CN117979840A

CN117979840A - Aerosol-generating composition

Info

Publication number: CN117979840A
Application number: CN202280050562.XA
Authority: CN
Inventors: 本杰明·詹金斯; 珍妮弗·路易丝·希罗科
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-07-22
Filing date: 2022-07-22
Publication date: 2024-05-03
Also published as: GB202202056D0

Abstract

The present invention provides an aerosol-generating material comprising: about 7wt% to about 13wt% aerosol generator, binder, about 35wt% to about 50wt% flavoring and filler. The invention also provides an aerosol-generating composition comprising the aerosol-generating material, a consumable comprising the aerosol-generating composition, a non-combustion aerosol-delivery system comprising the consumable, and the use of the aerosol-generating material or the aerosol-generating composition for generating an aerosol. The invention also provides a slurry that can be used to produce the aerosol-generating material, a method of preparing the aerosol-generating material and an aerosol-generating material obtainable by the method of the invention.

Description

Aerosol-generating composition

Technical Field

The present invention relates to an aerosol-generating material, an aerosol-generating composition comprising an aerosol-generating material; a consumable for use within a non-combustion aerosol provision system, the consumable comprising an aerosol-generating composition; and a non-combustion aerosol supply system. The invention also relates to a slurry that can be used for producing an aerosol-generating material, a method for producing an aerosol-generating material and an aerosol-generating material obtainable by the method of the invention.

Background

Smoking consumables, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Alternatives to these types of consumables are heated without burning to release compounds from the matrix material, thereby releasing inhalable aerosols or vapors. These may be referred to as non-combustion smoking consumables or aerosol-generating components.

One example of such a product is a heating device that releases a compound by heating, rather than burning, a solid aerosol-generating material. In some cases, such solid aerosol-generating material may comprise plant material. The heating causes at least one component of the material to vaporize, typically forming an inhalable aerosol. These products may be referred to as heating non-combustion devices, tobacco heating devices, or tobacco heating products. Various different arrangements for gasifying at least one component of a solid aerosol-generating material are known.

Another example is a mixing device. These 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 additionally contains a solid aerosol-generating material (which may or may not contain tobacco material) and components of the material are entrained in the inhalable vapour 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 aerosol-generating agent in an amount of about 7% to about 13% by weight of the aerosol-generating material on a dry weight basis;

-a binder;

-a flavouring agent in an amount of about 35% to about 50% by weight of the aerosol-generating material on a dry weight basis; and

-A filler.

In a second aspect, there is provided an aerosol-generating composition comprising the aerosol-generating material of the first aspect.

According to a further aspect of the present invention there is provided a consumable for use in a non-combustion aerosol provision system, the consumable comprising an aerosol generating composition as defined herein.

According to a further aspect of the present invention there is provided a non-combustion aerosol provision system comprising a consumable as defined herein and a non-combustion aerosol provision device comprising an aerosol generating device configured (or arranged) to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol provision device.

According to a further aspect of the present invention there is provided the use of an aerosol-generating composition as defined herein in a consumable for use in a non-combustion aerosol-supplying device, the non-combustion aerosol-supplying device comprising an aerosol-generating device configured to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol-supplying device.

According to a further aspect of the present invention there is provided the use of an aerosol-generating material or aerosol-generating composition as defined herein for generating an aerosol.

According to a further aspect of the present invention there is provided a method of preparing an aerosol-generating material or aerosol-generating composition as defined herein.

According to a further aspect, the present invention provides an aerosol-generating material obtainable or obtained by the method described herein.

According to a further aspect of the present invention there is provided a method of generating an aerosol using a non-combustion 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 about 220 to about 280 ℃.

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

Drawings

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

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

Fig. 3 shows a cross-sectional elevation view of an embodiment of an aerosol-generating article.

Fig. 4 shows a perspective view of the article of fig. 3.

Fig. 5 shows a perspective view of an embodiment of an aerosol-generating assembly.

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

Fig. 7 shows a perspective view of an embodiment of an aerosol-generating assembly.

Fig. 8 shows an exploded view of an exemplary consumable.

Fig. 9 shows an embodiment of a consumable comprising a plurality of discrete aerosol-generating material portions.

Detailed Description

The aerosol-generating materials/compositions described herein are, for example, materials/compositions that are capable of generating an aerosol when heated, irradiated, or energized in any other manner. The aerosol-generating composition may be in the form of, for example, a solid, liquid or gel, which may or may not contain nicotine. The aerosol-generating composition comprises an aerosol-generating material. The aerosol-generating material may be an "amorphous solid". In some embodiments, the amorphous solid is a "monolithic solid". The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a xerogel. The aerosol-generating material may be a solid material that may retain some fluid, such as a liquid, therein. In some embodiments, the aerosol-generating composition may, for example, comprise from about 50wt%, 60wt% or 70wt% of the aerosol-generating material to about 90wt%, 95wt% or 100wt% of the aerosol-generating material. In certain instances, the aerosol-generating composition consists of an aerosol-generating material.

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

-a binder;

-A filler.

In some cases, the aerosol-generating material comprises:

-an aerosol-generating agent in an amount of from about 7% to about 13% by weight of the aerosol-generating material;

-a binder in an amount of about 1wt% to about 57wt% of the aerosol-generating material;

-a flavouring agent in an amount of about 35% to about 50% by weight of the aerosol-generating material; and

-A filler in an amount of about 1% to about 50% by weight of the aerosol-generating material;

Wherein these amounts are all calculated on a dry weight basis.

The inventors have demonstrated that flavor losses can be reduced during the production of aerosol-generating materials by controlling the amounts of aerosol-generating agent (e.g. glycerin) and flavor (e.g. menthol) to the claimed range. The aerosol-generating materials disclosed herein comprise relatively low amounts of aerosol-generating agents (such as glycerin). Without wishing to be bound by theory, it is believed that a flavoring agent (e.g., menthol) and an aerosol-generating agent (e.g., glycerin) may compete for the emulsification sites in the aerosol-generating material, and thus reducing the amount of aerosol-generating agent may result in an increase in flavor retention. Reducing flavor loss during production of aerosol-generating materials reduces wastage and is more cost effective.

In addition, the amount of flavoring agents (e.g., menthol) retained in the materials of the present invention may vary less. This is advantageous for the consumer, as the material composition (and thus the aerosol produced) between different batches of aerosol-generating material may be more constant.

The aerosol-generating material may comprise from about 7wt%, 8wt%, 9wt%, 10wt% or 10.3wt% to about 13wt%, 12wt% or 11wt% of the aerosol-generating agent (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-generating material comprises from 8wt% to 13wt%, from 9wt% to 12wt%, from 10wt% to 12wt%, from greater than 10wt% to less than 12wt%, or from 10.3wt% to 11.9wt% of an aerosol-generating agent (all calculated on a dry weight basis). These amounts represent the total amount of aerosol-generating agent in the aerosol-generating material.

In some embodiments, the aerosol-generating agent may comprise one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillin, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixtures, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some cases, the aerosol-generating agent comprises, consists essentially of, or consists of glycerin.

The aerosol-generating material may comprise the binder in an amount of about 1wt%, 5wt%, 10wt%, 12wt%, 15wt%, 17wt%, 19wt%, or 20wt% to about 25wt%, 27wt%, 30wt%, 40wt%, 45wt%, 50wt%, or 57wt% (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise the binder (on a dry weight basis) in an amount of 1wt% to 57wt%, 5wt% to 50wt%, 15wt% to 35wt%, 20wt% to 30wt%, or 20wt% to 25 wt%. These amounts represent the total amount of binder in the aerosol-generating material.

