CN115243569A

CN115243569A - Aerosol-generating material comprising an amorphous solid comprising menthol and calcium cross-linked alginate

Info

Publication number: CN115243569A
Application number: CN202080094839.XA
Authority: CN
Inventors: 托马斯·利娅; 巴纳比·奥克利
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2019-11-29
Filing date: 2020-11-27
Publication date: 2022-10-25
Also published as: WO2021105465A1; AU2020391944A1; US20230024853A1; EP4064866B1; BR112022010455A2; EP4064866A1; PL4064866T3; PT4064866T; JP2023504250A; GB201917472D0; KR20220122607A; IL293172A; CA3159870A1; LT4064866T

Abstract

The present invention provides an aerosol-generating material comprising an amorphous solid comprising: 0.1wt% to 80wt% menthol; 1-60 wt% of a gelling agent comprising a calcium-crosslinked alginate comprising α - (1-4) -linked L-guluronate (G) units; and 0.1wt% to 50wt% of an aerosol former material; wherein Ca ²⁺ The molar ratio of cation to G unit is 0.2.

Description

Aerosol-generating material comprising an amorphous solid comprising menthol and calcium cross-linked alginate

Technical Field

The present invention relates to aerosol generation.

Background

Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release inhalable aerosols or vapors by releasing the compound from the substrate material by heating without combustion. These may be referred to as non-burning smoking articles or aerosol-generating components.

One example of such a product is a heating device that releases a compound by heating without burning the solid aerosolizable material. In some cases, such solid aerosolizable material can comprise tobacco material. Heating vaporizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. Various arrangements for gasifying at least one component of a solid aerosolizable material are known.

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

Disclosure of Invention

According to a first aspect of the present invention there is provided an aerosol-generating material comprising an amorphous solid comprising:

-0.1% to 80% by weight of menthol;

-1-60 wt% of a gelling agent comprising a calcium cross-linked alginate comprising α - (1-4) -linked L-guluronic acid ester (guluronate) (G) units; and

-from 0.1wt% to 50wt% of aerosol former material.

Wherein Ca ²⁺ The molar ratio of cations to G units is from 0.2 to 1.

According to a third aspect of the present invention there is provided a substrate comprising an aerosol-generating material as described herein and a carrier having the aerosol-generating material disposed thereon.

According to a further aspect of the present invention there is provided an article for use with a non-combustible aerosol provision device, the article comprising an aerosol-generating material as described herein and/or a substrate as described herein.

According to a further aspect of the present invention there is provided a non-combustible aerosol provision system comprising an article as described herein and a non-combustible aerosol provision device, wherein the non-combustible aerosol provision device is configured to generate an aerosol from the article when the article is used with the non-combustible aerosol provision device.

According to a further aspect of the present invention there is provided a method of producing an aerosol-generating material as described herein.

According to a further aspect of the present invention there is provided a method of generating an aerosol using a non-combustible aerosol provision system as described herein, the method comprising heating an aerosol generating material. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of less than or equal to 350 ℃. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of from about 220 to about 280 ℃.

According to a further aspect of the present invention there is provided a use of a non-flammable aerosol delivery system as described herein.

Other features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.

Drawings

Figure 1 shows a cross-sectional view of one example of an aerosol-generating article.

Fig. 2 shows a perspective view of the article of fig. 1.

Figure 3 shows a cross-sectional view of one example of an aerosol-generating article.

Figure 4 shows a perspective view of the article of figure 3.

Figure 5 shows a perspective view of an example of an aerosol-generating component.

Figure 6 shows a cross-sectional view of an example of an aerosol-generating assembly.

Figure 7 shows a perspective view of an example of an aerosol-generating assembly.

Figure 8 shows puff by puff sensory data for an example of an aerosol-generating material.

Detailed Description

An aerosol-generating material herein is a material that is capable of generating an aerosol, for example when heated, irradiated or excited in any other way. For example, the aerosol-generating material may be in the form of a solid, liquid or gel, which may or may not contain nicotine and/or flavourings. The aerosol-generating material comprises an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that can retain some fluid, such as a liquid, therein. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 60wt% or 70wt% amorphous solids to about 90wt%, 95wt% or 100wt% amorphous solids. In some cases, the aerosol-generating material is comprised of an amorphous solid.

As described above, the present invention provides an aerosol-generating material comprising an amorphous solid comprising:

-0.1% to 80% by weight of menthol;

-1wt% to 60wt% of a gelling agent comprising a calcium cross-linked alginate comprising α - (1-4) -linked L-guluronate (G) units; and

-from 0.1wt% to 50wt% of aerosol former material.

Wherein Ca ²⁺ The molar ratio of cations to G units is 0.2。

The gelling agent of the present invention comprises alginate (also referred to as "alginate"). Alginates are derivatives of alginic acid and are linear polysaccharides comprising G units and usually M units. When divalent cations are added to alginic acid, the alginate will crosslink and form a gel.

As used herein, "G unit" refers to an α - (1-4) -linked L-guluronate. alpha-L-guluronic acid esters are the conjugate bases of alpha-L-guluronic acid. The G unit may also be referred to as a guluronate monomer or a G residue. As used herein, "M unit" refers to β - (1-4) -linked D-mannuronate. beta-D-mannuronate is the conjugate base of beta-D-mannuronic acid. The M units may also be referred to as mannuronate monomers or M residues.

Divalent cations such as Ca ²⁺ Interact with the carboxylate groups of the alginate monomers to form ionic crosslinks; the amorphous solid of the invention comprises calcium cross-linked alginate. The present inventors have determined that the physical properties of amorphous solids comprising calcium cross-linked alginate depend on calcium cations (Ca) ²⁺ ) And, in particular, the molar ratio of alginate G units in the amorphous solid.

The amorphous solid of the invention comprises menthol. Menthol is present as an active substance in the amorphous solid. That is, menthol is contained in the amorphous solid such that upon heating the amorphous solid menthol is aerosolized and may be delivered to the user to achieve a physiological and/or olfactory response.

Due to the physical properties of menthol (e.g., its volatility, solubility, etc.), it is difficult to provide menthol-containing amorphous solids that have an acceptable shelf life and deliver an acceptable inhalable aerosol to a user when heated in a non-flammable aerosol delivery system. In one aspect, the amorphous solid should retain a desired amount of menthol during storage until the amorphous solid is heated in the non-flammable aerosol delivery system. On the other hand, the amorphous solid should be configured to release a desired amount of menthol as part of an inhalable aerosol upon heating the amorphous solid.

The present inventors have determined that the amorphous solid is configured as Ca in alginate ²⁺ A molar ratio to the G unit of 0.2 to 1 provides a menthol-containing aerosol-generating material having a good shelf life and releasing a desired amount of menthol when heating the aerosol-generating material in a non-combusting aerosol provision device. In some embodiments, ca in alginate ²⁺ The molar ratio to the G unit is 0.3. In some embodiments, ca in the alginate ²⁺ The molar ratio to G units is about 0.4.

