BR112021001920A2 - aerosol generating material, assembly, article and method - Google Patents

Abstract

AEROSOL GENERATING MATERIAL, ASSEMBLY, ARTICLE AND METHOD. Disclosed herein is an aerosol generating material comprising an aerosol forming layer, the aerosol forming layer comprising an amorphous solid, wherein the aerosol forming layer has a thickness of 0.015 mm to 1.0 mm.

Description

AEROSOL GENERATING MATERIAL, ASSEMBLY, ARTICLE AND METHOD Technical Field

[0001] The present invention relates to the generation of aerosol.

Background

[0002] Smoking articles, such as cigarettes, cigars and the like, burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapor, releasing compounds from a substrate material by heating without burning. These can be referred to as non-combustible smoking articles or aerosol generator sets.

[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 cases, contain a tobacco material. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. Such products may be referred to as non-burn heating devices, tobacco heating devices or tobacco heating products. Several different arrangements for volatilizing at least one component of the solid aerosolizable material are known.

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

summary

[0005] A first aspect of the invention provides an aerosol generating material comprising an aerosol forming layer, the aerosol forming layer comprising an amorphous solid, wherein the aerosol forming layer has a thickness of 0.015 mm to 1.0 mm . In one embodiment, the aerosol forming layer has a thickness of 0.05 mm to 1.0 mm.

[0006] In one embodiment, the amorphous solid comprises one or more of an active substance, an aerosol generating agent, a flavoring and a gelling agent. In a particular embodiment, the amorphous solid comprises one or more of nicotine, a tobacco material, an aerosol generating agent, a flavoring and a gelling agent.

[0007] A second aspect of the invention provides an aerosol generating set comprising an aerosol generating material according to the first aspect of the invention and a heater configured to heat, but not burn, the aerosol generating material.

[0008] A third aspect of the invention provides an aerosol generating article for use in an aerosol generating set, the article comprising an aerosol generating material according to the first aspect.

[0009] A fourth aspect of the invention provides a method for manufacturing an aerosol generating material according to the first aspect.

[0010] Other aspects of the invention described herein may provide for the use of the aerosol generating material, the aerosol generating article or the aerosol generating set in generating an inhalable aerosol.

[0011] Other features and advantages of the invention will become evident from the following description, given by way of example only and with reference to the attached figures.

Brief Description of Figures

[0012] Figure 1 is an exploded schematic diagram of an aerosol generating material.

[0013] Figure 2 shows a sectional view of an example of an aerosol generating article.

[0014] Figure 3 shows a perspective view of the article in Figure 2.

[0015] Figure 4 shows a cross-sectional elevation of an example of an aerosol generating article.

[0016] Figure 5 shows a perspective view of the article in Figure 4.

[0017] Figure 6 shows a perspective view of an example of an aerosol generator set.

[0018] Figure 7 shows a sectional view of an example of an aerosol generator set.

[0019] Figure 8 shows a perspective view of an example of an aerosol generator set.

Detailed Description

[0020] The aerosol forming layer described herein comprises an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or as a "dry gel". Amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some cases, the aerosol forming layer comprises from about 50% by weight, 60% by weight or 70% by weight amorphous solid, to about 90% by weight, 95% by weight or 100% by weight solid. amorphous. In some cases, the aerosol forming layer consists of an amorphous solid.

[0021] As described above, the invention provides an aerosol generating material comprising an aerosol forming layer, the aerosol forming layer comprising an amorphous solid, and wherein the aerosol forming layer has a thickness of from about 0.015 mm to about of 1.0 mm. Suitably, the thickness may range from about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The aerosol forming layer may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

[0022] The inventors have established that if the aerosol forming layer is too thick, then the heating efficiency will be compromised. This negatively affects the energy consumption and application time of the aerosol in use. On the other hand, if the aerosol forming layer is too thin, it is difficult to manufacture and handle; a very thin material is more difficult to melt and may be brittle, compromising aerosol formation in use.

[0023] The inventors have established that the layer thicknesses stipulated here optimize material properties in view of these competing considerations.

[0024] The thickness stipulated here is an average thickness for the material. In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

[0025] In some cases, the aerosol generating material may comprise built-in heating means such as resistive or inductive heating elements. For example, the heating medium can be embedded in the amorphous solid.

[0026] The aerosol generating material may comprise a carrier on which the amorphous solid is provided. Figure 1 provides a schematic illustration of such an aerosol generating material. The laminated structure (indicated by dotted lines) includes a carrier layer 4 and an amorphous solid layer 2.

[0027] The conveyor works as a support on which the amorphous solid layer forms, facilitating fabrication. The conveyor can provide tensile strength to the amorphous solid layer, making handling easier.

[0028] The carrier can be any suitable material that can be used to support an amorphous solid. In some cases, the conveyor may be formed from selected materials such as sheet metal, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. . In some cases, the carrier may comprise or consist of a tobacco material, such as a reconstituted tobacco sheet. In some cases, the carrier can be formed from selected materials of sheet metal, paper, cardboard, wood, or combinations thereof. In some cases, the conveyor itself may be a laminated structure comprising layers of materials selected from previous lists. In some cases, the carrier can also function as a flavor carrier. For example, the carrier can be impregnated with a flavoring or tobacco extract.

[0029] In some cases, the carrier may be magnetic. This functionality can be used to secure the conveyor to the assembly in use or it can be used to generate particular amorphous solid shapes. In some cases, the aerosol generating material can comprise one or more magnets that can be used to secure the material to an induction heater in use.

[0030] In some cases, the carrier may be substantially or completely impermeable to gas and/or aerosol. This prevents the passage of aerosol or gas through the carrier layer, thus controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use, for example, on the surface of a heater provided in an aerosol generator set. Thus, consumption efficiency and hygiene can be improved in some cases.