The binder may include a cellulosic binder and/or a non-cellulosic binder. Examples of cellulose binders that may be used include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose Acetate (CA), cellulose Acetate Butyrate (CAB), and Cellulose Acetate Propionate (CAP). Examples of non-cellulosic binders that may be used include alginates, pectins, starches (and derivatives thereof), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof.

In some embodiments, the binder is selected from the group consisting of alginate, pectin, pullulan (pullulan), xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

In some embodiments, the binder comprises alginate and/or pectin.

In some embodiments, the binder comprises, consists essentially of, or consists of alginate and pectin.

In some embodiments, the binder includes a cellulosic binder and a non-cellulosic binder. The use of a cellulosic binder (e.g., CMC) in combination with a non-cellulosic binder can increase the temperature at which flavoring agents (e.g., menthol) are released. The list of suitable cellulosic and non-cellulosic binders described above is equally applicable to this embodiment. In some embodiments, the cellulosic binder comprises or consists of CMC, and/or the non-cellulosic binder comprises or consists of alginate and/or guar gum. In particular embodiments, the binder comprises, consists essentially of, or consists of CMC, alginate, and guar gum.

In some embodiments, the aerosol-generating material comprises a cross-linking agent. In some cases, the crosslinker comprises calcium ions. In some embodiments, the crosslinker comprises calcium lactate and/or calcium acetate. In some embodiments, the crosslinking agent comprises calcium lactate. In some cases, the aerosol-generating material may comprise calcium crosslinked alginate. The crosslinking agent may also be described as a curing agent.

The aerosol-generating material may comprise from about 0.5wt%, 1wt%, 3wt% or 5wt% to about 10wt%, 9wt%, 8wt% or 7wt% of the cross-linking agent (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise 10wt%, 3wt% to 8wt% or 5wt% to 7wt% of the cross-linking agent (on a dry weight basis). These amounts represent the total amount of cross-linking agent in the aerosol-generating material.

In some embodiments, the aerosol-generating material does not comprise a cross-linking agent.

The aerosol-generating material may be substantially free of cellulosic binders. By "substantially free" is meant that the material comprises less than 1wt%, such as less than 0.5wt%, of the relevant components (dry weight). In some embodiments, the aerosol-generating material does not comprise a cellulosic binder.

The aerosol-generating material may be substantially free of carboxymethylcellulose (CMC). In some embodiments, the aerosol-generating material does not comprise CMC.

In some embodiments, the binder comprises an alginate, and the alginate is present in the aerosol-generating material in an amount of 5wt% to 50wt%, 8wt% to 40wt%, 10wt% to 30wt%, or 15wt% to 25 wt% (calculated on a dry weight basis) of the aerosol-generating material. In some embodiments, the alginate is the only binder present in the aerosol-generating material. In other embodiments, the binder comprises an alginate and at least one additional non-cellulosic binder, such as pectin.

In some embodiments, the binder comprises pectin, and the pectin is present in the aerosol-generating material in an amount of from 1wt% to 10wt%, from 2wt% to 8 wt%, or from 3wt% to 7wt% (calculated on a dry weight basis) of the aerosol-generating material.

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of from 5wt% to 50wt%, 8wt% to 40wt%, 10wt% to 30wt% or 15wt% to 25wt% of the aerosol-generating material, and the pectin is present in the aerosol-generating material in an amount of from 1wt% to 10wt%, 2wt% to 8wt% or 3wt% to 7wt% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of from 8wt% to 40wt% of the aerosol-generating material, and the pectin is present in the aerosol-generating material in an amount of from 1wt% to 10wt% of the aerosol-generating material (all calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of from 10wt% to 30wt% of the aerosol-generating material, and the pectin is present in the aerosol-generating material in an amount of from 2wt% to 8wt% of the aerosol-generating material (calculated on a dry weight basis).

In some embodiments, the binder comprises alginate and pectin, and the alginate is present in the aerosol-generating material in an amount of 15wt% to 25wt% of the aerosol-generating material, and the pectin is present in the aerosol-generating material in an amount of 3wt% to 7wt% of the aerosol-generating material (calculated on a dry weight basis).

The aerosol-generating material may comprise from about 35wt%, 36wt% or 37wt% to about 50wt%, 45wt% or 43wt% flavouring agent (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise from 35wt% to 45wt%, from 36wt% to 45wt% or from 37wt% to 43wt% of the flavouring agent. These amounts represent the total amount of flavoring in the aerosol-generating material.

As used herein, the terms "flavoring" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatosensory sensation in a product for an adult consumer, as permitted by local regulations. They may include naturally occurring flavor materials, botanical preparations, botanical preparation extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice), hydrangea, eugenol, japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, green tea, menthol, japanese mint, star anise (fennel), cinnamon, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, du Linbiao (Drambuie), book (bourbon), scotch whiskey, juniper, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, acacia tea (khat), naswale (naswar), betel nut, water tobacco (shisha), pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry blossom, cassia seed, caraway (caraway), cognac brandy, jasmine flower, ylang-ylang (ylang-ylang), sage, fennel, mustard, pigment, ginger, caraway, coffee, hemp, peppermint oil from any mint species, eucalyptus, star anise, cocoa, lemon grass, such as doctor tea, flax, ginkgo leaf, hazelnut, lotus, bay tree, plant chaperones, orange peel, roses, teas such as green tea and black tea, thyme, juniper, elder, basil, laurel, fennel, oregano, chilli powder, rosemary, saffron, lemon peel, peppermint, perilla (beefsteak plant), turmeric, coriander leaf, myrtle, blackcurrant, valerian, allspice, mese, damianne, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, limonene, thymol, camphor, odorants, bitter receptor site blockers, sensory receptor site activators or stimulators, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanical preparations, or breath fresheners. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as oil, solid such as powder, or gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring agent comprises, consists essentially of, or consists of menthol.

In some embodiments, the aerosol-generating material comprises from about 1wt%, 5wt%, 10wt%, 18wt% or 20wt% to about 50wt%, 45wt%, 40wt%, 35wt% or 30wt% filler (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise from 5wt% to 45wt%, from 10wt% to 40wt%, from 18wt% to 35wt%, or from 20wt% to 30wt% of filler (all calculated on a dry weight basis). These amounts represent the total amount of filler in the aerosol-generating material.

The filler may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate and suitable inorganic absorbents such as molecular sieves. The filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In particular cases, the aerosol-generating material does not comprise calcium carbonate, such as chalk.

In a specific embodiment, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp, cellulose or cellulose derivatives, such as microcrystalline cellulose (MCC) and/or nanocrystalline cellulose. Without wishing to be bound by theory, it is believed that including fibrous fillers in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided in sheet form, such as when the sheet of aerosol-generating material is wrapped around a rod of aerosol-generating composition.

In some cases, the filler comprises (or is) wood pulp.