Without wishing to be bound by theory, it is believed that Ca is present in an amount higher than the present invention ²⁺ The content of amorphous solids will cause the aerosol-generating material to condense and thus deteriorate during storage, and has Ca ²⁺ Amounts below the amorphous solids of the present invention will not retain the desired amount of menthol after storage.

In embodiments, the calcium cross-linked alginate comprises a combination of G units and M units. In some embodiments, the G units and M units are present in a molar ratio of 1. In some embodiments, the G units and M units are present in a molar ratio of 1.

In some embodiments, the aerosol-generating material comprises menthol at least 60%,70%, 80% or 90% of the dry weight of menthol present in the aerosol-generating material prior to storage when stored according to ISO 3402 (22 ℃;60% relative humidity; 1013 mbar) in a sealed container for 30 days.

In some embodiments, the aerosol-generating material comprises menthol at least 60%,70%, 80% or 90% of the dry weight of menthol present in the aerosol-generating material prior to storage when stored in a sealed container according to ISO 3402 (22 ℃;60% relative humidity; 1013 mbar) for 6 weeks (42 days).

In some embodiments, the aerosol-generating material comprises menthol at least 60%,70%, 80% or 90% of the dry weight of menthol present in the aerosol-generating material prior to storage when stored in a sealed container according to ISO 3402 (22 ℃;60% relative humidity; 1013 mbar) for 16 weeks (112 days).

In some embodiments, the alginate is included in the gelling agent in an amount of 15wt% to 40wt% of the amorphous solid. That is, the amorphous solid comprises alginate in an amount of 15wt% to 40wt% of the dry weight of the amorphous solid. In some embodiments, the amorphous solid comprises alginate in an amount of 10wt% to 35wt%, or 15wt% to 30 wt%.

In some embodiments, the gelling agent further comprises pectin. In some embodiments, the alginate and pectin are present in an alginate/pectin ratio of 1. In some embodiments, the ratio of alginate to pectin is 3. The alginate/pectin ratio is expressed as a dry weight ratio (w/w).

The present inventors have determined that providing a gelling agent comprising alginate and pectin in such a ratio can provide an improved amorphous solid. Without wishing to be bound by theory, it is believed that the combination of alginate and pectin may have a synergistic effect on binding in the amorphous solid. Furthermore, combining alginate and pectin in specific ratios can affect the temperature at which menthol is released from the amorphous solid upon heating.

Due to the lower material costs, it may be advantageous to provide a gelling agent comprising more alginate than pectin. However, gelling agents comprising only alginate may have a high viscosity, which means that it is difficult to process the gelling agent during the manufacture of amorphous solids. The present inventors have determined that by mixing alginate in combination with pectin, wherein the pectin is present as a minority fraction, the viscosity of the gelling agent can be more easily handled during the manufacture of the amorphous solid.

In some embodiments, the amount of pectin contained in the gelling agent is between 3wt% and 10wt% of the amorphous solid. That is, the amorphous solid comprises pectin in an amount of 3wt% to 10wt% based on dry weight of amorphous solid. In some embodiments, the amorphous solid comprises pectin in an amount of 3wt% to 8wt% or 4wt% to 6 wt%.

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

In some embodiments, the gelling agent further comprises hydrocolloids other than those described above. In some embodiments, the gelling agent further comprises one or more compounds selected from the group consisting of starch (and derivatives), cellulose (and derivatives such as, for example, methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent further comprises one or more of hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

The gelling agent may also comprise one or more compounds selected from the group consisting of cellulosic gelling agents, non-cellulosic gelling agents, guar gum, gum arabic, and mixtures thereof.

In some embodiments, the cellulose gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose Acetate (CA), cellulose Acetate Butyrate (CAB), cellulose Acetate Propionate (CAP), and combinations thereof.

In some embodiments, the gelling agent further comprises one or more of hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose, guar gum, or gum arabic.

In some embodiments, the gelling agent further comprises one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, carrageenan, starch, and combinations thereof. In a preferred embodiment, the non-cellulose gelling agent further comprises agar.

The aerosol-generating material comprises menthol in an amount of 0.1wt% to 80 wt%. In some embodiments, the aerosol-generating material comprises menthol in an amount of about 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 70wt%, 50wt%, 45wt%, or 40wt% (calculated on a dry weight basis). In particular embodiments, the amorphous solid comprises 10wt% to 60wt%, 40wt% to 60wt%, or 45wt% to 55wt% menthol.

The amorphous solid contains from 0.1wt% to 50wt% of aerosol former material. In some embodiments, the amorphous solid comprises 10wt% to 30wt% aerosol former material, or 15wt% to 25wt% aerosol former material.

In some embodiments, the aerosol former material may include one or more of glycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

In some embodiments, the aerosol former includes one or more polyols, such as propylene glycol, triethylene glycol, 1, 3-butanediol, and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di-or triacetate; and/or aliphatic esters of monocarboxylic, dicarboxylic or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In one embodiment, the amorphous solid comprises:

-20% to 35% by weight of a gelling agent;

-15wt% to 25wt% of an aerosol former material;

-45% to 55% by weight of menthol;

wherein the weights are calculated on a dry weight basis.

The amorphous solid may have any suitable water content, such as 1wt%0-15wt% (by wet weight, "WWB"). Suitably, the water content of the amorphous solid may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB).

The aerosolizable material or the non-aerosol generating material can be present on or within a carrier to form a substrate. The support serves as a support on which an amorphous solid layer is formed, thereby being easy to manufacture. The support may provide rigidity to the amorphous solid layer, thereby facilitating handling.

The carrier may be any suitable material that can be used to support an amorphous solid. In some cases, the support may be composed of a material selected from the group consisting of metal foil, 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 may be composed of a material selected from the group consisting of metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the support comprises paper. In some cases, the support itself is a laminated structure comprising layers of material selected from the foregoing list. In some cases, the carrier may also serve as a flavoring carrier. For example, the carrier may be impregnated with a flavour or tobacco extract.

Suitably, the support layer may have a thickness in the range of from about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm or 0.1mm to about 2.5mm, 2.0mm, 1.5mm, 1.0mm or 0.5mm. The carrier may comprise more than one layer, and the thickness herein refers to the total thickness of those layers.

In some cases, the carrier may be magnetic. This function may be used to fix the carrier to the component when in use, or may be used to create a specific amorphous solid shape. In some cases, the aerosol-generating substrate may comprise one or more magnets that may be used to secure the substrate to the induction heater in use.

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

In some cases, the surface of the support adjacent to the amorphous solid may be porous. For example, in one case, the carrier comprises paper. The inventors have found that porous supports such as paper are particularly suitable for use in the present invention. The porous (e.g., paper) layer adjoins the amorphous solid layer and forms a strong bond. The amorphous solid is formed by drying the gel, and without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous support (e.g., paper) such that when the gel sets and forms crosslinks, the support is partially incorporated into the gel. This provides a strong bond between the gel and the support (and between the dried gel and the support).