[0031] In one case, the surface of the conveyor that abuts the amorphous solid may be porous. For example, in some cases,

the carrier comprises paper. The inventors have found that a porous support such as paper is particularly suitable for the present invention; the porous layer abuts the amorphous solid layer and forms a strong bond. The amorphous solid is formed by drying a gel and, without being limited by theory, it is thought that the suspension from which the gel is formed partially impregnates the porous carrier (eg paper) so that when the gel hardens and crosslinks, the carrier is partially bound to the gel. This provides a strong bond between the gel and the carrier (and between the dry gel and the carrier). The porous layer (eg paper) can also be used to transport flavors. In some cases, the porous layer may comprise paper, suitably having a porosity of 0-300 Coresta units (CU), suitably 5-100 CU or 25-75 CU.

[0032] In addition, surface roughness can contribute to the bond strength between the amorphous material and the carrier. The inventors have found that the roughness of the paper (for the surface adjoining the conveyor) can suitably be in the range of 50-1000 seconds Bekk, suitably 50-150 seconds Bekk, suitably 100 seconds Bekk (measured over an air pressure range of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is drawn between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air flowing between these surfaces is the "Bekk smoothness").

[0033] On the other hand, the conveyor surface facing away from the amorphous solid can be arranged in contact with the heater and a smoother surface can provide more efficient heat transfer. Thus, in some cases, the carrier is arranged to have a rougher side facing the amorphous material and a smoother side facing away from the amorphous material.

[0034] In a particular case, the carrier may be a sheet with paper on the back; the paper layer abuts the amorphous solid layer and the properties discussed in the previous paragraphs are offered by this abutment. The back of the sheet is substantially waterproof, providing control of the aerosol flow path. A sheet metal back can also serve to conduct heat to the amorphous solid.

[0035] In another case, the sheet layer of the paper-backed sheet abuts the amorphous solid. The sheet is substantially impermeable, thus preventing water supplied in the amorphous solid from being absorbed by the paper, which could weaken its structural integrity.

[0036] In some cases, the carrier is formed or comprises sheet metal, such as aluminum foil. A metallic carrier can allow better conduction of thermal energy to the amorphous solid. Additionally, or alternatively, a sheet metal can function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a sheet metal layer and a backing layer such as cardboard. In such embodiments, the sheet metal layer may have a thickness of less than 20 µm, such as from about 1 µm to about 10 µm, suitably about 5 µm.

[0037] In some cases, the carrier may have a thickness between about 0.010 mm and about 2.5 mm, suitably from about 0.015 mm, 0.017 mm 0.02 mm, 0.05 mm or 0.1 mm to about 1.5mm, 1.0mm or 0.5mm.

COMPOSITION OF AEROSOL-FORMING MATERIAL

[0038] In some cases, the amorphous solid may comprise 1-60% by weight of a gelling agent, these weights being calculated on a dry weight basis.

Suitably, the amorphous solid may comprise from about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, 30% by weight or 27% by weight of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50% by weight, 5-40% by weight, 10-30% by weight or 15-27% by weight of a gelling agent.

[0040] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica compounds or silicones, 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 cases,

the gelling agent comprises alginate and/or pectin and can be combined with a fixing agent (such as a source of calcium) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium cross-linked alginate and/or a calcium cross-linked pectin.

[0041] 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 of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

[0042] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

Suitably, the amorphous solid may comprise 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 of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent can act as a plasticizer. For example, the amorphous solid may comprise 10-60% by weight, 15-50% by weight or 20-40% by weight of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists of, or consists essentially of glycerol. The inventors have established that if the plasticizer content is too high, the amorphous solid can absorb water resulting in a material that does not create a proper consumption experience in use. The inventors have established that if the plasticizer content is too low, the amorphous solid can be brittle and easily broken. The plasticizer content specified herein provides an amorphous solid flexibility that allows the amorphous solid sheet to be wound on a coil, which is useful in the manufacture of aerosol generating articles.

[0044] In some cases, the amorphous solid may comprise a taste. Suitably, the amorphous solid may comprise 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 flavor. In some cases, the amorphous solid may comprise 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 flavor (all calculated on a dry weight basis). For example, the amorphous solid may comprise 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. weight of a flavor. In some cases, the flavor (if present) comprises, consists of, or consists essentially of menthol. In some cases, the amorphous solid does not contain a taste.

[0045] In some cases, the amorphous solid additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco and/or nicotine material. For example, the amorphous solid can further comprise tobacco powder and/or nicotine and/or a tobacco extract. In some cases, the amorphous solid may comprise from about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 70% by weight, 50 % by weight, 45% by weight or 40% by weight (calculated on a dry weight basis) of active substance. In some cases, the amorphous solid may comprise from about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 70% by weight. % by weight, 50% by weight, 45% by weight or 40% by weight (calculated on a dry weight basis) of a tobacco and/or nicotine material.

[0046] In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 1% by weight, 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 based on dry weight) of tobacco extract. 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 in a concentration 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. weight, 4.5% by weight or 4% by weight (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that resulting from the tobacco extract.

[0047] In some embodiments, the amorphous solid does not comprise any tobacco material, but does comprise nicotine. In some such cases, the amorphous solid may comprise 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 dry weight) of nicotine. For example, the amorphous solid can comprise 1-20% by weight or 2-5% by weight of nicotine.

[0048] In some cases, the total content of active substance and/or flavor 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 cases, the total content of active substance and/or flavor may be less than about 70% by weight, 60% by weight, 50% by weight or 40% by weight (all calculated on a dry weight basis).

[0049] In some cases, the total content of tobacco material, nicotine and flavor may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight. weight, 25% by weight or 30% by weight. In some cases, the total content of tobacco material, nicotine and flavor may be less than about 70% by weight, 60% by weight, 50% by weight or 40% by weight (all calculated on a dry weight basis).