In some cases, the filler comprises maltodextrin or microcrystalline cellulose (MCC). As is well known to those skilled in the art, microcrystalline cellulose may be formed by depolymerizing cellulose by chemical means (e.g., using acids or enzymes). One exemplary method of forming microcrystalline cellulose includes acid hydrolysis of cellulose using an acid such as HCl. The cellulose produced after this treatment is crystalline (i.e., no amorphous regions remain). Suitable methods and conditions for forming microcrystalline cellulose are well known in the art.

In some cases, the filler has a density of less than about 2g/cm ³, such as less than about 0.5g/cm ³ or less than about 0.3g/cm ³.

The aerosol-generating material may have any suitable water content, such as from 1wt% to 15wt%. Suitably, the water content of the aerosol-generating material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (based on Wet Weight) (WWB). The moisture content of the aerosol-generating material may be determined by, for example, karl fischer (Karl Fisher) titration or gas chromatography using a thermal conductivity detector (GC-TCD).

The amounts of the components of the aerosol-generating material, such as the aerosol-generating agent (e.g., glycerin) and the flavoring agent (e.g., menthol), may be determined by gas chromatography. One example of a suitable gas chromatography protocol is set forth in the examples section below.

The aerosol-generating material may comprise a colourant. The addition of a colorant may alter the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color matched with other components of the aerosol-generating composition or other components of the article comprising the aerosol-generating material.

Various colorants may be used depending on the desired color of the aerosol-generating material. The colour of the aerosol-generating material may be, for example, white, green, red, violet, 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 a caramel color, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components of the aerosol-generating composition (e.g., tobacco material) including the aerosol-generating material. In some embodiments, a colorant is added to the aerosol-generating material to make it visually indistinguishable from other components in the aerosol-generating composition.

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

In some embodiments, the aerosol-generating composition further comprises an active. For example, in some cases, the aerosol-generating composition additionally comprises tobacco material and/or nicotine. In some cases, the aerosol-generating composition may comprise from 5wt% to 60wt% (by dry weight) of tobacco material and/or nicotine. In some cases, the aerosol-generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt% or 30wt% (calculated on a dry weight basis) of active. In some cases, the aerosol-generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry basis) of tobacco material. For example, the aerosol-generating composition may comprise from 10wt% to 50wt%, from 15wt% to 40wt% or from 20wt% to 35wt% of the tobacco material. In some cases, the aerosol-generating composition may comprise from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the aerosol-generating composition may comprise from 1wt% to 20wt%, from 2wt% to 18wt% or from 3wt% to 12wt% nicotine.

In some cases, the aerosol-generating composition comprises an active substance, such as a tobacco extract. In some cases, the aerosol-generating composition may comprise from 5wt% to 60wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the aerosol-generating composition may comprise from about 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of the tobacco extract. For example, the aerosol-generating composition may comprise from 10wt% to 50wt%, from 15wt% to 40wt% or from 20wt% to 35wt% of the tobacco extract. The tobacco extract may contain a concentration of nicotine such that the aerosol-generating composition comprises 1wt%, 1.5wt%, 2wt% or 2.5wt% to about 10wt%, 8wt%, 6wt%, 5wt%, 4.5wt% or 4wt% (on a dry basis) nicotine. In some embodiments, the aerosol-generating composition may comprise from 1wt% to 10wt%, from 2.5wt% to 8wt%, or from 2wt% to 6wt% nicotine. In some cases, the aerosol-generating composition may be free of nicotine other than that produced by the tobacco extract.

In some embodiments, the aerosol-generating composition does not comprise tobacco material, but comprises nicotine. In some such cases, the aerosol-generating composition may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) nicotine. For example, the aerosol-generating composition may comprise from 1wt% to 20wt%, from 2wt% to 18wt% or from 3wt% to 12wt% nicotine.

The aerosol-generating composition 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 functionality. 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 composition comprises nicotine, it is particularly preferred to comprise an acid. The presence of the acid may reduce or substantially prevent nicotine vaporization during drying of the slurry, thereby reducing nicotine loss during manufacture. The presence of an acid may also improve the flavor of the aerosol when nicotine is present. For example, perceived tartness of nicotine (harshness) can be reduced by the presence of an acid.

In some embodiments, the aerosol-generating material is substantially free of tobacco. By "substantially free" it is meant that the material comprises less than 1wt% tobacco, such as less than 0.5wt% tobacco (on a dry weight basis). In some embodiments, the aerosol-generating material is free of tobacco. In some embodiments, the aerosol-generating material does not comprise tobacco fibers. In a specific embodiment, the aerosol-generating material does not comprise a fibrous material.

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

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

The aerosolizable or aerosol-generating material may be present on or in the support to form the substrate. The support acts as a carrier on which the layer of aerosol-generating material is formed, thereby facilitating manufacture. The support may provide rigidity to the aerosol-generating material layer to facilitate handling.

The support may be any suitable material that can be used to support the aerosol-generating material. In some cases, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotrope (such as graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some cases, the support may comprise or consist of a tobacco material, such as reconstituted tobacco sheet. In some cases, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the support comprises paper. In some cases, the support itself may be a laminate structure comprising layers of materials selected from the foregoing list. In some cases, the support may also act as a flavor carrier. For example, the support may be impregnated with a flavoring agent or tobacco extract.

Suitably, the thickness of the support layer may be in the range of 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 0.5 mm. The support may comprise more than one layer, the thickness described herein referring to the total thickness of these layers.

In some cases, the support may be magnetic. This function may be used to secure the support in the assembly in use, or may be used to generate a particular aerosol-generating material shape. In some cases, the aerosol-generating substrate may comprise one or more magnets, which may be used to secure the substrate to the induction heater in use.

In some cases, the support may be substantially or completely impermeable to gases and/or aerosols. This prevents the aerosol or gas from passing through the support layer, thereby controlling the flow and ensuring that it is delivered to the user. This may also be used to prevent condensation or other deposition of gas/aerosol in use on the surface of a heater provided in, for example, an aerosol-generating assembly. Thus, the consumption efficiency and hygiene can be improved in some cases.

In some cases, the surface of the support adjacent the aerosol-generating material may be porous. For example, in one instance, the support comprises paper. Porous supports such as paper are particularly suitable for the present invention; a porous (e.g., paper) layer adjoins the aerosol-generating layer and forms a strong bond. The aerosol-generating material is formed from a xerogel and, without being limited by theory, it is believed that the gel-forming slurry portion impregnates the porous support (e.g., paper) such that the support portion is incorporated into the gel as the gel cures and forms crosslinks. This provides a strong bond between the gel and the support (and between the xerogel and the support).

Furthermore, the surface roughness may contribute to the bond strength between the aerosol-generating material and the support. The paper roughness (for the surface abutting the support) may suitably be in the range 50-1000Bekk seconds, suitably 50-150Bekk seconds, suitably 100Bekk seconds (measured in air pressure intervals of 50.66-48.00 kPa). (Bekk smoothness tester is an instrument for measuring the smoothness of a paper surface in which air at 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 permeate between these surfaces is "Bekk smoothness")

Conversely, the surface of the support facing away from the aerosol-generating material may be configured to contact the heater, while a smoother surface may provide more efficient heat transfer. Thus, in some cases, the support is provided with a rougher side adjacent the aerosol-generating material and a smoother side facing away from the aerosol-generating material.

In one particular case, the support may be a paper-backed foil; the paper layer is adjacent to the aerosol-generating material layer and the characteristics discussed in the preceding paragraphs are provided by such abutment. The foil backing is substantially impermeable, thereby providing control of the aerosol flow path. The metal foil backing may also be used to conduct heat to the aerosol generating material.