Furthermore, the surface roughness may contribute to the bonding strength between the amorphous material and the carrier. The inventors have found that the roughness (for the surface abutting the support) of the paper may suitably be in the range of 50-1000Bekk seconds, suitably in the range of 50-150Bekk seconds, suitably 100Bekk seconds (measured in the gas pressure interval of 50.66-48.00 kilopascals). (Bekk smoothness tester is an instrument for measuring the smoothness of a paper surface in which air of a specified pressure leaks between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is "Bekk smoothness")

Conversely, the surface of the carrier facing away from the amorphous solid may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is arranged to have a smoother side that adjoins the rougher side of the amorphous material and faces away from the amorphous material.

In one particular case, the support may be a paper-backed foil; the paper layer adjoins the amorphous solid layer, and the properties discussed in the preceding paragraph are provided by this abutment. The foil backing is substantially impermeable, providing control over the aerosol flow path. A metal foil backing may also be used to conduct heat to the amorphous solid.

In another case, the foil layer of the paper backing foil abuts the amorphous solid. The foil is substantially impermeable to prevent water provided in the amorphous solid from being absorbed into the paper, which would impair its structural integrity.

In some cases, the carrier is formed from or comprises a metal foil, such as aluminum foil. The metal carrier may allow conducting thermal energy to the amorphous solid to be performed better. Additionally or alternatively, the metal foil may be used as a susceptor in an induction heating system. In a particular embodiment, the carrier includes a metal foil layer and a carrier layer, such as paperboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, such as from about 1 μm to about 10 μm, suitably about 5 μm.

In some cases, the support may have a thickness of from about 0.017mm to about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm, 1.0mm or 0.5mm.

In some cases, the aerosol-generating substrate may comprise an embedded heating device, such as a resistive or inductive heating element. For example, a heating device may be embedded in the amorphous solid.

The amorphous solid may be made of a gel, and the gel may further include a solvent in an amount of 0.1wt% to 50wt%. However, the present inventors have determined that including a solvent in which the flavoring is soluble can reduce the gel stability and the flavoring will crystallize out of the gel. Thus, in some cases, the gel does not include a solvent in which the flavoring agent is soluble.

In some embodiments, the amorphous solid comprises less than 60wt%, such as 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt% filler.

In other embodiments, the amorphous solid contains less than 20wt%, suitably less than 10wt% or less than 5wt% filler. In some cases, the amorphous solid contains less than 1wt% filler, and in some cases, no filler.

One aspect of the present invention relates to an article. Such an article is a consumable article, which is intended to be consumed, partially or wholly, by a user during use. The consumable may comprise or consist of an aerosol-generating material. The consumable may comprise one or more other elements, such as a filter or an aerosol-modifying substance. The consumable may comprise a heating element which, in use, generates heat to cause the aerosol generating material to generate an aerosol. For example, the heating element may comprise a combustible material, or may comprise a susceptor (susceptor) that can be heated by penetration with a varying magnetic field.

The articles of the invention may be provided in any suitable shape. In some embodiments, the article is provided as a rod (e.g., substantially cylindrical). The article provided as a rod may comprise the aerosol generating material as a shredded sheet, optionally blended with tobacco cut filler. Alternatively or additionally, the article provided as a rod may comprise the aerosol-generating material as a sheet material, such as a sheet material surrounding a rod of aerosol-generating material (e.g. tobacco). In some embodiments, the article comprises a layer portion of aerosol-generating material disposed on a carrier. In embodiments, the article may have at least one substantially planar (flat) surface.

Susceptors are materials that can be heated by penetration with a changing magnetic field, such as an alternating magnetic field. The heating material may be an electrically conductive material such that penetration thereof with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that penetration thereof with a varying magnetic field results in hysteresis heating of the heating material. The heating material may be electrically conductive and magnetic, enabling the heating material to be heated by two heating mechanisms.

Induction heating is the process of heating an electrically conductive object by penetrating the object with a varying magnetic field. The process is described by faraday's law of induction and ohm's law. The induction heater may comprise an electromagnet and means for passing a varying current (e.g. an alternating current) through the electromagnet. When the electromagnet and the object to be heated are positioned relative to each other such that the resultant varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has an impedance to the flow of current. Thus, when such eddy currents are generated in the object, they cause the object to be heated against the flow of the object's electrical resistance. This process is known as joule, ohmic or resistive heating.

In some embodiments, the susceptor is in the form of a closed loop. It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved joule heating.

Hysteresis heating is the process of heating an object made of a magnetic material by penetrating the object with a varying magnetic field. Magnetic materials are considered to include many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipole aligns with the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field, generated by, for example, an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipole changes with the applied varying magnetic field. This reorientation of the magnetic dipoles can result in the generation of heat in the magnetic material.

When an object is both electrically conductive and magnetic, penetrating the object with a varying magnetic field can cause joule heating and hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the magnetic field, and thus joule heating.

In each of the above processes, since heat is generated within the object itself, rather than by an external heat source through heat conduction, rapid temperature rise and more uniform heat distribution within the object can be achieved, particularly by selecting appropriate object materials and geometries, and appropriate varying magnetic field magnitudes and directions relative to the object. Furthermore, because induction heating and hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater and costs may be lower.

The filler, if present, may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, the amorphous solid does not contain calcium carbonate, such as chalk.

In embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler, such as wood pulp, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that the inclusion of fibrous filler in the amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in embodiments in which the amorphous solid is provided as a sheet, for example when the amorphous solid sheet is wrapped around a rod of aerosol-generating material.

In some embodiments, the amorphous solid does not comprise tobacco fiber. In a specific embodiment, the amorphous solid does not comprise fibrous material.

In some embodiments, the aerosol-generating material does not comprise tobacco fibres. In a particular embodiment, the aerosol-generating material does not comprise fibrous material.

In some embodiments, the aerosol-generating article does not comprise tobacco fibres. In particular embodiments, the aerosol-generating article does not comprise fibrous material.

In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, an aerosol-generating agent, water, and menthol.

The aerosol-generating material comprising the amorphous solid may have any suitable areal density, such as 30g/m ² -120 g/m ² . In some embodiments, the aerosol-generating material may have a density of about 30-70g/m ² Or about 40 to 60g/m ² The area density of (a). In some embodiments, the amorphous solid may have a concentration of about 80-120g/m ² Or about 70-110g/m ² Or specifically about 90-110g/m ² The area density of (a). Such an areal density may be particularly suitable when the aerosol-generating material is included in the aerosol-generating article/component in sheet form or as a shredded sheet (described further below).

One aspect of the invention provides a non-combustible aerosol provision system comprising an article according to the disclosure and a non-combustible aerosol provision device comprising a heater configured to heat without combusting the aerosol-generating article. The combustible aerosol supply system may also be referred to as an aerosol-generating assembly. The non-combustible aerosol provision device may be referred to as an aerosol generating device.

In some cases, in use, the heater may heat the aerosol-generating material to a temperature equal to or less than 350 ℃, such as 120-350 ℃, without combusting the aerosol-generating material. In some cases, the heater may heat the aerosol generating material to 140-250 ℃, or 220-280 ℃ in use without combusting the aerosol generating material. In some cases when used, substantially all of the amorphous solid is less than about 4mm, 3mm, 2mm, or 1mm from the heater. In some cases, the solid is placed about 0.010mm to 2.0mm, suitably about 0.02 to 1.0mm, suitably 0.1 to 0.5mm from the heater. In some cases, these minimum distances may reflect the thickness of the support supporting the amorphous solid. In some cases, the surface of the amorphous solid may directly abut the heater.

