some examples, the aerosol-generating assembly may be a heat-not-burn device. That is, the aerosol-generating assembly may include a solid tobacco-containing material (but not a liquid aerosolizable material). In some examples, the amorphous solid may comprise the tobacco material. A heat-not-burn device is disclosed in WO2015 / 062983A2, the entire publication of which is incorporated herein by reference.

[0072] In some examples, the aerosol-generating assembly may be an e-cigarette hybrid device. That is, the aerosol-generating assembly may comprise a solid aerosolizable material and a liquid aerosolizable material. In some examples, the amorphous solid may comprise nicotine. In some examples, the amorphous solid may comprise tobacco material. In some examples, the amorphous solid may comprise tobacco material and a separate nicotine source. These separate aerosolizable materials may be heated by separate heaters or by the same heater, and in some examples, the downstream aerosolizable material may be heated by a high-temperature aerosol generated from the upstream aerosolizable material. The e-cigarette hybrid device is disclosed in WO2016 / 135331A1, the entirety of which is incorporated herein by reference.

[0073] An aerosol product comprising an aerosol-generating material according to a first aspect of the present invention may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol-generating device. In some examples, the article may further comprise a filter and / or a cooling element, as described above. In some examples, the aerosol product may be surrounded by packaging material such as paper.

[0074] The aerosol product may further include vents, which may be located on the side walls of the article. In some examples, the vents may be located on the filter and / or cooling element. These vents allow cold air to be drawn into the article during use, and this cold air can mix with the heated volatile components, thereby cooling the aerosol.

[0075] Ventilation facilitates the generation of visible heat-volatile components from the article when the article is heated during use. These heat-volatile components are made visible by a process of cooling them to the point where supersaturation occurs. The heat-volatile components then undergo droplet formation (also known as nucleation), and ultimately, the size of the heat-volatile component aerosol particles increases due to further condensation of the heat-volatile components and the aggregation of newly formed droplets from the heat-volatile components.

[0076] In some cases, the ratio of cold air to the total amount of heated volatile components (known as the permeability ratio) is at least 15%. A permeability ratio of 15% makes it possible to visualize the heated volatile components in the manner described above. The visibility of heated volatile components allows the user to identify that volatile components have been generated, enhancing the perceptual experience of the smoking experience.

[0077] In another example, the permeability ratio is 50% to 85% to further cool the heated volatile components. In some examples, the permeability ratio may be at least 60% or 65%.

[0078] Referring to Figures 2 and 3, a partial fractured section and perspective view of an example of an aerosol product 101 are shown. Article 101 is adapted for use with a device having a power supply and a heater. Article 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 6 to 8, which are described below. When in use, article 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 6.

[0079] One example article 101 has the form of a substantially cylindrical rod, comprising an aerosol-generating material body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises a laminated aerosol-generating material as described herein. In the illustrated embodiment, the laminated aerosol-generating material is provided as a rod in the form of a rolled sheet (i.e., in the form of a tube). In yet another embodiment (not shown), the aerosol-generating material as described herein may be incorporated, for example, as a flat sheet.

[0080] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouth-end segment 111. Article 101 has a first end 113, also known as the mouth-end or proximal end, and a second end 115, also known as the distal end. The aerosol-generating material 103 is located on the distal end 115 side of article 101. In one example, the cooling segment 107 is located adjacent to the aerosol-generating material 103 between the aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in contact with the aerosol-generating material 103 and the filter segment 109. In other examples, there may be separations between the aerosol-generating material 103 and the cooling segment 107, and between the aerosol-generating material 103 and the filter segment 109. The filter segment 109 is located between the cooling segment 107 and the mouth-end segment 111. The mouth end segment 111 is positioned on the proximal end 113 side of the article 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in contact with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is 37 mm to 45 mm, and more preferably, the total length of the filter assembly 105 is 41 mm.

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

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

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

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

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

[0086] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient between the two ends of the cooling segment 107 in the longitudinal direction. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In another example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference between the two ends of the cooling element 107 in the longitudinal direction protects the temperature-sensitive filter segment 109 from the high temperature 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 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and may not effectively perform its required function.

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

[0088] The cooling segment 107 is made of paper, meaning that the cooling segment 107 is composed of a material that does not generate compounds of concern (e.g., toxic compounds) when it is adjacent to the heater of the device 51 during use. In one example, the cooling segment 107 is manufactured from a spiral-wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spiral-wound paper tube can meet the stringent dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and straightness of the tube.