[0050] In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20% by weight of water calculated based on wet weight. In some cases, the hydrogel may comprise less than about 15% by weight, 12% by weight or 10% by weight of water calculated on a wet weight basis (WWB). In some cases, the hydrogel may comprise at least about 1% by weight, 2% by weight or at least about 5% by weight of water (WWB).

[0051] The amorphous solid can be made of a gel and this gel can additionally comprise a solvent, included at 0.1-50% by weight. However, the inventors have established that the inclusion of a solvent in which the taste is soluble can reduce gel stability and the taste can crystallize out of the gel. As such, in some cases the gel does not include a solvent in which the flavor is soluble.

[0052] In some embodiments, the amorphous solid comprises less than 60% by weight of a filler, such as from 1% by weight to 60% by weight, or 5% by weight to 50% by weight, or 5% by weight to 30% by weight, or 10% by weight to 20% by weight.

[0053] In other embodiments, the amorphous solid comprises less than 20% by weight, suitably less than 10% by weight or less than 5% by weight of a filler. In some cases, the amorphous solid comprises less than 1% by weight of a filler and, in some cases, no filler at all.

[0054] The filler, if present, may comprise one or more inorganic fillers, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate and sorbents suitable inorganics such as molecular sieves. The filler can comprise one or more organic fillers such as wood pulp, cellulose and cellulose derivatives. In particular, in some cases, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0055] In particular embodiments that include filler, the filler is fibrous. For example, the filler can be an organic fibrous filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including a fibrous filler in an amorphous solid can increase the tensile strength of the material. This may be particularly advantageous in examples where the amorphous solid is provided as a sheet, such as where a sheet of amorphous solid circumscribes a rod of aerosolizable material.

[0056] In some embodiments, the amorphous solid does not comprise tobacco fibers. In particular embodiments, the amorphous solid does not comprise fibrous material.

[0057] In some embodiments, the aerosol generating material does not comprise tobacco fibers. In particular embodiments, the aerosol generating material does not comprise fibrous material.

[0058] In some embodiments, the aerosol generating substrate does not comprise tobacco fibers. In particular embodiments, the aerosol generating substrate does not comprise fibrous material.

[0059] In some embodiments, the aerosol generating article does not comprise tobacco fibers. In particular embodiments, the aerosol generating article does not comprise fibrous material.

[0060] In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, an aerosol generating agent, an active substance, water and, optionally, a flavor.

[0061] In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, an aerosol generating agent, tobacco material and/or a source of nicotine, water, and optionally a flavor.

[0062] The aerosol generating material comprising the amorphous solid may have any suitable areal density, such as from 30 g/m2 to 120 g/m2. In some embodiments, an aerosol generating material can have a density of between about 30 and 70 g/m 2 , or about 40 to 60 g/m 2 . In some embodiments, the amorphous solid can have an areal density of from about 80 to 120 g/m2, or from about 70 to 110 g/m2, or particularly from about 90 to 110 g/m2. Such areal densities may be particularly suitable where the aerosol generating material is included in an aerosol generating article/assembly in sheet form or as a shredded sheet (described later).

ARTICLE AND AEROSOL GENERATOR ASSEMBLY

[0063] A second aspect of the invention provides an aerosol generating set comprising an aerosol generating material according to the first aspect of the invention and a heater configured to heat, but not burn, the aerosol generating material.

[0064] In some cases, the heater may heat, without burning, the aerosolizable material(s) between 120ºC and 350ºC in use. In some cases, the heater may heat, without burning, the aerosolizable material(s) between 140°C and 250°C in use. In some cases, in use, substantially all of the amorphous solid is less than about 4mm, 3mm, 2mm or 1mm from the heater. In some cases, the amorphous solid is disposed between about 0.017 mm and 2.0 mm from the heater, suitably between about 0.1 mm and 1.0 mm. In some cases, an amorphous solid surface may directly touch the heater.

[0065] The heater is configured to heat and not burn the aerosol generating material. The heater may in some cases be an electrically resistive thin-film heater. In other cases, the heater may comprise an induction heater or the like. The heater can be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to produce heat in use. The aerosol generator set may comprise a plurality of heaters. The heater(s) can be battery powered.

[0066] The aerosol generator set may additionally comprise a cooling element and/or a filter. The cooling element, if present, can act or function to cool gaseous components or aerosols. In some cases, it can act to cool gaseous components so that they condense to form an aerosol. It can also be used to keep very hot parts of the device away from the user. The filter, if present, can comprise any suitable filter known in the art, such as a cellulose acetate buffer.

[0067] In some cases, the aerosol generator set may be a non-burning heat device. That is, it can contain a solid tobacco-containing material (and no aerosolizable liquid material). In some cases, the amorphous solid may comprise tobacco material. A non-burning heat device is disclosed in WO 2015/062983 A2 which is incorporated by reference in its entirety.

[0068] In some cases, the aerosol generator set may be a hybrid electronic tobacco device. That is, it can contain a solid aerosolizable material and a liquid aerosolizable material. In some cases, the amorphous solid can comprise nicotine. In some cases, the amorphous solid may comprise a tobacco material. In some cases, the amorphous solid may comprise a tobacco material and a separate source of nicotine. The separate aerosolizable materials can be heated by separate heaters, the same heater or, in one case, a downstream aerosolizable material can be heated by a hot aerosol that is generated from the upstream aerosolizable material. A hybrid electronic tobacco device is described in WO 2016/135331 A1 which is incorporated herein by reference in its entirety.