The heater is configured to heat without combusting the aerosol-generating article, and thus heat without combusting the aerosol-generating material. In some cases, the heater may be a thin film resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which, in use, undergoes an exothermic reaction to generate heat. The aerosol-generating assembly may comprise a plurality of heaters. Each heater may be powered by a battery.

The aerosol-generating article may additionally comprise a cooling element and/or a filter. The cooling element, if present, may function or cool the gaseous or aerosol component. In some cases, it may act to cool the gaseous components, causing them to condense to form an aerosol. It may also serve to shield very hot parts of the device from the user. The filter, if present, may comprise any suitable filter known in the art, such as a cellulose acetate plug.

In some cases, the aerosol-generating component may be a heating, non-combustion device. I.e. it may comprise solid tobacco-containing material (and not liquid aerosolizable material). In some cases, the amorphous solid may comprise tobacco material. A heating and non-combustion device is disclosed in WO 2015/062983 A2, which is incorporated herein by reference in its entirety.

In some cases, the aerosol-generating component may be an electronic tobacco mixing device. I.e. it may comprise both solid and liquid aerosolizable materials. In some cases, the amorphous solid may comprise nicotine. In some cases, the amorphous solid may comprise tobacco material. In some cases, the amorphous solid may comprise a tobacco material and a separate nicotine source. The separate aerosolizable material may be heated by a separate heater, the same heater, or in one case, the downstream aerosolizable material may be heated by a hot aerosol generated by the upstream aerosolizable material. An electronic tobacco mixing device is disclosed in WO 2016/135331 A1, which is incorporated herein by reference in its entirety.

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

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

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

In embodiments where the aerosol-generating material or the amorphous solid comprises nicotine, it is particularly preferred to comprise an acid. In such embodiments, the presence of the acid may stabilise the species in which the aerosol-generating material or amorphous solid is dissolved from the slurry in which it is produced. The presence of the acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacture.

The amorphous solid may contain a colorant. The visual appearance of the amorphous solid can be altered by the addition of colorants. The presence of the colorant in the amorphous solid may enhance the visual appearance of the amorphous solid and the aerosol-generating material. By adding a colorant to the amorphous solid, the amorphous solid may be color matched to other components of the aerosol-generating material or to other components of the article comprising the amorphous solid.

A variety of colorants can be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown or black. Other colors are also contemplated. Natural or synthetic colorants such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants may be used. In certain embodiments, the colorant is caramel, which can impart a brown appearance to the amorphous solid. In such embodiments, the colour of the amorphous solid may be similar to the colour of other components (e.g. tobacco material) in the aerosol-generating material comprising the amorphous solid. In some embodiments, the addition of a colourant to the amorphous solid makes it visually indistinguishable from other components in the aerosol-generating material.

The colorant can be introduced during the formation of the amorphous solid (e.g., when forming a slurry comprising the material forming the amorphous solid), or it can be applied to the amorphous solid after it is formed (e.g., by spraying it onto the amorphous solid).

The aerosol-generating article (which may be referred to herein as an article, cartridge or consumable) may be suitable for use in a THP, an e-tobacco mixing device or another aerosol-generating device. In some cases, the article may additionally include a filter and/or a cooling element (already described above). In some cases, the aerosol-generating article may be wrapped by a wrapper such as paper.

The aerosol-generating article may additionally comprise ventilation holes. These may be provided on the side walls of the article. In some cases, the vent may be disposed on the filter and/or the cooling element. These vents may allow cool air to be drawn into the article during use, which may mix with the heated volatile components, thereby cooling the aerosol.

Venting enhances the production of heated volatile components visible in the article when the article is heated during use. The heated volatile components are made visible by the process of cooling the heated volatile components, thus supersaturating the heated volatile components. The heated volatile component then undergoes droplet formation, also known as nucleation, and finally the aerosol particles of the heated volatile component increase in size by further condensation of the heated volatile component and by condensation of newly formed droplets from the heated volatile component.

In some cases, the ratio of cold air to the sum of heated volatile components and cold air, referred to as the aeration rate, is at least 15%. An aeration rate of 15% makes the heated volatile components visible by the method described above. The visibility of the heated volatile components enables the user to identify that volatile components have been generated and increases the sensory experience of the smoking experience.

In another embodiment, the aeration rate is 50% to 85% to provide additional cooling to the heated volatile components. In some cases, the ventilation rate may be at least 60% or 65%.

In some cases, the aerosol-generating material may be contained in the article/component in the form of a sheet. In some cases, the aerosol-generating material may be included as a planar sheet. In some cases, the aerosol-generating material may be included as a planar sheet, a bundled or aggregated sheet, a crimped sheet, or a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in an aerosol-generating article/component as a sheet, such as a sheet wrapped around a rod of aerosol-generating material (e.g., tobacco). In some other cases, the aerosol-generating material may be formed into a sheet and subsequently shredded and introduced into an article. In some cases, the shredded sheet material may be mixed with shredded tobacco and incorporated into an article.

In some embodiments, the sheet-like amorphous solid may have a tensile strength of about 200N/m to about 900N/m. In some examples, the amorphous solid may have a tensile strength of 200N/m to 400N/m or 200N/m to 300N/m or about 250N/m, such as where the amorphous solid does not include a filler. Such tensile strength may be particularly useful in embodiments where the aerosol-generating material is formed into a sheet and then shredded and incorporated into an aerosol-generating article. In some examples, the amorphous solid may have a tensile strength of 600N/m-900N/m or 700N/m-900N/m or about 800N/m, such as where the amorphous solid includes a filler. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol-generating article/component as a web sheet, suitably in the form of a tube.

The assembly may comprise an integrated aerosol-generating article and heater, or may comprise a heater arrangement into which the article is inserted in use.

Referring to fig. 1 and 2, a partial cross-sectional view and a perspective view of an embodiment of an aerosol-generating article 101 are shown. The article 101 is suitable 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 apparatus 51 shown in fig. 5-7, as described below. In use, the article 101 may be removably inserted into the device shown in fig. 5 at the insertion point 20 of the device 51.

The article 101 of an embodiment is in the form of a generally cylindrical rod comprising a body 103 of aerosol generating material and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in the form of shredded chips. In some embodiments, the aerosol-generating material herein may be introduced in sheet and chip form.