[0089] In another example, the cooling segment 107 is a recess made from rigid plug wrap or chipping paper. The rigid plug wrap or chipping paper is manufactured to be rigid enough to withstand the axial compressive forces and bending moments that may occur during manufacturing and while the article 101 is being used during insertion into the device 51.

[0090] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heat-volatile components of 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 irritation reduction of the heat-volatile components without depleting the amount of heat-volatile components to an unsatisfactory level for the user.

[0091] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. This capsule may be positioned substantially at the center of the filter segment 109 in both the radial and longitudinal directions. In other examples, the capsule may be offset from the center in one or more dimensions. In some examples, if a capsule is present, it may contain volatile components such as flavorings or aerosol-generating agents.

[0092] The density of the cellulose acetate tow material in the filter segment 109 controls the pressure drop between the ends of the filter segment 109, and consequently controls the suction resistance of article 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the suction resistance of article 101. Furthermore, the filter segment performs a filtration function in article 101.

[0093] In one example, filter segment 109 is made of 8Y15 grade filter tow material. This filter tow material provides a filtering effect against heated volatile materials while reducing the size of condensed aerosol droplets generated from the heated volatile materials.

[0094] The presence of the filter segment 109 provides an insulating effect by further cooling the heated volatile components that exit the cooling segment 107. This further cooling effect lowers the contact temperature of the user's lips with the surface of the filter segment 109.

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

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

[0097] The mouth end segment 111 may be manufactured from a helical paper tube that provides a hollow internal chamber while maintaining important mechanical rigidity. The helical paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0098] The mouth end segment 111 provides a function to prevent liquid condensation accumulating at the outlet of the filter segment 109 from coming into direct contact with the user.

[0099] In one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, and the filter segment 109 may be placed inside that tube to separate the mouth end segment 111 and the cooling segment 107.

[0100] Referring to Figures 4 and 5, a partial fractured section view and a perspective view of an example of article 301 are shown. The reference numerals shown in Figures 4 and 5 correspond to the reference numerals shown in Figures 2 and 3, but the numerals are increased by 200.

[0101] In the example of article 301 shown in Figures 4 and 5, a ventilation region 317 is provided in the article 301 to allow air to flow from the outside of the article 301 into the inside of the article 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301. These ventilation holes may be located in a cooling segment 307 to help cool the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes arranged along the outer circumference of the article 301 in a cross section substantially perpendicular to the longitudinal axis of the article 301.

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

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

[0104] In one example, the row of vents 317 is located at least 11 mm from the proximal end 313 of the article, preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The position of the vents 317 is determined so that the user does not block the vents 317 when using the article 301.

[0105] By providing a row of vents 17mm to 20mm from the proximal end 313 of article 301, the vents 317 can be positioned outside the device 51 when article 301 is fully inserted into the device 51, as shown in Figures 7 and 8. Positioning the vents outside the device allows unheated air to enter article 301 from outside the device 51 through the vents, helping to cool article 301.

[0106] The length of the cooling segment 307 is such that when the article 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 has two functions: firstly, it provides a physical gap between the heating device and the heat-sensitive filter device 309 of the device 51, and secondly, it allows the vents 317 to be located within the cooling segment while also being located outside the device 51 when the article 301 is fully inserted into the device 51. As can be seen from Figures 7 and 8, the majority of the cooling element 307 is located inside the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vents 317 are located in this portion of the cooling element 307 that extends outside the device 51.

[0107] Referring more closely to Figures 6 to 8, an example of a device 51 is shown which is configured to heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby typically forming an inhalable aerosol. Device 51 is an oven-type heating device that releases compounds by heating but not burning the aerosol-generating material.

[0108] The first end 53 may be referred to herein as the oral end 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 user to start / stop the entire device 51 as desired.

[0109] The device 51 includes a housing 59 for arranging and protecting various internal components of the device 51. In the illustrated example, the housing 59 comprises a single sleeve 11 surrounding the outer edge of the device 51, which is covered by a top panel 17 that generally forms the “upper” part of the device 51 and a bottom panel 19 that generally forms the “bottom” part of the device 51. In another example, the housing comprises a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and the bottom panel 19.