[0069] The invention also provides an aerosol generating article for use in an aerosol generating set comprising an aerosol generating material according to the first aspect of the invention. The article (which may be referred to herein as an aerosol generating article, cartridge, or consumable) may be adapted for use in a THP, electronic tobacco hybrid device, or other aerosol generating device. In some cases, the article may additionally comprise a filter and/or cooling element (which were described above). In some cases, the aerosol generating article may be surrounded by a wrapping material such as paper.

[0070] The aerosol generating article may additionally comprise vent openings. These can be provided on the side wall of the article. In some cases, ventilation openings may be provided on the filter and/or cooling element. These openings can allow cold air to be drawn into the article during use, which can mix with the heated volatilized components, thereby cooling the aerosol.

[0071] Ventilation increases the generation of visible heated volatilized components of the article when it is heated during use. The heated volatilized components are made visible by the cooling process of the heated volatilized components so that supersaturation of the heated volatilized components occurs. The heated volatilized components then undergo droplet formation, also known as nucleation, and eventually the aerosol particle size of the heated volatilized components increases by further condensation of the heated volatilized components and by coagulation of newly formed droplets from the heated volatilized components.

[0072] In some cases, the proportion of cold air to the sum of heated volatilized components and cold air, known as the ventilation ratio, is at least 15%. A 15% ventilation ratio allows the heated volatilized components to be made visible by the method described above. The visibility of the heated volatilized components allows the user to identify which volatilized components were generated and adds to the sensory experience of the smoking experience.

[0073] In another example, the ventilation ratio is between 50% and 85% to provide additional cooling for the heated volatilized components. In some cases, the ventilation ratio can be at least 60% or 65%.

[0074] In some cases, the aerosol generating material may be included in the article/assembly in sheet form. In some cases, the aerosol generating material may be included as a flat sheet. In some cases, the aerosol generating material may be included as a flat sheet, as a grouped or gathered sheet, as a corrugated sheet, or as a rolled sheet.

(ie in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g., tobacco). In some other cases, the aerosol generating material may be formed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with shredded tobacco and incorporated into the article.

[0075] In some examples, the sheet-shaped amorphous solid may have a tensile strength of about 200 N/m to about 900 N/m. In some examples, such as where the amorphous solid does not comprise 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 where the aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the amorphous solid comprises 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 where the aerosol generating material is included in an aerosol generating article/assembly as a rolled sheet, suitably in the form of a tube.

[0076] With reference to Figures 2 and 3, a partially cut-away sectional view and a perspective view of an example of an aerosol generating article 101 are shown. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 6 to 8, described below. In use, the article 101 can be removably inserted into the device shown in Figure 6 at an insertion point 20 of the device 51.

[0077] The article 101 of an example is in the form of a substantially cylindrical rod that includes a body of aerosol generating material 103 and a filter assembly 105 in the form of a rod. The aerosol generating material comprises a 0.2 mm thick layer of amorphous aerosol forming solid. In the illustrated embodiment, the aerosol generating material was incorporated as a rolled sheet (i.e., tube-shaped). In other embodiments, the aerosol generating material may be incorporated in other forms as described above, including, without limitation, as a flat sheet, as a grouped or gathered sheet, as a corrugated sheet or in shredded form.

[0078] The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or proximal and a second end 115, also known as the distal end. The body of aerosol generating material 103 is located towards the distal end 115 of the article.

101. In one example, the cooling segment 107 is located adjacent the aerosol generating material body 103 between the aerosol generating material body 103 and the filter segment 109, so that the cooling segment 107 is in a relationship abutment with the aerosol generating material 103 and the filter segment 103. In other examples,

there may be a separation between the aerosol generating material body 103 and the cooling segment 107 and between the aerosol generating material body 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 located toward the proximal end 113 of the article 101, adjacent the filter segment 109. In one example, the filter segment 109 is in abutting relationship with the mouth end segment

111. In one embodiment, the total length of filter assembly 105 is between 37mm and 45mm, more preferably, the total length of filter assembly 105 is 41mm.

[0079] In one example, the aerosol generating material rod 103 is between 34 mm and 50 mm long, suitably between 38 mm and 46 mm long, suitably 42 mm long.

[0080] In one example, the total length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

[0081] An axial end of the aerosol generating material body 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 comprise an end member (not shown) covering the axial end of the aerosol generating material body 103.

[0082] The aerosol generating material body 103 is joined to the filter assembly 105 by annular tip paper (not shown), which is located substantially around the circumference of the filter assembly 105 to encircle the filter assembly

105 and extends partially along the length of the aerosol generating material body 103. In one example, the tip paper is made of standard 58GSM base tip paper. In one example, the edge paper has a length between 42 mm and 50 mm, suitably 46 mm.

[0083] In one example, the cooling segment 107 is an annular tube and is located around and defines an air space within the cooling segment. The air space provides a chamber for heated volatilized components generated from the aerosol generating material body 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but rigid enough to withstand axial compressive forces and bending moments that can arise during fabrication and while the article 101 is in use during insertion into the device 51. In one example, the wall thickness of cooling segment 107 is approximately 0.29 mm.

[0084] 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 will provide a thermal gradient along the length of the cooling segment 107. In In an example, the cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a volatilized heated component entering a first end of the cooling segment 107 and a volatilized heated component exiting a second end of the cooling segment 107. In one example, cooling segment 107 is configured to provide a temperature differential of at least 60 degrees Celsius between a heated volatilized component that enters a first end of cooling segment 107 and a heated volatilized component that exits from a second end of cooling segment 107. Es The temperature differential over the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperatures of the aerosol generating material 103 when it is heated by the device 51. If physical displacement is not provided between the filter segment 109 and the aerosol generating material body 103 and the heating elements of the device 51, then the temperature sensitive filter segment can get damaged during use, and thus it would not perform its necessary functions with the same efficiency.

[0085] 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 particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm.