The filter assembly 105 includes three sections, a cooling section 107, a filter section 109, and a mouth end section 111. The article 101 has a first end 113, also referred to as the mouth end or proximal end, and a second end 115, also referred to 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 portion 107 is located adjacent to the body 103 of aerosol-generating material between the body 103 of aerosol-generating material and the filter portion 109, with the cooling portion 107 being in abutting relationship with the aerosol-generating material 103 and the filter portion 103. In other examples, there may be a separation between the body of aerosol-generating material 103 and the cooling portion 107 and between the body of aerosol-generating material 103 and the filter portion 109. The filter portion 109 is located between the cooling portion 107 and the mouth end portion 111. The mouth end portion 111 faces the proximal end 113 of the article 101, adjacent the filter portion 109. In one example, the filter portion 109 is in an abutting relationship with the mouth end portion 111. In one embodiment, the overall length of the filter assembly 105 is 37mm to 45mm, and more preferably the overall length of the filter assembly 105 is 41mm.

In one example, the length of the aerosol-generating material rod 103 is from 34mm to 50mm, suitably from 38mm to 46mm, suitably 42mm.

In one example, the article 101 has an overall length of 71mm to 95mm, suitably 79mm to 87mm, suitably 83mm.

A shaft end of the body 103 of aerosol generating material 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) covering an axial end of the body 103 of aerosol generating material.

The body of aerosol generating material 103 is attached to the filter assembly 105 by an annular tipping paper (not shown) which is located substantially around the filter assembly 105 to surround the filter assembly 105 and extends part way along the length of the body of aerosol generating material 103. In one example, the tipping paper is made from 58GSM standard tipping base paper. In one example, the tipping paper has a length of 42mm to 50mm, suitably 46 mm.

In one example, the cooling portion 107 is an annular tube and is located around the cooling portion and defines an air gap within the cooling portion. The air gap provides a chamber for the flow of heated volatile components generated from the body 103 of aerosol-generating material. The cooling portion 107 is hollow to provide a chamber for aerosol accumulation, but is sufficiently rigid to withstand axial compression forces and bending moments that may occur during manufacture and use during insertion of the article 101 into the apparatus 51. In one example, the wall thickness of the cooling portion 107 is about 0.29mm.

The cooling portion 107 provides a physical displacement between the aerosol-generating material 103 and the filter portion 109. The physical displacement provided by the cooling portion 107 will provide a thermal gradient over the entire length of the cooling portion 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 40 ℃ between the heated volatile components entering a first end of the cooling section 107 and the heated volatile components exiting a second end of the cooling section 107. In one example, the cooling section 107 is configured to provide a temperature difference of at least 60 ℃ between the heated volatile components entering a first end of the cooling section 107 and the heated volatile components exiting a second end of the cooling section 107. Such a temperature difference over the entire length of the cooling element 107 will protect the temperature sensitive filter portion 109 from the high temperatures at which the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter portion 109 and the body 103 of aerosol generating material and the heating element of the device 51, the temperature sensitive filter portion 109 may be damaged in use and therefore will not be able to effectively perform its required function.

In one example, the length of the cooling portion 107 is at least 15mm. In one example, the length of the cooling section 107 is 20mm to 30mm, more specifically 23mm to 27mm, more specifically 25mm to 27mm, suitably 25mm.

The cooling portion 107 is made of paper, which means that the cooling portion 107 is composed of a material that does not produce compounds of interest, such as toxic compounds, when used in the vicinity of the heater of the device 51. In one example, the cooling portion 107 is made of a spirally wound paper tube that provides a hollow interior chamber while maintaining mechanical rigidity. The helically wound paper tube is required to meet the stringent dimensional accuracy requirements in terms of tube length, outside diameter, roundness and straightness during high speed manufacturing.

In another example, the cooling portion 107 is a recess made of hard plug wrap (plug wrap) or tipping paper. The hard plug wrap or tipping paper is manufactured with sufficient rigidity to withstand the axial compression and bending forces that may occur during the manufacturing process and during use of the article 101 in insertion into the apparatus 51.

The filter portion 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol-generating material. In one example, the filter portion 109 is made of a monoacetate material, such as cellulose acetate. Filter portion 109 provides cooling and irritation reduction to the heated volatile components without wasting the amount of heated volatile components to a level that is not satisfactory to the user.

In some embodiments, a capsule (not shown) may be provided in the filter portion 109. Which may be disposed substantially centrally of filter portion 109, both along the diameter of filter portion 109 and along the length of filter portion 109. In other cases, it may be offset in one or more dimensions. In some cases, the capsules, if present, may contain volatile components such as flavouring agents or aerosol generating agents.

The density of the cellulose acetate tow material of the filter portion 109 controls the pressure drop across the filter portion 109, which in turn controls the tensile strength of the article 101. Therefore, the selection of the material of the filter portion 109 is important in controlling the tensile properties of the article 101. In addition, the filter portion also performs a filtering function in the product 101.

In one example, the filter section 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatile material while also reducing the size of aerosol condensate droplets produced by the heated volatile material.

The presence of the filter portion 109 provides insulation by providing further cooling of the heated volatile components exiting the cooling portion 107. This further cooling action reduces the contact temperature of the user's lips on the surface of the filter portion 109.

In one example, the length of the filter portion 109 is 6mm to 10mm, suitably 8mm.

The mouth end portion 111 is an annular tube and is located around the mouth end portion 111 and defines an air gap therein. The air gap provides a chamber for heated volatile components that flow from filter portion 109. The mouth end portion 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial pressures and bending moments that may occur during manufacture and use during insertion of the article into the device 51. In one example, the wall thickness of the mouth end portion 111 is about 0.29mm. In one example, the length of the mouth end portion 111 is from 6mm to 10mm, suitably 8mm.

The mouth end portion 111 may be made from a spirally wound paper tube that provides a hollow internal chamber yet retains a critical mechanical stiffness. The spirally wound paper tube can meet strict dimensional accuracy requirements in high-speed manufacturing processes in terms of tube length, outer diameter, roundness, and straightness.

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

It should be understood that in one example, the mouth end portion 111 and the cooling portion 107 may be formed from a single tube, and the filter portion 109 is located within the tube separating the mouth end portion 111 and the cooling portion 107.

Referring to fig. 3 and 4, a partially cut-away cross-sectional view and a perspective view of one example of an article 301 are shown. The reference numerals shown in figures 3 and 4 correspond to those shown in figures 1 and 2 with an increase of 200.

In the example of the article 301 shown in fig. 3 and 4, a ventilation zone 317 is provided in the article 301 to enable air to flow from the exterior of the article 301 into the interior of the article 301. In one example, the vented zone 317 takes the form of one or more vents 317 formed through the outer layer of the article 301. Vents may be located on the cooling portion 307 to assist in cooling the article 301. In one example, the vented zone 317 comprises one or more rows of apertures, and preferably each row of apertures is arranged circumferentially around the article 301 in a cross-section substantially perpendicular to the longitudinal axis of the article 301.

In one example, there are one to four rows of vents to provide ventilation for the article 301. Each row of vents may have 12-36 vents 317. The vent 317 may have a diameter of, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25mm to 0.75mm, suitably 0.5mm.

In one example, the vent holes 317 are of uniform size. In another example, the vent holes 317 may vary in size. The vents may be manufactured using any suitable technique, for example one or more of the following: laser techniques, mechanical perforation of the cooling portion 307, or pre-perforation of the cooling portion 307 prior to forming the article 301. The vents 317 are positioned so as to provide effective cooling to the article 301.