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

[0111] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, so that when in use, the user can insert articles 101, 301 containing aerosol-generating material into and out of the device 51 through this opening 20.

[0112] The housing 59 houses or secures the heating device 23, the control circuit 25, and the power supply 27. In this example, the heating device 23, the control circuit 25, and the power supply 27 are located close together laterally (i.e., close together when viewed from one end), and the control circuit 25 is generally located between the heating device 23 and the power supply 27, although other arrangements are possible.

[0113] The control circuit 25 may include a controller, such as a microprocessor, configured and positioned to control the heating of the aerosol-generating material in articles 101, 301, as will be further discussed below.

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

[0115] The advantage of positioning the power supply 27 laterally close to the heating device 23 is that a physically larger power supply 25 can be used without making the entire device 51 excessively long. Naturally, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours, etc.) and therefore can extend the battery life of the device 51.

[0116] In one example, the heating device 23 generally takes the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which articles 101, 301 containing aerosol-generating material are inserted for heating during use. Various configurations are possible for the heating device 23. For example, the heating device 23 may have a single heating element, or it may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The heating element or each heating element may be annular or tubular, or at least partially annular or at least partially tubular along its outer circumference. In one example, the heating element or each heating element may be a thin-film heater. In another example, the heating element or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramics, aluminum nitride ceramics, and silicon nitride ceramics, which may be laminated and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by emitting infrared radiation), and resistance heating elements formed by resistive electric windings.

[0117] In one particular example, the heating device 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heating device 23 is sized such that when articles 101, 301 are inserted into the device 51, substantially the entire body of articles 101, 301, consisting of aerosol-generating material 103, 303, is inserted into the heating device 23.

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

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

[0120] The housing 59, like the heating device 23, may further comprise various internal support structures 37 for supporting all internal components.

[0121] The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the housing 59, and a substantially tubular chamber 35 positioned between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a number of spaced-apart cooling fins 35f along the outer surface of the chamber 35, each cooling fin arranged to surround the outer surface of the chamber 35. When articles 101, 301 are 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 articles 101, 301. The gap 36 surrounds the entire outer circumference of the articles 101, 301 over at least a portion of the cooling segment 307.

[0122] The collar 33 is provided with a plurality of protrusions 60 arranged to surround the outer periphery of the opening 20, and these protrusions project into the opening 20. The protrusions 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the protrusions 60 is smaller than the opening distance of the opening 20 at the location without the protrusions 60. The protrusions 60 are configured to engage with the articles 101, 301 inserted into the device, and to help secure them within the device 51. The open spaces (not shown) defined by adjacent pairs of protrusions 60 and the articles 101, 301 form ventilation paths around the outer surfaces of the articles 101, 301. These ventilation paths allow hot vapor escaping from the articles 101, 301 to exit the device 51, and allow cooling air to flow into the device 51 around the articles 101, 301 within the void 36.

[0123] During operation, articles 101 and 301 are removably inserted into the insertion points 20 of the device 51, as shown in Figures 6-8. Referring particularly to Figure 7, in one example, the aerosol-generating material bodies 103 and 303 (located on the distal ends 115 and 315 of articles 101 and 301) are fully housed within the heating element 23 of the device 51. The proximal ends 113 and 313 of articles 101 and 301 extend from the device 51 and function as a mouthpiece assembly for the user.

[0124] During operation, the heating device 23 heats the articles 101 and 301 to volatilize at least one component of the aerosol-generating material from the aerosol-generating material bodies 103 and 303.

[0125] The primary channel for heated volatile components from the aerosol-generating material bodies 103, 303 passes axially through articles 101, 301, through the inner chambers of the cooling segments 107, 307, through the filter segments 109, 309, and through mouth-end segments 111, 313 to the user. In one example, the temperature of the heated volatile components produced from the aerosol-generating material is 60°C to 250°C, which may exceed the user's acceptable inhalation temperature. As the heated volatile components move through the cooling segments 107, 307, they are cooled, and some of the volatile components condense on the inner surfaces of the cooling segments 107, 307.

[0126] In the example of article 301 shown in Figures 4 and 5, cold air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cold air mixes with the heated volatile components to further cool them.

[0127] Manufacturing method A further aspect of the present invention provides a method for producing a layered aerosol generating material according to the first aspect.

[0128] This method comprises the steps of (a) forming a slurry comprising amorphous solid components or precursors thereof, (b) applying the slurry to a carrier, (c) curing the slurry to form a gel, and (d) drying to form an amorphous solid.