In another case, the foil layer of the paper-backed foil abuts the aerosol-generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol-generating material from being absorbed into the paper, which may impair its structural integrity.

In some cases, the support is formed from or comprises a metal foil, such as an aluminum foil. The metal support may allow for better conduction of thermal energy to the aerosol-generating material. Additionally, or alternatively, the metal foil may be used as a susceptor in an induction heating system. In particular embodiments, the support comprises a metal foil layer and a support layer, such as paperboard. In these embodiments, the metal foil layer can 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 about 0.017mm to about 2.0mm, suitably about 0.02mm, 0.05mm or 0.1mm to about 1.5mm, 1.0mm or 0.5 mm.

The aerosol-generating material may be made of a gel, and the gel may additionally comprise 0.1wt% to 50wt% solvent. However, inclusion of a solvent in which the flavoring agent is soluble may reduce gel stability and the flavoring agent may crystallize out of the gel. Thus, in some cases, the gel does not contain a solvent in which the flavoring agent is soluble.

One aspect of the present invention relates to an article of manufacture (also referred to herein as a consumable). Consumable refers to an article, part or all of which is consumed by a user during use. The consumable may comprise or consist of an aerosol-generating composition. 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 emits heat to cause the aerosol-generating composition to generate an aerosol in use. The heating element may comprise, for example, a combustible material, or may comprise a susceptor that is capable of heating by penetration with a varying magnetic field.

The articles of the present 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 composition as a shredded sheet, optionally blended with tobacco. Alternatively or additionally, the article provided as a rod may comprise the aerosol-generating composition as a sheet, such as a sheet (e.g., tobacco, or a combination of tobacco and aerosol-generating materials, as described herein) wrapped around a rod of aerosol-generating material. In some embodiments, the article comprises a layer portion of an aerosol-generating composition disposed on a carrier. In various embodiments, the article may have at least one substantially planar (flat) surface.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may be substantially free of plant preparation materials. In particular, in some embodiments, the aerosol-generating film is substantially free of tobacco.

The aerosol-generating film may have a thickness of about 0.015mm to about 1 mm. For example, the thickness may be in the range of about 0.05mm, 0.1mm, or 0.15mm to about 0.5mm, or 0.3 mm.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, which may be pleated (gathered) to form a pleated sheet, or which may be shredded to form a shredded sheet. The shredded sheet material may comprise one or more strands or strips of aerosol-generating material.

In one case, the aerosol-generating film is chopped and blended with another chopped aerosol-generating film.

In one instance, a consumable for use in a non-combustion aerosol-delivery system is provided that includes a planar support (e.g., a continuous aerosol-generating film) that completely covers an aerosol-generating material. Fig. 8 provides a schematic illustration of such a consumable comprising a support layer 4 and an aerosol-generating material layer 2.

The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

In some cases, the discrete portions of aerosol-generating material are substantially circular, cylindrical or hemispherical. In some cases there is a net-like distribution of substantially circular, cylindrical or hemispherical aerosol-generating material.

In some cases, a consumable for use in a non-combustion aerosol-delivery system is provided, the consumable comprising a planar support having a discontinuous aerosol-generating film (comprising a plurality of discrete portions of aerosol-generating material) deposited thereon.

Fig. 9 provides an embodiment of a consumable (401) in which a discontinuous aerosol-generating film comprising a plurality of discrete portions of aerosol-generating material (403) is provided on the consumable.

Susceptors (susceptors) are materials that are capable of being heated by penetrating a varying magnetic field, such as an alternating magnetic field. The heating material may be an electrically conductive material such that penetration of a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that penetration of a varying magnetic field causes hysteresis heating of the heating material. The heating material may be electrically conductive or magnetic, allowing the heating material to be heated by two heating mechanisms.

Induction heating is the process of heating a conductive object by penetrating the object with a varying magnetic field. This 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. alternating current) through the electromagnet. When the electromagnet and the object to be heated are positioned correctly relative to each other such that the resulting varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. This object has an impedance to the current flow. Thus, when such eddy currents are generated in an object, their flow against the object's resistance may cause the object to be heated. This process is known as joule, ohmic or resistive heating.

In some embodiments, the susceptor is in the form of a closed circuit. 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 magnetic material by penetrating the object with a varying magnetic field. Magnetic materials can be considered to contain a number of 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 changing magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipole changes with the applied changing magnetic field. This reorientation of the magnetic dipoles can lead to heat generation in the magnetic material.

Penetration of an object with a varying magnetic field can cause joule heating and hysteresis heating to occur in the object when the object is both conductive and magnetic. In addition, the use of a magnetic material can enhance the magnetic field, thereby enabling the joule heating to be enhanced.

In each of the above processes, a rapid temperature rise and a more uniform heat distribution in the object can be achieved, particularly by selecting a suitable object material and geometry, and a suitable varying magnetic field amplitude and orientation relative to the object, since the heat itself is generated inside the object, rather than by heat conduction from an external heat source. Furthermore, since induction heating and hysteresis heating do not require a physical connection between the varying magnetic field source and the object, the design freedom and control of the heating profile can be greater and the cost can be lower.

The thickness values specified herein are thickness averages. In some cases, the thickness may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

The "thickness" of the aerosol-generating material describes the shortest distance between the first surface and the second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet relative to the first planar surface of the sheet. In some cases, the aerosol-generating composition may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of from about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm. The aerosol-generating material may comprise more than one layer, the thickness described herein referring to the total thickness of these layers.

In some cases, the aerosol-generating material may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of from about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm. The aerosol-generating material may comprise more than one layer, the thickness described herein referring to the total thickness of these layers.

The aerosol-generating composition comprising the aerosol-generating material may have any suitable areal density, such as 30g/m ²-120 g/m². In some embodiments, the aerosol-generating composition may have an areal density of about 30 to 70g/m ², or about 40 to 60g/m ². In some embodiments, the aerosol-generating composition may have an areal density of about 80 to 120g/m ², or about 70 to 110g/m ², or specifically about 90 to 110g/m ². Such area densities may be particularly suitable when the aerosol-generating composition is contained in the aerosol-generating article/component in the form of a sheet or as a shredded sheet (described further below).

One aspect of the present invention provides a non-combustion aerosol provision system comprising an article according to the description herein and a non-combustion aerosol provision device comprising a heater configured to heat without combusting the aerosol-generating article. The non-combustion aerosol provision system may also be referred to as an aerosol-generating assembly. The non-combustion 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 below 350 ℃, such as 120-350 ℃, without combustion. In some cases, the heater may heat the aerosol-generating composition to 140-250 ℃, or 220-280 ℃ in use without combustion. In some cases substantially all of the aerosol-generating material will be less than about 4mm, 3mm, 2mm or 1mm from the heater when in use. In some cases, the material is disposed about 0.010mm to 2.0mm, suitably about 0.02mm to 1.0mm, suitably 0.1mm to 0.5mm from the heater. In some cases, these minimum distances may reflect the thickness of the support supporting the aerosol-generating material. In some cases, the surface of the aerosol-generating material may directly abut the heater.