In one example, each row of ventilation holes 317 is located at least 11mm from the proximal end 313 of the article, suitably 17mm to 20mm from the proximal end 313 of the article 301. The location of the vent 317 is positioned such that the vent 317 is not blocked by the user when the article 301 is used.

When the article 301 is fully inserted into the device 51, as seen in fig. 6 and 7, the rows of vents are positioned between 17mm and 20mm from the proximal end 313 of the article 301 so that the vents 317 can be located outside of the device 51. By providing vents on the exterior of the device, unheated air can enter the article 301 from the exterior of the device 51 through the vents to assist in cooling the article 301.

The length of the cooling portion 307 is such that when the article 301 is fully inserted into the device 51, the cooling portion 307 is partially inserted into the device 51. The length of the cooling portion 307 provides a first function of providing a physical gap between the heater means of the device 51 and the heat sensitive filter means 309, and a second function of enabling the vent 317 to be located within the cooling portion while also being located outside the device 51 when the article 301 is fully inserted into the device 51. As can be seen from fig. 6 and 7, a large part of the cooling element 307 is located within the device 51. However, a portion of the cooling element 307 extends outside the device 51. The vent 317 is located in the portion of the cooling element 307 that extends out of the device 51.

Referring now in more detail to figures 5 to 7, there is shown an example of a device 51, the device 51 being configured to heat an aerosol generating material to volatilise at least one component of the aerosol generating material, typically to form an aerosol which can be inhaled. The device 51 is a heating device that releases the compound by heating without burning the aerosol-generating material.

The first end 53 is sometimes referred to herein as the mouth or proximal end 53 of the device 51, while the 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 57 to allow the device 51 as a whole to be turned on and off as required by the user.

The device 51 includes a housing 59 for locating and protecting the various internal components of the device 51. In the example shown, the housing 59 comprises a one-piece sleeve 11 around the periphery of the device 51, which is covered by a top panel 17, which generally defines the "top" of the device 51, and a bottom panel 19, which generally defines the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably secured to the one-piece sleeve 11 to allow easy access to the interior of the device 51, or may be "permanently" secured to the one-piece sleeve 11, for example, to prevent user access to the interior of the device 51. In one example, the

panels

17 and 19 are made of plastic, including glass filled nylon formed by, for example, injection molding, while the unitary sleeve 11 is made of aluminum, although other materials and other manufacturing methods may be used.

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, an

article

101, 301 comprising aerosol generating material may be inserted into the device 51 and removed from the device 51 by a user.

The housing 59 has the heater device 23, the control circuit 25 and the power supply 27 located or secured therein. In this example, the heater device 23, control circuitry 25 and power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuitry 25 is typically located between the heater device 23 and power supply 27, although other locations are possible.

The control circuitry 25 may comprise a controller, such as a microprocessor device, configured to control heating of the aerosol-generating material in the

article

101, 301, as discussed further below.

The energy source 27 may be, for example, a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically connected to the heater device 23 to provide power to heat the aerosol-generating material in the article (to vaporise the aerosol-generating material without causing combustion of the aerosol-generating material, as discussed above) when required and under the control of the control circuit 25.

The advantage of locating the power supply 27 laterally adjacent the heater means 23 is that a physically larger power supply 25 can be used without causing the apparatus 51 to be overall too long. It should be appreciated that the typically physically larger power source 25 has a higher capacity (i.e., the total power that can be provided is typically measured in amp-hours, etc.), so the battery life of the device 51 can be longer.

In one example, the heater device 23 is typically in the form of a hollow cylindrical tube having a hollow interior heating chamber 29 into which the

article

101, 301 containing the aerosol generating material is inserted for heating in use. Different arrangements of the heater means 23 are possible. For example, the heater device 23 may comprise a single heating element, or may be formed from a plurality of heating elements aligned along the longitudinal axis of the heater device 23. The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its periphery. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating means are possible, including, for example, induction heating, infrared heating elements heated by emitting infrared radiation, or resistive heating elements formed, for example, by resistive electrical windings.

In one particular example, the heater device 23 is supported by a stainless steel support tube and contains a polyimide heating element. The heater device 23 is dimensioned such that when the

article

101, 301 is inserted into the device 51, substantially the entire body of aerosol-generating

material

103, 303 of the

article

101, 301 is inserted into the heater device 23.

The or each heating element is configured to enable selected regions of the aerosol-generating material to be heated independently, for example sequentially (as above, over time) or together (simultaneously) as required.

The heater means 23 in this example is surrounded along at least a portion of its length by insulation 31. The thermal insulator 31 helps to reduce the transfer of heat from the heater unit 23 to the exterior of the unit 51. This helps to reduce the power requirements of the heater device 23 as it reduces heat losses overall. The insulation 31 also helps to keep the device 51 externally cooled during operation of the heater device 23. In one example, the insulator 31 may be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. That is, the thermal insulator 31 may be, for example, a "vacuum" tube, i.e., a tube that has been at least partially evacuated such that heat transfer by conduction and/or convection is minimized. Other arrangements of the thermal insulator 31 are possible in addition to or in lieu of the double-walled sleeve, including the use of thermally insulating materials, including, for example, suitable foam-type materials.

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

The apparatus 51 further comprises: a collar 33 extending around opening 20 and projecting from opening 20 into the interior of housing 59; and a generally tubular chamber 35 located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 also includes a cooling structure 35f, which in this example includes a plurality of fins 35f spaced along the outer surface of the chamber 35, and each fin 35f is arranged circumferentially around the outer surface of the chamber 35. Over at least a portion of the length of the hollow chamber 35, there is an air gap 36 between the hollow chamber 35 and the

article

101, 301 when the

article

101, 301 is inserted into the device 51. The air gap 36 surrounds the entire circumference of the

article

101, 301 in at least a portion of the cooling portion 307.

Collar 33 includes a plurality of ridges 60 disposed circumferentially around the circumference of opening 20 and projecting into opening 20. The ridge 60 occupies space within the opening 20 such that the opening 20 has an opening span at the location of the ridge 60 that is less than the opening span of the opening 20 at the location of the absence of the ridge 60. The ridge 60 is configured to engage with an

article

101, 301 inserted into the device to assist in securing it within the device 51. The open space (not shown in the figures) defined by the adjacent pair of ridges 60 and the

article

101, 301 forms a ventilation path around the exterior of the

article

101, 301. These ventilation paths allow hot vapor escaping from the

article

101, 301 to exit the device 51 and allow cooling air to flow into the device 51 to coat the

article

101, 301 of the air gap 36.

In operation, the

article

101, 301 is removably inserted into the insertion point 20 of the device 51, as shown in FIGS. 5-7. With particular reference to figure 6, in one example, the body of

aerosol generating material

103, 303, which is located proximate the

distal end

115, 315 of the

article

101, 301, is fully contained within the heater device 23 of the device 51. The

proximal end

113, 313 of the

article

101, 301 extends from the device 51 and serves as a mouthpiece component for the user.