[0129] Step (b) for forming a slurry layer may include, for example, spraying, casting, or extruding the slurry. In some examples, the layer is formed by electrostatic spraying of the slurry. In some examples, the layer is formed by casting the slurry.

[0130] In some examples, steps (b) and / or (c) and / or (d) may be performed at least partially simultaneously (for example, during electrostatic spraying). In some examples, these steps may be performed sequentially.

[0131] Step (c) for curing the gel may include adding a curing agent to the slurry. For example, the slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a curing agent comprising a calcium source (e.g., calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0132] The total amount of the curing agent, such as a calcium source, may be 0.5 to 5% by weight (calculated on a dry weight basis). The inventors have found that if the amount of curing agent added is too small, it may result in a gel in which the gel components are not stabilized and these components detach from the gel. The inventors have also found that if the amount of curing agent added is too large, it may result in a gel that is very sticky and, as a result, difficult to handle.

[0133] The drying step may reduce the thickness of the cured material by at least 80%, preferably 85% or 87%.

[0134] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (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. When calcium cations are added, alginates crosslink to form a gel. The inventors have determined that alginates with a high G monomer content form a gel more readily when a calcium source is added. Therefore, 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.

[0135] The slurry itself may also form part of the present invention. In some examples, the slurry solvent is essentially water or may consist of water. In some examples, the slurry may contain about 50% by weight, 60% by weight, 70% by weight, 80% by weight, or 90% by weight or more of the solvent (WWB).

[0136] In some cases, the slurry has a viscosity of approximately 10 Pa·s to 20 Pa·s at 46.5°C, such as approximately 14 Pa·s to 16 Pa·s at 46.5°C.

[0137] In examples where the solvent is water, the dry weight content of the slurry may be equal to the dry weight content of the amorphous solid. Thus, the discussions herein regarding the composition of the solid are explicitly disclosed in combination with the slurry embodiments of the present invention.

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

[0139] In certain embodiments, the amorphous solid may have the following composition (DWB): namely, a gelling agent (preferably comprising an alginate, more preferably a combination of alginate and pectin) in an amount of about 20% to about 40% by weight, or about 25% to 35% by weight (in DWB); menthol in an amount of about 35% to about 60% by weight, or about 40% to 55% by weight; and an aerosol-generating agent (preferably comprising glycerol) in an amount of about 10% to about 30% by weight, or about 15% to about 25% by weight.

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

[0141] The amorphous solid may be provided as a sheet. Preferably, the sheet has a thickness of about 0.015 mm to about 1 mm, more preferably about 0.02 mm to about 0.07 mm.

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

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

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

[0145] As described above, the amorphous solid of these embodiments may be provided as a sheet. In one embodiment, the sheet is placed on a carrier comprising paper. In another embodiment, the sheet is placed on a carrier comprising metal foil, preferably aluminum metal foil. In this embodiment, the amorphous solid may be in contact with the metal foil.

[0146] In one embodiment, the sheet, together with layers (preferably made of paper) attached to the top and bottom surfaces of the sheet, forms part of the laminated material. Preferably, the amorphous solid sheet has a thickness of about 0.015 mm to about 1 mm.

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

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

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

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

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

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

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

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

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

[0156] definition The active substances used herein are physiologically active materials, i.e., materials for achieving or enhancing physiological reactions. Active substances may be selected from, for example, functional foods, nootropics, and psychoactive substances. Active substances may be naturally occurring or obtained by synthesis. Active substances may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, and C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. Active substances may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

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

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

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

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

[0161] As described herein, the active substance may comprise or be derived from one or more plant materials or components, derivatives, or extracts thereof. As used herein, the term “plant material” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the material may comprise an active compound that is naturally present in the plant material or obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, shards, sheets, etc. Examples of plant-based ingredients include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, clove, 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, damian, 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: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

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

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

[0164] As used herein, the terms “flavoring” and “flavoring” refer to materials that can be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where local regulations permit. These include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango). 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, citrus Shisha, pine, 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 variety of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, laurel, mate, orange peel, rose, tea (green tea, black tea, etc.), Thai (Lumin, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators, or stimulants, sugars and / or sugar substitutes (e.g., sucralose,It may contain acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives, such as charcoal, chlorophyll, minerals, plant materials, or breath fresheners. These may be imitation ingredients, synthetic ingredients, natural ingredients, or blends thereof. They may be in any suitable form, such as liquid (e.g., oil), solid (e.g., powder), or gas.