The heater is configured to heat without burning the aerosol-generating article, thereby heating without burning the aerosol-generating composition. 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 produce heat. The aerosol-generating assembly may comprise a plurality of heaters. The 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 serve the function or function of cooling the gas or aerosol components. In some cases, it may cool the gas component, causing it to condense to form an aerosol. It may also act to isolate the very hot parts of the non-combustion aerosol provision 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 heated non-combustion device. That is, it may contain solid aerosol-generating material (and not liquid aerosol-generating material). In some cases, the aerosol-generating material may comprise tobacco material. A heating non-combustion device is disclosed in WO 2015/062983 A2, which is incorporated herein in its entirety.

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

An aerosol-generating article (which may be referred to herein as an article, cartridge (or consumable) may be suitable for use in a THP, electronic tobacco mixing device or another aerosol-generating device. In some cases, the article may additionally contain a filter and/or cooling element (which has been 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 a vent. These vents may be provided in the side walls of the article. In some cases, vents may be provided in the filter and/or the cooling element. The apertures may allow cool air to be drawn into the article during use, which may mix with the heated volatile components, thereby cooling the aerosol.

When the article is heated in use, venting enhances the production of heated volatile components visible in the article. The heated volatile components are rendered visible by the process of cooling the heated volatile components, while the heated volatile components are supersaturated. Then, droplet formation of the heated volatile component occurs, also called nucleation, and eventually aerosol particles of the heated volatile component are increased in size by further condensation of the heated volatile component and by newly formed droplets of condensed heated volatile component.

In some cases, the ratio of cold air to the sum of heated volatile components and cold air, also referred to as ventilation, is at least 15%. A 15% aeration rate would allow the heated volatile components to become visible by the method described above. The visibility of the heated volatile component enables the user to recognize that the volatile component has been produced and to enhance the sensory experience of the smoking experience.

In another embodiment, the aeration rate is 50% -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 composition may be included in the article/component in sheet form. In some cases, the aerosol-generating composition may be contained in a planar sheet form. In some cases, the aerosol-generating composition may be included as a planar sheet, a pleated (bunched) or pleated sheet, a curled sheet, or a rolled sheet (i.e., in the form of a tube). In some such cases, the aerosol-generating material 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 composition may be formed into a sheet and then shredded and incorporated into an article. In some cases, the shredded sheet material may be mixed with shredded tobacco and incorporated into the article.

In some embodiments, the aerosol-generating material in sheet form may have a tensile strength of about 200N/m to about 900N/m. In some embodiments, the aerosol-generating material may have a tensile strength of 200N/m to 400N/m, or 200N/m to 300N/m, or about 250N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating composition is formed into a sheet and then shredded and incorporated into an aerosol-generating article. In some embodiments, the aerosol-generating material may have a tensile strength of 600N/m to 900N/m, or 700N/m to 900N/m, or about 800N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating composition is included in an aerosol-generating article/component, as a rolled sheet, suitably in the form of a tube.

In some embodiments, the aerosol-generating material is formed as a film on a support. The aerosol-generating film may be a continuous film or a discontinuous film, such as discrete portions of the film arranged on a support.

Referring to fig. 1 and 2, a partial cross-sectional view and a perspective view of one embodiment of an aerosol-generating article 101 is 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 1 shown in fig. 5-7 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 1.

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

The filter assembly 105 includes three sections, a cooling section 107, a filter section 109, and an 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 103 of aerosol-generating composition is positioned towards the distal end 115 of the article 101. In one embodiment, the cooling section 107 is positioned between the aerosol-generating composition body 103 and the filter section 109, adjacent to the aerosol-generating composition body 103, such that the cooling section 107 is in an abutting relationship with the aerosol-generating composition body 103 and the filter section 109. In other embodiments, there may be a separation between the aerosol-generating composition body 103 and the cooling section 107 and between the aerosol-generating composition body 103 and the filter section 109. The filter section 109 is located between the cooling section 107 and the mouth section 111. The mouth end section 111 is positioned toward the proximal end 113 of the article 101, abutting the filter section 109. In one embodiment, the filter section 109 is in an abutting relationship with the mouth end section 111. In one embodiment, the total length of the filter assembly 105 is 37mm-45mm, more preferably the total length of the filter assembly 105 is 41mm.

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

In one embodiment, the total length of the article 101 is 71mm to 95mm, suitably 79mm to 87mm, suitably 83mm.

The axial end of the body 103 of the aerosol-generating composition 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 body 103 of aerosol-generating composition.

The aerosol-generating composition body 103 is attached to the filter assembly 105 by an annular tipping paper (TIPPING PAPER) (not shown) positioned substantially around the circumference of the filter assembly 105 to encase the filter assembly 105 and extend partially along the length of the aerosol-generating composition body 103. In one embodiment, the tipping paper is made from 58GSM standard tipping base paper. In one embodiment, the tipping paper has a length of 42mm to 50mm, suitably 46 mm.

In one embodiment, the cooling section 107 is an annular tube and is positioned around and defines an air gap within the cooling section. The air gap provides a chamber for the flow of heated volatile components generated from the body 103 of aerosol-generating composition. The cooling section 107 is hollow to provide a chamber for aerosol accumulation, but is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 101 is used during insertion into the device 1. In one embodiment, the wall of the cooling section 107 has a thickness of about 0.29mm.

The cooling section 107 provides a physical displacement between the aerosol-generating composition 103 and the filter section 109. The physical displacement provided by the cooling section 107 will provide a thermal gradient over the entire length of the cooling section 107. In one embodiment, the cooling section 107 is configured to provide a temperature difference of at least 40 ℃ between the heated volatile components entering the first end of the cooling section 107 and the heated volatile components exiting the second end of the cooling section 107. In one embodiment, the cooling section 107 is configured to provide a temperature difference of at least 60 ℃ between the heated volatile components entering the first end of the cooling section 107 and the heated volatile components exiting the second end of the cooling section 107. The temperature difference across the length of the cooling element 107 protects the temperature sensitive filter section 109 from the high temperature of the aerosol-generating composition when the aerosol-generating composition 103 is heated by the device 1. If no physical displacement is provided between the filter section 109 and the aerosol-generating composition body 103 and the heating element of the device 1, the temperature-sensitive filter section 109 may be damaged in use and therefore it will not be able to effectively perform its required function.

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

The cooling section 107 is made of paper, which means that it is composed of a material that does not generate a compound of interest, such as a toxic compound, when used adjacent to the heater of the device 1. In one embodiment, the cooling section 107 is made of a helically wound paper tube that provides a hollow lumen, but retains mechanical rigidity. The spiral wound paper tube can meet the strict dimensional accuracy requirements of the high-speed manufacturing process on the length, the outer diameter, the roundness and the straightness of the tube.

In another embodiment, the cooling section 107 is a depression created by a hard plug wrap (plug wrap) or tipping paper. The hard plug wrap or tipping paper is made with sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 101 is used during insertion into the device 1.

The filter section 109 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components of the aerosol-generating material. In one embodiment, the filter section 109 is made of a monoacetate material such as cellulose acetate. The filter section 109 provides cooling and reduced irritation to the heated volatile components without consuming 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 section 109. It may span the diameter of the filter section 109 and be disposed substantially centrally in the filter section 109 along the length of the filter section 109. In other cases, it may be offset in one or more dimensions. In some cases, the capsules, when present, may contain volatile components, such as flavoring agents or aerosol generating agents.