In operation, the heater device 23 will heat the

article

101, 301 to volatilize at least one component of the aerosol generating material from the

body

103, 303 of aerosol generating material.

The primary flow path of the heated volatile components from the

body

103, 303 of aerosol generating material is axially through the

article

101, 301, through the chamber inside the cooling

portion

107, 307, through the

filter portion

109, 309, through the

mouth end portion

111, 313 to the user. In one example, the temperature of the heated volatile component produced by the body of aerosol-generating material is between 60-250 ℃, which may be above the user-acceptable inhalation temperature. As the heated volatile component travels through the

cooling section

107, 307, it will cool and some of the volatile component will condense on the inner surface of the

cooling section

107, 307.

In the example of the article 301 shown in fig. 3 and 4, cool air will be able to enter the cooling portion 307 via vents 317 formed in the cooling portion 307. The cold air will mix with the heated volatile components to provide additional cooling to the heated volatile components.

A further aspect of the invention provides a method of producing an aerosol-generating material according to the first aspect.

The method may include (a) forming a slurry comprising components of an amorphous solid or a precursor thereof, (b) forming a layer of the slurry, (c) allowing the slurry to cure to form a gel, and (d) drying to form an amorphous solid.

Step (b) of forming a layer of the slurry may comprise, for example, spraying, casting or extruding the slurry. In some cases, the layer is formed by electrospray slurry. In some cases, the layer is formed by casting a slurry.

In some cases, steps (b) and/or (c) and/or (d) may occur at least partially simultaneously (e.g., during electrospray). In some cases, (b), (c), and (d) may occur sequentially.

In some cases, the slurry is applied to a support. The layer may be formed on a carrier.

In various embodiments, the slurry comprises a gelling agent, an aerosol former material, and menthol. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol-generating material. For example, the slurry may comprise:

-0.1% to 80% by weight of menthol;

-from 1% to 60% by weight of gelling agent/gelling agent precursor; and

-from 0.1wt% to 50wt% of aerosol former material.

The slurry may comprise a gellant precursor. For example, the slurry may comprise sodium, potassium or ammonium alginate as the gel precursor. In some embodiments, the G units and M units are present in the gellant precursor in a molar ratio of 1. In some embodiments, the G units and M units are present in a molar ratio of 1.

Curing of the gel (c) may include adding a curing agent to the slurry. For example, (c) may include adding Ca ²⁺ Cations are added to the slurry. Ca ²⁺ The cation may be provided as part of the calcium source. For example, the slurry may include sodium, potassium or ammonium alginate salts as gel precursors, and a curing agent comprising a calcium source (such as a calcium salt, e.g., calcium chloride) may be added to the slurry to form a calcium-crosslinked alginate gel. Ca ²⁺ A calcium source is supplied to the slurry in an amount to provide Ca in the slurry ²⁺ The molar ratio of cation to G unit is 0.2.

In some embodiments, the curing agent or calcium source comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some embodiments, the solidifying agent or calcium source comprises or consists of calcium formate and/or calcium lactate. In particular embodiments, the curing agent or calcium source comprises or consists of calcium formate. The present inventors have determined that the use of calcium formate as a curing agent or calcium source generally results in an amorphous solid with greater tensile strength and greater resistance to elongation.

In each example, ca ²⁺ The cations are provided to the slurry as part of a fluid system comprising a calcium source and an aqueous carrier. The calcium source may comprise a combination of calcium-containing compounds. In some embodiments, the calcium source comprises one or more calcium salts, such as calcium chloride, calcium lactate, calcium citrate, calcium acetate, or calcium citrate.

In some embodiments, the calcium source is dissolved and optionally suspended in an aqueous carrier. In some embodiments, the calcium source is present in the fluid system in an amount greater than the amount soluble in the aqueous carrier at ambient temperature and pressure. Normal temperature and pressure are defined by the national institute of standards and technology, and refer to a temperature of 20 deg.C and an absolute pressure of 1atm.

In some embodiments, the fluid source is a supersaturated solution of a calcium source, such as a supersaturated solution of a calcium salt. In some embodiments, the fluid source comprises a dissolved and suspended (particulate) calcium source, such as a dissolved and suspended (particulate) calcium salt. Providing the slurry with a source of calcium in a small amount of aqueous carrier can reduce the evaporation load during drying (d), allowing faster and less energy intensive production of the aerosol-generating material.

In some cases, drying (d) can remove about 50wt%, 60wt%, 70wt%, 80wt%, or 90wt% to about 80wt%, 90wt%, or 95wt% (WWB) of the water in the slurry.

In some cases, drying (d) may reduce the cast material thickness by at least 80%, suitably 85% or 87%. For example, the slurry may be cast at a thickness of 2mm, and the resulting dry amorphous solid material may have a thickness of 0.2 mm.

The slurry itself may also form part of the invention. In some cases, the slurry solvent may consist essentially of, or consist of, water. In some cases, the slurry can include about 50wt%, 60wt%, 70wt%, 80wt%, or 90wt% solvent (WWB).

In some embodiments, the slurry has a viscosity of about 10 to about 20 Pa-s at 46.5 ℃, for example, a viscosity of about 14 to about 16 Pa-s at 46.5 ℃.

In the case where the solvent consists of water, the dry weight content of the slurry may be matched to the dry weight content of the amorphous solids. Thus, the discussion herein regarding the solid composition is expressly disclosed in connection with the slurry aspect of the present invention.

According to one aspect of the present invention, there is provided a method of generating an aerosol using a non-combustible aerosol delivery system as described herein. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of less than or equal to 350 ℃. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of from about 220 to about 280 ℃. In some embodiments, the method comprises heating at least a portion of the aerosol-generating material to a temperature of from about 220 to about 280 ℃ during use.

As used herein, "use period" refers to a single period of time during which a user uses a non-flammable aerosol delivery system. The use period starts from the point of time when power is first supplied to at least one heating unit present in the heating assembly. After a period of time has elapsed from the beginning of the use period, the device will be ready for use. The lifetime ends when any heating element in the aerosol-generating device is unpowered. The end of the use period may coincide with the point at which the smoking article is exhausted (the point at which the total particulate matter yield (mg) in each puff is considered by the user to be unacceptably low). The use period will have a duration of multiple puffs. The use period may have a duration of less than 7 minutes or 6 minutes or 5 minutes or 4 minutes 30 seconds or 4 minutes or 3 minutes 30 seconds. In some embodiments, the use period may have a duration of 2-5 minutes or 3-4.5 minutes or 3.5-4.5 minutes or suitably 4 minutes. The user may initiate the use period by actuating a button or switch on the device, causing the at least one heating element to begin warming.

In some embodiments, at least 20wt% or at least 30wt%, 40wt%, or 50wt% of the menthol present in the amorphous solid is aerosolized during the period of use. That is, the amount of menthol in the amorphous solid may consume 20wt%, 30wt%, 40wt%, or 50wt% after a period of use. Ca in amorphous solids as described herein ²⁺ The molar ratio to G units may allow for efficient delivery of menthol to a user (e.g., a high proportion of active material aerosolized from the amorphous solid) while maintaining a longer shelf life before the amorphous solid is heated by the non-flammable aerosol provision device.