[0086] The cooling segment 107 is made of paper, meaning that it is composed of a material that does not generate compounds of concern, eg toxic compounds when in use adjacent to the heater of device 51. In one example, the segment of Cooling 107 is manufactured from a spirally wound paper tube that provides a hollow inner chamber while maintaining mechanical rigidity. Spiral-wound paper tubes are capable of meeting the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outside diameter, roundness and straightness.

[0087] In another example, the cooling segment 107 is a recess created from a hard cap casing or edge paper. The rigid plug wrap or tip paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that may arise during manufacture and while the article 101 is in use during insertion into the device 51 .

[0088] The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilized compounds from the heated volatilized components of the aerosol generating material. In one example, the filter segment 109 is made of a mono-acetate material, such as cellulose acetate. The 109 filter segment provides cooling and irritation reduction of heated volatilized components without depleting the amount of heated volatilized components to a level unsatisfactory for a user.

[0089] In some embodiments, a capsule (not shown) may be provided on the filter segment 109. It may be disposed substantially centrally on the filter segment 109, both along the diameter of the filter segment 109 and along the length of the filter segment 109. In other cases, it may be offset by one or more dimensions. The capsule may, in some cases, when present, contain a volatile component, such as a flavoring or aerosol generating agent.

[0090] The density of the cellulose acetate buffer material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the drag resistance of the article 101. Therefore, the material selection of the filter segment 109 is important in controlling the drag resistance of the article 101. In addition, the filter segment performs a filtering function in the article 101.

[0091] In one example, the filter segment 109 is made of an 8Y15 grade filter plug material, which provides a filtration effect on the heated volatilized material, while also reducing the size of the condensed aerosol droplets that result from the material. heated volatilized.

[0092] The presence of the filter segment 109 provides an insulating effect by providing additional cooling to the heated volatilized components exiting the cooling segment

107. This additional cooling effect reduces the contact temperature of the user's lips on the surface of the filter segment 109.

[0093] In one example, the filter segment 109 is between 6 mm and 10 mm long, suitably 8 mm.

[0094] The mouth end segment 111 is an annular tube and is located around and defines an air space within the mouth end segment 111. The air space provides a chamber for heated volatilized components that flow from the mouth segment. filter 109. The mouth end segment 111 is hollow to provide an aerosol accumulation chamber, but rigid enough to withstand axial compressive forces and bending moments that can arise during fabrication and while the article is in use during insertion into device 51. In one example, the wall thickness of mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, suitably 8 mm.

[0095] The mouth end segment 111 can be fabricated from a spirally wound paper tube that provides a hollow inner chamber but maintains critical mechanical stiffness. Spiral-wound paper tubes are capable of meeting the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outside diameter, roundness and straightness.

[0096] The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with a user.

[0097] It should be recognized that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed as a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.

[0098] With reference to Figures 4 and 5, a partially cut-away section and perspective views of an example of an article 301 are shown. The reference signs shown in Figures 4 and 5 are equivalent to the reference signs shown in Figures 2 and 3, but with an increment of 200.

[0099] In the example of article 301 shown in Figures 4 and 5, a vent region 317 is provided in article 301 to allow air to flow into the article 301 from the exterior of article 301. In one example, the vent region 317 takes the form of one or more vent holes 317 formed through the outer layer of the article 301. The vent holes may be located in the cooling segment 307 to aid in cooling the article 301. In one example, the region Vent 317 comprises one or more rows of holes, and preferably, each row of holes is arranged circumferentially around article 301 in a cross section that is substantially perpendicular to a longitudinal axis of article 301.

[0100] In one example, there are between one and four rows of vent holes to provide ventilation for the article.

301. Each row of vent holes can have between 12 and 36 vent holes 317. Vent holes 317 can, for example, have a diameter between 100 and 500 µm. In one example, an axial separation between rows of vent holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

[0101] In one example, vent holes 317 are of uniform size. In another example, vent holes 317 vary in size. Vent holes can be made using any suitable technique, for example one or more of the following techniques: laser technology, mechanical drilling of cooling segment 307 or pre-drilling of cooling segment 307 before being formed into the article.

301. Vent holes 317 are positioned so as to provide effective cooling to article 301.

[0102] In one example, the rows of vent holes 317 are located at least 11 mm from the proximal end 313 of the article, suitably between 17 mm and 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is positioned so that the user does not block the vent holes 317 when the article 301 is in use.

[0103] Providing rows of vent holes between 17 mm and 20 mm from the proximal end 313 of article 301 allows vent holes 317 to be located outside of device 51 when article 301 is fully inserted into device 51, as may to be seen in Figures 7 and 8. By locating the vent holes outside the device, unheated air is able to enter the article 301 through the vent holes from outside the device 51 to aid in cooling the article 301.

[0104] The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 51, when the item 301 is fully inserted into the device 51. The length of the cooling segment 307 provides a first function of providing a physical space between the heater arrangement of the device 51 and the heat-sensitive filter arrangement 309, and a second function of allowing the vent holes 317 to be located in the cooling segment, although they are also located outside the device 51, when the article 301 is fully inserted into device 51. As can be seen in Figures 7 and 8, the majority of cooling element 307 is located inside device 51. However, there is a portion of cooling element 307 that extends outwardly of the device 51. It is in this portion of the cooling element 307 that extends out of the device 51 that the vent holes 317 are not located.

[0105] Referring now to Figures 6 to 8 in more detail, there is shown an example of a device 51 arranged to heat the aerosol generating material to volatilize at least one component of said aerosol generating material, typically to form an aerosol that can be inhaled. Device 51 is a heating device that releases compounds by heating, but not burning, the aerosol generating material.

[0106] A first end 53 is sometimes referred to herein as the mouth or proximal end 53 of the device 51 and a second end 55 is sometimes referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button. turns off 57 to allow the device 51 as a whole to be turned on and off as desired by a user.