The density of the cellulose acetate tow material of the filter section 109 will control the pressure drop within the filter section 109, which in turn controls the stretch resistance of the article 101. Thus, the choice of material for the filter section 109 is important for controlling the stretch resistance of the article 101. Furthermore, the filter section will fulfill a filtering function in the product 101.

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

The presence of the filter section 109 provides an insulating effect by providing further cooling to the heated volatile components exiting the cooling section 107. This further cooling effect reduces the contact temperature of the user's lips on the surface of the filter section 109.

In one embodiment, the filter section 109 has a length of 6mm-10mm, suitably 8mm.

The mouth-end section 111 is an annular tube and is located around the mouth-end section 111 and defines an air gap within the mouth-end section 111. The air gap provides a chamber for heated volatile components flowing from the filter section 109. The mouth section 111 is hollow to provide a chamber for aerosol accumulation, but is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and during use during insertion of the article into the device 1. In one embodiment, the wall of the mouth end section 111 has a thickness of about 0.29mm. In one embodiment, the length of the mouth end section 111 is about 6-10mm, suitably 8mm.

The mouth end section 111 may be made of a helically wound paper tube that provides a hollow lumen while maintaining critical mechanical stiffness. The spiral wound paper tube can meet the strict dimensional accuracy requirements of the high-speed manufacturing process on the length, the outer diameter, the roundness and the straightness of the tube.

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

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

Referring to fig. 3 and 4, a partial cross-sectional view and a perspective view of one embodiment of an article 301 is shown. The reference symbols shown in fig. 3 and 4 are equivalent to those shown in fig. 1 and 2, but with an increase of 200.

In the embodiment 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 embodiment, the ventilation area 317 is in the form of one or more ventilation holes 317 formed through the outer layer of the article 301. Vents may be located in the cooling section 307 to assist in cooling the article 301. In one embodiment, the ventilation zone 317 comprises one or more rows of cells, and preferably, each row of cells is circumferentially arranged about the article 301 in a cross-section substantially perpendicular to the longitudinal axis of the article 301.

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

In one embodiment, the vent 317 has a uniform size. In another embodiment, the vents 317 are different in size. The vent may be made using any suitable technique, for example, one or more of the following: laser technology, mechanical perforation of the cooling section 307, or pre-perforation of the cooling section 307 prior to forming the article 301. The vent 317 is positioned to provide effective cooling to the article 301.

In one embodiment, each row of ventilation apertures 317 is located at least 11mm from the proximal end 313 of the article, suitably between 17mm and 20mm from the proximal end 313 of the article 301. The vent 317 is positioned such that a user does not block the vent 317 when the article 301 is in use.

As shown in fig. 6 and 7, when the article 301 is fully inserted into the device 1, each row of vent holes is provided between 17mm-20mm from the proximal end 313 of the article 301 such that the vent holes 317 are located outside the device 1. By locating the vent outside the device, unheated air can enter the article 301 through the vent from outside the device 1 to assist in cooling the article 301.

The length of the cooling section 307 is such that when the article 301 is fully inserted into the device 1, the cooling section 307 will be partially inserted into the device 1. The length of the cooling section 307 provides a first function of providing a physical gap between the heater device of the device 1 and the thermo-sensitive filter arrangement 309, and a second function of enabling the vent 317 to be located in the cooling section while also being located outside the device 1 when the article 301 is fully inserted into the device 1. As can be seen from fig. 6 and 7, a large part of the cooling element 307 is located within the device 1. However, a portion of the cooling element 307 extends out of the device 1. It is in this portion of the cooling element 307 that extends out of the device 1 that the vent 317 is located.

Referring now in more detail to fig. 5-7, there is shown an embodiment of a device 1 configured to heat an aerosol-generating composition to vaporize at least one component of the aerosol-generating composition, typically forming an inhalable aerosol. The device 1 is a heating device which releases a compound by heating, not burning, an aerosol-generating composition.

The first end 3 is sometimes referred to herein as the mouth end or proximal end 3 of the device 1, and the second end 5 is sometimes referred to herein as the distal end 5 of the device 1. The device 1 has an on/off button 7 to allow the device 1 as a whole to be turned on and off as desired by the user.

The device 1 comprises a housing 9 for positioning and protecting the various internal components of the device 1. In the embodiment shown, the housing 9 comprises an integral sleeve 11 enveloping the periphery of the device 1, which is covered by a top plate 17 generally defining the "top" of the device 1 and a bottom plate 19 generally defining the "bottom" of the device 1. In another embodiment, the housing includes a front panel, a rear panel, and a pair of opposed side panels in addition to the top panel 17 and the bottom panel 19.

The top plate 17 and/or the bottom plate 19 may be removably secured to the one-piece sleeve 11 to allow easy access to the interior of the device 1, or may be "permanently" secured to the one-piece sleeve 11, e.g., to prevent a user from accessing the interior of the device 1. In one embodiment, panels 17 and 19 are made of a plastic material, including glass-filled nylon, for example, formed by injection molding, while integral sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which opening 20 the article 101, 301 comprising the aerosol-generating composition may be inserted into the device 1 and removed from the device 1 by a user in use.

The housing 9 has a heater device 23, a control circuit 25 and a power supply 27 located or secured therein. In this embodiment, the heater device 23, the control circuit 25 and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from the end), with the control circuit 25 generally located between the heater device 23 and the power supply 27, although other locations are possible.

The control circuit 25 may include a controller, such as a microprocessor device, constructed and arranged to control heating of the aerosol-generating composition in the article 101, 301, as discussed further below.

The power supply 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 means 23 and provides electrical power as needed and under the control of the control circuit 25 to heat the aerosol-generating composition in the article (as discussed to volatilize the aerosol-generating material without causing combustion of the aerosol-generating composition).

The advantage of locating the power supply 27 laterally adjacent the heater means 23 is that a physically larger power supply 25 may be used without making the device 1 as a whole overly lengthy. It will be appreciated that the power supply 25, which is typically physically larger, has a higher capacity (i.e. the total power that can be provided, typically measured in ampere-hours, etc.), and thus the battery life of the device 1 can be longer.

In one embodiment, the heater means 23 is generally in the form of a hollow cylindrical tube having a hollow interior heating chamber 29 into which the article 101, 301 comprising 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 comprised of a plurality of heating elements arranged along the longitudinal axis of the heater device 23. The or each heating element may be annular or tubular, or at least partially annular or partially tubular around its circumference. In one embodiment, the or each heating element may be a thin film heater. In another embodiment, 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 also possible including, for example, induction heating, infrared heating elements heated by emitting infrared radiation, or resistive heating elements formed, for example, of resistive electrical windings.

In one particular embodiment, the heater device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater means 23 is dimensioned such that substantially the whole of the body 103, 303 of the aerosol-generating composition of the article 101, 300 is inserted into the heater means 23 when the article 101, 301 is inserted into the device 1.

The or each heating element may be arranged so that selected regions of the aerosol-generating material can be heated independently, for example sequentially (as discussed above over time) or together (simultaneously) as required.

In this embodiment, heater device 23 is surrounded by insulation 31 along at least a portion of its length. Insulator 31 helps to reduce the amount of heat transferred from heater assembly 23 to the exterior of assembly 1. This helps to reduce the power requirements of the heater device 23, as it generally reduces heat loss. The insulator 31 also helps to keep the exterior of the device 1 cool during operation of the heater device 23. In one embodiment, insulator 31 may be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. That is, insulator 31 may be, for example, a "vacuum" tube, i.e., a tube that has been at least partially evacuated to minimize heat transfer by conduction and/or convection. Other arrangements for insulation 31 are possible, including the use of insulation materials, including, for example, suitable foam-type materials, in addition to or in lieu of double-walled sleeves.