According to one aspect of the present invention, there is provided a use of a non-combustible aerosol provision system as described herein. Use of the non-combustible aerosol provision system may comprise interacting with the non-combustible aerosol provision means (e.g. activating an actuator) to initiate a smoking session.

Examples

A first aerosol-generating material and a second aerosol-generating material are prepared according to the methods herein. Both aerosol-generating materials were prepared from a slurry having the following composition (w/w on a dry weight basis):

50% menthol

-20% glycerol

26% sodium alginate

-4% pectin

Calcium lactate was added to the slurry as a curing agent. The aerosol-generating material only differs in the amount of calcium lactate provided to the slurry to cross-link the alginate. The first aerosol-generating material is prepared by adding Ca in sodium alginate to the slurry ²⁺ Calcium lactate in a cation to G unit molar ratio of 0.4; the second aerosol generating material is prepared by adding Ca in sodium alginate to the slurry ²⁺ Calcium lactate in a cation to G unit molar ratio of 0.2.

The dried material is formed into a sheet which is subsequently shredded and mixed with tobacco to provide a mixture. Each mixture of aerosol-generating material and tobacco is made into a rod-shaped consumable and provided with a filter as described herein, thereby providing a first consumable comprising a first aerosol-generating material and a second consumable comprising a second aerosol-generating material.

A puff-by-puff sensory analysis was performed for each consumable. The puff-by-puff analysis was performed according to the Health canadian ministry of Health intensive (HCI) smoking regime (Health Canada Intense (HCI) puffing region): no exhaust blockage, 55mL aspirate for more than 2 seconds every 30 seconds. Each puff is captured in an airtight syringe connected to a smoking engine (smoke engine). The captured samples were extracted using a solvent and analyzed using gas chromatography with flame ionization detector (GC-FID) to quantify menthol according to the calibration range.

The results of this analysis are depicted in fig. 8. It can be seen that both materials provide acceptable puff by puff menthol organoleptic properties. It was found that the first material, having Ca ²⁺ Cation to G unit molar ratio 0.4Smoking menthol sensory properties.

The above embodiments are to be understood as illustrative examples of the invention. Other embodiments of the invention are contemplated. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other 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 accompanying claims.

Claims

1. An aerosol-generating material comprising an amorphous solid comprising:

0.1wt% to 80wt% menthol;

-1-60 wt% gelling agent comprising a calcium cross-linked alginate comprising α - (1-4) -linked L-guluronic acid ester (G) units; and

-from 0.1wt% to 50wt% of an aerosol former material;

wherein Ca ²⁺ The molar ratio of cation to G unit is 0.2.

2. An aerosol-generating material according to claim 1, wherein the molar ratio of calcium to G units is from 0.3.

3. An aerosol-generating material according to claim 1 or claim 2, wherein the calcium cross-linked alginate further comprises β - (1-4) -linked D-mannuronate (M) units.

4. An aerosol-generating material according to claim 3, wherein the molar ratio of G units to M units is 1.

5. An aerosol-generating material according to any of claims 1 to 4, wherein the aerosol-generating material comprises at least 60% menthol by dry weight of the menthol present in the aerosol-generating material prior to storage when stored in a sealed container for 30 days at ambient conditions (22 ℃;60% relative humidity; 1013 mbar).

6. An aerosol-generating material according to any of claims 1 to 5, wherein the amorphous solid comprises the aerosol former material in an amount of 10wt% to 30 wt%.

7. An aerosol-generating material according to any of claims 1 to 6, wherein the amorphous solid comprises the menthol in an amount of 40wt% to 60 wt%.

8. An aerosol-generating material according to any of claims 1 to 7, wherein the amorphous solid comprises:

-20% to 35% by weight of a gelling agent;

-15wt% to 25wt% of an aerosol former material;

-45% to 55% by weight of menthol;

wherein the weights are calculated on a dry weight basis.

9. An aerosol-generating material according to any of claims 1 to 8, wherein the cross-linked alginate comprised in the gelling agent is present in the amorphous solids in an amount of about 15-40 wt% of the amorphous solids on a dry weight basis.

10. An aerosol-generating material according to any of claims 1 to 9, wherein the gelling agent further comprises pectin.

11. An aerosol-generating material according to claim 10, wherein the dry weight ratio of cross-linked alginate to pectin is from 1 to 1.

12. An aerosol-generating material according to claim 10 or claim 11, wherein the pectin comprised in the gelling agent is present in the amorphous solids in an amount of about 3-10 wt% of the amorphous solids on a dry weight basis.

13. An aerosol-generating material according to any of claims 1 to 12, comprising from about 1wt% to about 15wt% water (WWB).

14. An aerosol-generating material according to any of claims 1 to 13, wherein the aerosol former material is selected from erythritol, propylene glycol, glycerol and mixtures thereof.

15. A substrate comprising an aerosol-generating material according to any of claims 1 to 14 and a carrier on which the aerosol-generating material is disposed.

16. An article for use in a non-combustible aerosol provision device, the article comprising an aerosol generating material according to any of claims 1 to 14 and/or a substrate according to claim 15.

17. A non-combustible aerosol provision system comprising an article according to claim 16 and a non-combustible aerosol provision device, wherein the non-combustible aerosol provision device is configured to generate an aerosol from the article when the article is used with the non-combustible aerosol provision device.

18. The system of claim 17, wherein the non-combustible aerosol provision device comprises a heater configured to heat without combusting the article.

19. The system of claim 17, wherein the heater is configured to heat the article to a temperature of less than 350 ℃ in use.

20. The system of claim 19, wherein the heater is configured to heat the article to a temperature of about 220 to about 280 ℃ in use.

21. The system of any of claims 17-19, wherein the article is provided in a stick form.

22. A method of making an aerosol-generating material according to any of claims 1 to 14.

23. The method of claim 22, the method comprising:

-providing a slurry comprising the gelling agent, the aerosol former material and menthol;

-forming a layer of the slurry;

-allowing the slurry to cure to form a gel; and

-drying the gel to form the amorphous solid.

24. The method of claim 22 or 23, wherein solidifying the slurry comprises adding Ca to the slurry ²⁺ A calcium source of cations.

25. The method of claim 24, wherein the calcium source is provided as part of a fluid system comprising the calcium source and an aqueous carrier.

26. The method of claim 25, wherein the calcium source is dissolved and optionally suspended in the aqueous carrier.

27. The method of claim 25 or 26, wherein the calcium source is present in the fluid system in an amount greater than soluble in the aqueous carrier at ambient temperature and pressure.

28. A method of generating an aerosol using a non-combustible aerosol provision system according to any of claims 17 to 21, the method comprising heating the aerosol generating material to a temperature of less than 350 ℃.

29. The method of claim 28, wherein the temperature is from about 220 ℃ to about 280 ℃.

30. The method of claim 28 or 29, wherein at least 20wt% of menthol present in the amorphous solid aerosolizes during use.

31. Use of a non-combustible aerosol provision system according to any one of claims 17-21.