[0107] The device 51 comprises a housing 59 to locate and protect various internal components of the device

51. In the example shown, housing 59 comprises a uni-body sleeve 11 spanning the perimeter of device 51, covered with an upper panel 17 generally defining the "top" of device 51 and a lower panel 19 generally defining the " bottom" of device 51. In another example, the housing comprises a front panel, a back panel and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

[0108] The top panel 17 and/or the bottom panel 19 can be removably attached to the uni-body sleeve 11 to allow easy access to the interior of the device 51, or can be "permanently" attached to the uni-body sleeve 11 , for example, to dissuade a user from accessing the inside of the 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 the uni-body sleeve 11 is made of aluminum, although other materials and others manufacturing processes can be used.

[0109] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51 through which, in use, the article 101, 301 including the aerosol generating material can be inserted into the device 51 and removed from the device. 51 by a user.

[0110] The housing 59 has located or fixed therein a heater arrangement 23, control circuit 25 and a power source 27. In this example, the heater arrangement 23, the control circuit 25 and the power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), with the control circuit 25 being generally located between the heater arrangement 23 and the power source 27, although other locations are possible.

[0111] The control circuit 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating material in article 101, 301, as discussed further below.

[0112] The power source 27 can be, for example, a battery, which can be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium ion battery, a nickel battery (such as a nickel cadmium battery), an alkaline battery and/or the like. Battery 27 is electrically coupled to heater arrangement 23 to provide electrical power when needed and under control of control circuits 25 to heat the aerosol generating material in the article (as discussed, to volatilize the aerosol generating material without causing it to burn) .

[0113] An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 can be used without causing the device 51 as a whole to be unduly long. As will be understood, in general, a physically large power source 25 has a greater capacity (that is, the total electrical power that can be supplied, often measured in Amp-hours or the like) and therefore the battery life for device 51 may be longer.

[0114] In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 comprising the aerosol generating material is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, heater arrangement 23 may comprise a single heating element or may be formed of a plurality of heating elements aligned along the longitudinal axis of heater arrangement 23. The or each heating element may be annular or tubular, or at least. less partially annular or 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 can be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which can be laminated and sintered. Other heating arrangements are possible, including, for example, inductive heating, infrared heating elements, which heat by emitting infrared radiation, or resistive heating elements formed by, for example, a resistive electrical winding.

[0115] In a particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned such that substantially the entire body of the aerosol generating material 103, 303 of the article 101, 301 is inserted into the heater arrangement 23 when the article 101, 301 is inserted into the device 51.

[0116] The or each heating element can be arranged so that selected zones of the aerosol generating material can be heated independently, for example, one at a time (over time, as discussed above) or together (simultaneously), as desired.

[0117] The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce the passage of heat from the heater arrangement 23 to the outside of the device 51. helps keep energy requirements low for heater arrangement 23 as it reduces overall heat losses. Insulator 31 also helps keep the exterior of device 51 cool during operation of heater arrangement 23. In one example, insulator 31 may be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 can be, for example, a "vacuum" tube, i.e. a tube that has been at least partially evacuated in order to minimize heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including the use of heat-insulating materials, including, for example, a suitable foam-type material, in addition to or instead of a double-walled sleeve.

[0118] The housing 59 may further comprise several internal support structures 37 to support all internal components, as well as the heating arrangement 23.

[0119] Device 51 further comprises a collar 33 that extends around and protrudes from opening 20 into housing 59 and a generally tubular chamber 35 that is located between collar 33 and one end of the vacuum sleeve.

31. Chamber 35 further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along the outer surface of chamber 35, and each disposed circumferentially around the outer surface of chamber 35. air space 36 between the hollow chamber 35 and the article 101, 301 when it is inserted into the device 51 along at least part of the length of the hollow chamber 35. The air space 36 is around the entire circumference of the article 101. 301 along at least part of the 307 cooling segment.

[0120] The collar 33 comprises a plurality of protrusions 60 arranged circumferentially around the periphery of the opening 20 and projecting into the opening 20. The protrusions 60 occupy space within the opening 20 so that the open span of the opening 20 at locations of the protrusions 60 is smaller than the open span of the opening 20 at locations without the protrusions 60. The protrusions 60 are configured to engage with an article 101, 301 inserted into the device to help secure it within the device 51.

Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 101, 301 form vent paths around the exterior of the article 101, 301. These vent paths allow hot vapors that have escaped from the article 101, 301 exit device 51 and allow cooling air to flow into device 51 around article 101, 301 in air space 36.

[0121] In operation, the article 101, 301 is removably inserted into an insertion point 20 of the device 51, as shown in Figures 6 to 8. With particular reference to Figure 7, in one example, the body of generator material aerosol dispenser 103, 303, which is located toward the distal end 115, 315 of the article 101, 301, is entirely received within the heater arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends to from device 51 and acts as a nozzle assembly for a user.

[0122] In operation, the heater arrangement 23 will heat the article 101, 301 to volatilize at least one component of the aerosol generating material from the body of the aerosol generating material 103, 303.

[0123] The primary flow path for the heated volatilized components of the aerosol generating material body 103, 303 is axially through article 101, 301, through the chamber within the cooling segment 107, 307, through the filter segment 109 , 309, through the mouth end segment 111, 313 to the user. In the illustrated example, the flow path also passes through the tube formed by the coiled aerosol generating material 103, 303.

[0124] In one example, the temperature of the heated volatilized components that are generated from the body of the aerosol generating material is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilized component travels through the cooling segment 107, 307, it will cool and some volatilized components will condense on the inner surface of the cooling segment 107, 307.

[0125] In the examples of article 301 shown in Figures 4 and 5, cold air will be able to enter cooling segment 307 through vent holes 317 formed in cooling segment 307. This cold air will mix with the heated volatilized components to provide cooling for the heated volatilized components.