The housing 9 may also include various internal support structures 37 for supporting all internal components as well as the heating device 23.

The device 1 further comprises a collar (collar) 33 extending around the opening 20 and protruding from the opening 20 into the interior of the housing 9, and a substantially tubular chamber 35 between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, in this embodiment, the cooling structure 35f includes a plurality of cooling fins 35f spaced along the outer surface of the chamber 35, and each cooling fin is circumferentially arranged about the outer surface of the chamber 35. When the article 101, 301 is inserted into the device 1 over at least a portion of the length of the hollow chamber 35, an air gap 36 exists between the hollow chamber 35 and the article 101, 301. The air gap 36 surrounds the entire circumference of the article 101, 301 over at least a portion of the cooling section 307.

The collar 33 includes a plurality of ridges 60, the ridges 60 being circumferentially arranged around the periphery of the opening 20 and protruding into the opening 20. The ridge 60 occupies space within the opening 20 such that the opening span of the opening 20 at the location of the ridge 60 is less than the opening span of the opening 20 where the ridge 60 is absent. The ridge 60 is configured to engage with an article 101, 301 inserted into the device to assist in securing it within the device 1. The open spaces (not shown) defined by adjacent pairs of ridges 60 and articles 101, 301 constitute ventilation paths around the exterior of articles 101, 301. These ventilation paths allow hot steam escaping from the articles 101, 301 to leave the device 1 and allow cooling air to flow into the device 1 around the articles 101, 301 in the air gap 36.

In operation, the articles 101, 301 are removably inserted into the insertion point 20 of the device 1, as shown in FIGS. 5-7. With specific reference to fig. 6, in one embodiment, the body of the aerosol-generating composition 103, 303 is positioned towards the distal end 115, 315 of the article 101, 301, fully received within the heater device 23 of the device 1. The proximal ends 113, 313 of the articles 101, 301 extend from the device 1 and function as a user's suction nozzle assembly.

In operation, the heater means 23 will heat the article 101, 301 to vaporise at least one component of the aerosol-generating composition from the body 103, 303 of the aerosol-generating composition.

The primary flow path of the heated volatile components from the aerosol-generating composition body 103, 303 passes axially through the article 101, 301, through the chamber inside the cooling section 107, 307, through the filter section 109, 309, through the mouth end section 111, 313 to the user. In one embodiment, the heated volatile components produced by the aerosol-generating composition are at a temperature of from 60 to 250 ℃, which may be above the user acceptable inhalation temperature. As the heated vaporized components travel through the cooling sections 107, 307, they will cool and some of the vaporized components will condense on the inner surfaces of the cooling sections 107 and 307.

In the embodiment of the article 301 shown in fig. 3 and 4, the cool air will enter the cooling section 307 through vents 317 formed in the cooling section 307. The cold air will mix with the heated vaporized component to provide additional cooling to the heated vaporized component.

Another aspect of the invention provides a method of preparing an aerosol-generating material according to the first aspect.

The method may comprise (a) forming a slurry comprising components of the aerosol-generating material or a precursor thereof and a solvent (typically water), (b) forming a slurry layer, (c) optionally curing the slurry, and (d) drying the slurry to form the aerosol-generating material.

In some cases, less than or equal to about 15wt% of the flavoring added to the slurry is lost in steps (a) - (d), such as less than or equal to 10wt% or less than or equal to 5wt% of the flavoring added to the slurry.

In some cases, the dried aerosol-generating material retains at least about 85wt% of the flavoring added to the slurry, such as at least about 90% or at least about 95% of the flavoring added to the slurry. The amount of components in the slurry may be determined based on the weight of each component added to the slurry. The amount of menthol and glycerin in the dried aerosol-generating material may be determined by gas chromatography.

Step (a) may comprise combining and mixing the aerosol-generating agent, the binder, the flavouring agent, the filler, the solvent (typically water) and any optional other components of the aerosol-generating material to form a slurry.

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

In some cases, (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 be performed sequentially.

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

In various embodiments, the slurry comprises a binder, an aerosol generator, a flavoring agent, and a filler. The slurry may comprise these components on a dry weight basis in any of the proportions given herein in relation to the composition of the aerosol-generating material. For example, the slurry may comprise:

-an aerosol generator in an amount of about 7wt% to about 13wt% of the slurry;

-a binder;

-a flavoring agent in an amount of about 35wt% to about 50wt% of the slurry; and

-A filler;

wherein each of the above amounts is calculated on a dry weight basis. The slurry also contains a solvent (typically water).

In one embodiment, the slurry comprises:

-an aerosol generator in an amount of about 7wt% to about 13wt%;

-a binder in an amount of about 1wt% to about 57wt%;

-a flavoring agent in an amount of about 35wt% to about 50wt%; and

-A filler in an amount of about 1% to about 50% by weight;

The curing step (c) may comprise adding a curing agent (also referred to as a cross-linking agent) to the slurry. Suitable curing/crosslinking agents and amounts thereof are as described above. For example, the slurry may contain sodium, potassium or ammonium alginate as a gel precursor, and a setting or crosslinking agent containing a calcium source (such as calcium chloride, calcium acetate or calcium lactate) may be added to the slurry to form a calcium alginate gel.

In some embodiments, the curing agent is applied by spraying the slurry with the curing agent.

The total amount of curing agent/cross-linking agent, such as a calcium source, may be from 0.5wt% to 7wt% (calculated on a dry weight basis). Too little curing agent/cross-linking agent may be added, which may result in the aerosol-generating material not being able to stabilize the components of the aerosol-generating material and in these components being detached from the aerosol-generating material. Too much addition of curing agent or crosslinking agent may result in the aerosol-generating material being very viscous and thus having poor operability.

Alginate is an alginic acid derivative and is typically a high molecular weight polymer (10-600 kDa). Alginic acid is a copolymer of β -D-mannuronic acid (M) and α -L-guluronic acid (G) units (blocks) linked together by (1, 4) -glycosidic linkages to form a polysaccharide. Upon addition of the calcium cations, the alginate crosslinks to form a gel. Alginates with high G monomer content are more prone to gel formation upon addition of a calcium source. Thus, in some cases, the gel precursor may comprise alginate in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginic acid copolymer are alpha-L-guluronic acid (G) units.

For example, when the only binder present is a cellulosic binder such as CMC, gel curing in step (c) may not be required. When a non-cellulosic binder such as alginate is present, the slurry may further comprise and/or a curing or crosslinking agent may be applied to the slurry. In this case, the method may further include the step (c) of curing the slurry.

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

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

During step (d), the slurry may be heated to remove at least about 60wt%, 70wt%, 80wt%, 85wt%, or 90wt% of the solvent. The solvent is typically water.

After the drying step (d), the aerosol-generating material may have a water content as defined above. In particular, the aerosol-generating material may have a weight percent (WWB) of 1 to 15. Suitably, the water content of the aerosol-generating material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (based on Wet Weight) (WWB). The moisture content of the aerosol-generating material may be determined, for example, by Karl-Fischer (Karl-Fischer) titration or gas chromatography using a thermal conductivity detector (GC-TCD).