[0165] The fragrance may preferably comprise one or more mint fragrances, and preferably mint oil obtained from any variety of the genus Mint. The fragrance may preferably comprise menthol, consist essentially of menthol, or consist of menthol.

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

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

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

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

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

[0171] In some embodiments, the fragrance may comprise sensory agents intended to achieve somatosensory effects that are normally 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 effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0172] As used herein, the term “aerosol-generating agent” refers to an agent that promotes aerosol formation. Aerosol-generating agents may promote aerosol formation by facilitating the initial volatilization and / or condensation of gases into inhalable solid and / or liquid aerosols.

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

[0174] As used herein, the term “tobacco material” refers to any material comprising tobacco or its derivatives. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, puffed tobacco, recombined tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, loose tobacco, extruded tobacco, tobacco leaf stalks, recombined tobacco, and / or tobacco extracts.

[0175] The tobacco used to manufacture the tobacco material may be any suitable tobacco, including Virginia and / or Burley and / or Oriental, single grade or blend, cut rag or whole leaf. It may also be tobacco particles, "fine powder" or dust, puffed tobacco, leaf stalks, puffed leaf stalks, and other processed leaf stalk materials (such as rolled cut leaf stalks). The tobacco material may be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may comprise tobacco fibers and may be formed by casting, a wire mesh papermaking approach with backing addition of tobacco extract, or extrusion.

[0176] All weight percentages (indicated as wt%) used herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights expressed on a dry weight basis refer to the entirety of the extract, slurry, or material other than water, and may include components that are liquid by themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages expressed on a wet weight basis refer to all components, including water.

[0177] To avoid misunderstanding, while the term “equipped with” is used herein to define the invention or its features, embodiments are also disclosed in which the terms “essentially comprised of” or “consisting of” may be used instead of “equipped with.” References to materials “equipped with” certain features mean that those features are contained in, incorporated into, or retained within the material.

[0178] The embodiments described above should be understood as illustrative examples of the present invention. Any feature described in relation to any one embodiment may be used alone or in combination with other features described, or 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 used without departing from the scope of the present invention as defined in the appended claims.

Claims

1. A laminated aerosol generating material comprising an aerosol-forming layer attached to a carrier layer, The aerosol-forming layer comprises a dry gel, the carrier layer has a thickness of about 10 μm to about 2.5 mm, and the aerosol-forming layer has a thickness of 0.015 mm to 1.5 mm. A laminated aerosol-generating material wherein the carrier layer is formed from one or more materials selected from paper, oil-resistant paper, plastic, cardboard, wood, or a combination thereof.

2. The laminated aerosol generating material according to claim 1, having a thickness of less than approximately 4 mm.

3. The aforementioned dried gel 1 to 60% by weight of a gelling agent, and / or 5 to 80% by weight of an aerosol-generating agent, and / or 0.1 to 60% by weight of active substance, And, optionally, flavorings A laminated aerosol-generating material according to claim 1 or 2, comprising, wherein these weights are calculated on a dry weight basis.

4. The laminated aerosol generating material according to any one of claims 1 to 3, wherein the dry gel is a hydrogel and contains 1% to 15% by weight of water calculated on a wet weight basis.

5. An aerosol product used in an aerosol generating assembly, comprising a laminated aerosol generating material according to any one of claims 1 to 4.

6. an aerosol generating assembly comprising a laminated aerosol generating material according to any one of claims 1 to 4, The heater is configured to heat the aerosol generating material but not to cause it to burn. An aerosol generating assembly in which substantially all of the aerosol-forming layer is located within the aerosol generating assembly at a distance of less than approximately 4 mm from the heater.

7. A method for producing a layered aerosol generating material according to any one of claims 1 to 4, A method comprising: (a) forming a slurry comprising components of a dry gel or precursors thereof; (b) applying the slurry to a carrier layer; (c) curing the slurry to form a gel; and (d) drying to form a dry gel.

8. The method according to claim 7, wherein the drying step reduces the thickness of the cured material by at least 80%, preferably 85% or 87%.

9. The method according to claim 7 or 8, wherein step (c) comprises adding a curing agent to the slurry.

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