MANUFACTURING METHOD

[0126] A fourth aspect of the invention provides a method for making an aerosol generating material according to the first aspect.

[0127] The method may comprise (a) forming a suspension comprising components of the amorphous solid or its precursors, (b) forming a layer of the suspension, and (c) fixing the suspension to form a gel and (d) drying to form a amorphous solid.

[0128] Step (b) of forming a layer of the suspension may comprise spraying, casting or extruding the suspension, for example. In some cases, the layer is formed by electrospraying the suspension. In some cases, the layer is formed by casting the suspension.

[0129] In some cases, the suspension is applied to a carrier.

[0130] In some examples, the suspension has a viscosity of from about 10 to about 20 Pa's at 46.5°C, such as from about 14 to about 16 Pa's at 46.5°C.

[0131] In some cases, steps (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electrospraying). In some cases, these steps can occur sequentially.

[0132] Step (c) of fixing the gel may comprise the addition of a fixing agent to the suspension. For example, the suspension may comprise sodium, potassium or ammonium alginate as a gel precursor and a binding agent comprising a source of calcium (such as calcium chloride) may be added to the suspension to form a calcium alginate gel.

[0133] The total amount of the fixation agent, as a source of calcium, can be 0.5-5% by weight (calculated based on dry weight). The inventors have discovered that the addition of too little fixation agent can result in an amorphous solid that does not stabilize the amorphous solid components and results in these components dropping out of the amorphous solid. The inventors have found that the addition of excess fixation agent results in an amorphous solid that is very sticky and, consequently, has poor handleability.

[0134] Alginate salts are derived from alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, alginate crosslinks to form a gel. The inventors have determined that alginate salts with a high G monomer content more readily form a gel with the addition of the calcium source. In some cases, therefore, the gel precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are units of α-L-guluronic acid (G).

[0135] The drying step can cause the melt thickness to reduce by at least 80%, suitably 85% or 87%. For example, the suspension can be cast to a thickness of 2 mm and the resulting dry amorphous solid material can have a thickness of 0.2 mm.

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

[0137] In cases where the solvent consists of water, the dry weight content of the suspension may correspond to the dry weight content of the amorphous solid. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the suspension aspect of the invention.

EXEMPLARY ACHIEVEMENTS

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

[0139] Particular embodiments comprising an amorphous solid containing menthol may be particularly suitable for including in an aerosol generating article/assembly such as a shredded sheet. In such embodiments, the amorphous solid can have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount from about 20% by weight to about 40% by weight , or about 25% by weight to 35% by weight; menthol in an amount of from about 35% by weight to about 60% by weight, or from about 40% by weight to 55% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10% by weight to about 30% by weight, or from about 15% by weight to about 25% by weight (DWB).

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

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

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

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

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

[0145] As noted above, the amorphous solid of these embodiments can be included as a sheet. In one embodiment, the sheet is provided in a support comprising paper. In one embodiment, the sheet is provided in a holder comprising sheet metal, suitably aluminum sheet metal. In this embodiment, the amorphous solid may abut the sheet metal.

[0146] In one embodiment, the sheet is part of a laminated material with a layer (preferably comprising paper) attached to an upper and lower surface of the sheet. Suitably, the amorphous solid sheet has a thickness of from about 0.015 mm to about 1 mm.

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

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

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

[0150] The amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a layer portion disposed on a carrier.

[0151] In some embodiments, the amorphous solid comprises tobacco extract. In such embodiments, the amorphous solid can have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5% by weight to about 40% by weight, or about 10% by weight at 30°C. % by weight, or about 15% by weight to about 25% by weight; tobacco extract in an amount of from about 30% by weight to about 60% by weight, or from about 40% by weight to 55% by weight, or from about 45% by weight to about 50% by weight ; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10% by weight to about 50% by weight, or from about 20% by weight to about 40% by weight, or from about 25% by weight to about 35% by weight (DWB).

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

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

[0154] The amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a shredded sheet, optionally blended with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a layer portion disposed on a carrier. Suitably, in any of these embodiments, the amorphous solid has a thickness of between about 50 µm to about 200 µm, or about 50 µm to about 100 µm, or about 60 µm to about 90 µm , suitably about 77 µm.

[0155] Suspension to form this amorphous solid may also form part of the invention. In some cases, the suspension may have an elastic modulus of about 5 to 1200 Pa (also referred to as a storage modulus); in some cases, the suspension may have a viscous modulus of about 5 to 600 Pa (also referred to as loss modulus).

DEFINITIONS

[0156] The active substance, as used herein, can be a physiologically active material, which is a material designed to achieve or improve a physiological response. The active substance can, for example, be selected from nutraceuticals, nootropics, psychoactives. The active substance can be naturally occurring or synthetically obtained. The active substance can comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids or constituents, derivatives or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or other botanicals.

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

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

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

[0160] Cannabinoids are a class of natural or synthetic chemical compounds that act at cannabinoid receptors (ie, CB1 and CB2) on cells that repress the release of neurotransmitters in the brain. Cannabinoids can occur naturally (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids) or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids and are divided into subclasses including cannabigeroes, cannabichromenes, cannabidiols, tetrahydrocannabinoids, cannabinoids and cannabinoids and other cannabinoids. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabindiol (CBDL), cannabicyclol (CBL), cannabicycline (CBV) , tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabicromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), propyl variant cannabinol (CBNV), cannabitriol (CBO), acid tetrahydrocannabinolic acid (THCA) and tetrahydrocannabivarinic acid (THCV A).

[0161] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any plant-derived material, including, but not limited to, extracts, leaves, bark, fibers, stalks, roots, seeds, flowers, fruits, pollen, bark, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets or the like. Exemplary botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba,

hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea, such as green tea or black tea, thyme, cloves, cinnamon, coffee, anise, basil, bay leaves, cardamom, coriander , cumin, nutmeg, oregano, paprika, rosemary, turmeric, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shisso, turmeric, saffron, sandalwood, cilantro, bergamot, orange blossom , blackcurrant, valerian, chili, nutmeg blossom, damien, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, geranium, blackberry, ginseng, theanine, theacrine, litter, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint can be chosen 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 botanist is selected from eucalyptus, star anise, cocoa and hemp.

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

[0164] As used herein, the terms "flavor" and "flavoring" refer to materials that, where local regulations permit, can be used to create a desired taste, aroma, or other somatosensory sensation in a product for adult consumers. They may include natural flavor materials, botanicals, botanical extracts, synthetically obtained materials or combinations thereof (eg tobacco,

cannabis, licorice, hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry , berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, blackberry, citrus, Drambuie, bourbon, whiskey, gin, tequila, rum, mint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, oil rose, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, cumin, brandy, jasmine, ylang-ylang, sage, fennel, wasabi, pepper, ginger, cilantro, coffee, hemp , a mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba , hazelnut, hibiscus, bay, mate, orange peel, rose, tea, such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, turmeric, bark lemon, mint, beef plant, turmeric, coriander, myrtle, blackcurrant, valerian, pepper, nutmeg flower, damien, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, limonene, thymol , camphene), flavor enhancers, bitterness receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (eg, sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose , glucose, fructose, sorbitol or mannitol) and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They can be imitation, synthetic or natural ingredients or mixtures thereof. They can be in any suitable form, eg liquid such as an oil, solid such as a powder, or gas.

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

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

[0167] In some embodiments, the flavor comprises cucumber, blueberry, citrus and/or cranberry flavor components.

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

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

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

[0171] In some embodiments, flavor may comprise a sensate, which is intended to achieve a somatosensory sensation that is usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of the aroma or aroma nerves or flavor, and these may include agents that provide a warming, cooling, tingling, and numbing effect. A suitable heat effect agent can be, but is not limited to, ethyl vanyl ether and a suitable cooling agent can be, but is not limited to eucalyptol, WS-3.

[0172] As used herein, the term "aerosol generating agent" refers to an agent that promotes the generation of an aerosol. An aerosol generating agent can promote the generation of an aerosol by promoting an initial vaporization and/or condensation of a gas into an aerosol solid and/or inhalable liquid.

[0173] Suitable aerosol generating agents include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol and glycols such as propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol generating agent may suitably have a composition that does not dissolve menthol. The aerosol generating agent may suitably comprise, consist essentially of or consist 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, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber,

cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

Tobacco used to produce tobacco material may be any suitable tobacco, such as single-grade or blends, cut rags or whole leaves, including Virginia and/or Burley and/or Oriental. It can also be 'fines' or dust from tobacco particles, expanded tobacco, stalks, expanded stalks and other processed stalk materials such as rolled cut stems. The tobacco material can be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material can comprise tobacco fibers and can be formed by casting, a Fourdrinier-based papermaking type approach with further addition of tobacco extract, or by extrusion.

[0176] All percentages by weight described herein (denoted in % by weight) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated based on dry weight. A weight quoted on a dry weight basis refers to all extract or suspension or material, except water, and may include components that themselves are liquid at ambient temperature and pressure, such as glycerol. On the other hand, a quoted weight percentage based on wet weight refers to all components, including water.

[0177] For the avoidance of doubt, where in this specification the term "comprises" is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature may be defined using the terms "consists essentially of" or " consisting of"

instead of “understands”. Reference to a material "comprising" certain characteristics means that those characteristics are included, contained or maintained within the material.

[0178] The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any 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 of the embodiments, or any combination of any other of the embodiments. . Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the appended claims.

Claims (13)

1. Aerosol generating material characterized in that it comprises an aerosol forming layer, the aerosol forming layer comprising an amorphous solid, wherein the aerosol forming layer has a thickness of 0.015 mm to 1.0 mm. 2. Aerosol generating material according to claim 1, characterized in that it comprises a carrier on which the amorphous solid is supplied. 3. Aerosol generating material according to any one of claims 1 to 2, characterized in that the amorphous solid comprises one or more of an active substance, an aerosol generating agent, a flavoring and a gelling agent. 4. Aerosol generating material according to claim 3, characterized in that the material comprises a gelling agent selected from cross-linked pectin, cross-linked alginate and their mixtures. 5. Aerosol generating material according to claim 3 or 4, characterized in that the material comprises an aerosol generating agent selected from erythritol, propylene glycol, glycerol and mixtures thereof. 6. Aerosol generating set characterized in that it comprises an aerosol generating material as defined in any one of claims 1 to 5 and a heater configured to heat, but not burn, the aerosol generating material. 7. Aerosol generator set according to claim 6, characterized in that the set is a non-burning heat device. 8. Aerosol generator set according to claim 6, characterized in that the set is a hybrid electronic tobacco device. 9. An aerosol generating article for use in an aerosol generating set, characterized in that it comprises an aerosol generating material as defined in any one of claims 1 to 5. 10. Method characterized in that it is for manufacturing an aerosol generating material as defined in any one of claims 1 to 5. 11. Method according to claim 10, characterized in that it comprises (a) forming a suspension comprising components of the amorphous solid or its precursors, (b) forming a layer of the suspension, and (c) fixing the suspension to form a gel and (d) drying the gel to form an amorphous solid. 12. Method according to claim 11, characterized in that the drying step causes the thickness of the melt to be reduced by at least 80%, suitably 85% or 87%. 13. Method according to claim 11 or claim 12, characterized in that step (c) comprises the addition of a fixing agent to the suspension.