The aerosol-generating material, optionally in the form of a film, may be formed by combining and mixing the aerosol-generating agent, binder, flavour, filler, solvent (typically water) and any optional other components to form a slurry and subsequently heating the slurry to volatilize at least some of the solvent to form an aerosol-generating film. The slurry may be heated to remove at least about 60wt%, 70wt%, 80wt%, 85wt%, or 90wt% of the solvent.

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

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 aerosol-generating material. Thus, in connection with the slurry aspects of the present invention, the discussion herein regarding solid compositions is explicitly disclosed. In particular, aspects and embodiments of the components of the aerosol-generating material and the amounts thereof defined above apply mutatis mutandis to the slurries of the invention and to the methods of the invention.

In a further aspect, the invention also provides an aerosol-generating material obtainable or obtained by the method of the invention. The various aspects and embodiments of the components of the aerosol-generating material and the amounts thereof defined above apply mutatis mutandis to this further aspect of the invention.

According to one aspect of the present invention, a method of generating an aerosol using a non-combustion aerosol delivery system herein is provided. 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 about 220 ℃ to about 280 ℃. In some embodiments, the method includes heating at least a portion of the aerosol-generating material to a temperature of about 220 ℃ to about 280 ℃ during the lifetime.

As used herein, "during use" refers to a single period of use of the non-combustion aerosol supply system by a user. The lifetime starts at the point where power is first supplied to at least one heating unit present in the heating assembly. After a period of time has elapsed from the start of the use period, the device will be ready for use. The use period ends at the point in time when no power is supplied to any heating element in the aerosol-generating device. The end of the period of use may coincide with the point in time when the smoking article is depleted (the point in time when the user considers the total particulate matter production (mg) per puff to be unacceptably low). The period of use will have the duration of multiple puffs. The lifetime 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 period of use may have a duration of 2-5 minutes, or 3-4.5 minutes, or 3.5-4.5 minutes, or suitably 4 minutes. The lifetime may be initiated by a user actuating a button or switch on the device causing at least one heating element to begin to warm up.

All weight percentages herein (expressed as wt%) are calculated on a Dry Weight (DWB) basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. The weight quoted on a dry weight basis refers to the entire slurry, aerosol-generating composition or aerosol-generating material other than water, and may include components that are themselves liquid at room temperature and pressure, such as glycerin. Conversely, weight percent (WWB) based on wet weight refers to all components including water.

For the avoidance of doubt, where the term "comprising" is used in this specification to define the invention or a feature of the invention, embodiments are also disclosed in which the use of the term "consisting essentially of …" or "consisting of …" in place of "comprising" is able to define the invention or a feature thereof. Reference to a material "comprising" certain features means that the features are included in, contained within, or maintained within the material.

Any feature described with respect to one aspect of the invention is expressly disclosed in connection with any other aspect described herein.

Exemplary embodiments

A further embodiment of the invention is as follows:

1. an aerosol-generating material comprising:

-a binder;

-A filler.

2. The aerosol-generating material of embodiment 1, wherein the flavoring agent comprises menthol.

3. The aerosol-generating material of embodiment 2, wherein the flavoring agent consists of menthol.

4. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating agent comprises one or more of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillin, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

5. The aerosol-generating material of embodiment 4, wherein the aerosol-generating agent consists of one or more of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillin, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

6. The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating agent comprises glycerin.

7. The aerosol-generating material of embodiment 6, wherein the aerosol-generating agent consists of glycerin.

8. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises the aerosol-generating agent in an amount of from 8wt% to 13wt% (on a dry weight basis).

9. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises the aerosol-generating agent in an amount of 9wt% to 12wt% (on a dry weight basis).

10. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises the aerosol-generating agent in an amount of from 10wt% to 12wt% (on a dry weight basis).

11. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises the aerosol-generating agent in an amount of from greater than 10wt% to less than 12wt% (on a dry weight basis).

12. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises the aerosol-generating agent in an amount of from 10.3wt% to 11.9wt% (on a dry weight basis).

13. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the flavoring agent in an amount of 35wt% to 45wt% (dry weight basis).

14. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the flavoring agent in an amount of 36wt% to 45wt% (dry weight basis).

15. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the flavoring agent in an amount of 37wt% to 43wt% (dry weight basis).

16. The aerosol-generating material of any of the preceding embodiments, wherein the binder comprises alginate and/or pectin.

17. The aerosol-generating material of any of the preceding embodiments, wherein the binder comprises alginate and pectin.

18. The aerosol-generating material of any of embodiments 1-16, wherein the binder consists of alginate and/or pectin.

19. The aerosol-generating material of any preceding embodiment, wherein the binder consists of alginate and pectin.

20. An aerosol-generating material according to any preceding embodiment, wherein the aerosol-generating material is substantially free of cellulosic binder.

21. The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating material is substantially free of carboxymethyl cellulose.

The aerosol-generating material of any of embodiments 1-17, wherein the binder comprises a cellulosic binder and a non-cellulosic binder.

The aerosol-generating material of embodiment 21a, wherein the cellulosic binder comprises, consists essentially of, or consists of carboxymethyl cellulose.

The aerosol-generating material of embodiment 21a or 21b, wherein the non-cellulosic binder comprises, consists essentially of, or consists of alginate and/or guar gum.

The aerosol-generating material of embodiment 21c, wherein the non-cellulosic binder comprises, consists essentially of, or consists of alginate and guar gum.

The aerosol-generating material of any of embodiments 21a-21d, wherein the binder comprises, consists essentially of, or consists of CMC, alginate, and guar gum.

22. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the binder in an amount of from 1wt% to 57wt% (dry weight basis).

23. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the binder in an amount of from 5wt% to 50wt% (dry weight basis).

24. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the binder in an amount of from 15wt% to 35wt% (dry weight basis).

25. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the binder in an amount of 20wt% to 30wt% (on a dry weight basis).

26. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises the binder in an amount of 20wt% to 25wt% (dry weight basis).

27. The aerosol-generating material of any of the preceding embodiments, wherein the filler comprises wood pulp.

28. The aerosol-generating material of any of the preceding embodiments, wherein the filler consists of wood pulp.

29. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises filler in an amount of from 5wt% to 45wt% (dry weight basis).

30. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material comprises filler in an amount such as from 10wt% to 40wt% (dry weight basis).

31. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises filler in an amount of from 18wt% to 35wt% (dry weight basis).

32. The aerosol-generating material of any of the preceding embodiments, wherein the aerosol-generating material comprises filler in an amount of 20wt% to 30wt% (dry weight basis).

33. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material further comprises a cross-linking agent.

34. The aerosol-generating material of embodiment 33, wherein the cross-linking agent comprises calcium ions.

35. The aerosol-generating material of embodiment 34, wherein the cross-linking agent comprises calcium lactate and/or calcium acetate.

36. The aerosol-generating material of embodiment 35, wherein the cross-linking agent consists of calcium lactate and/or calcium acetate.

The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating material comprises from 1wt% to 10wt% of the cross-linking agent (on a dry weight basis).

The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating material comprises from 3wt% to 8wt% of the cross-linking agent (on a dry weight basis).

The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating material comprises from 5wt% to 7wt% of the cross-linking agent (on a dry weight basis).

37. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material is substantially free of tobacco.

38. An aerosol-generating material according to any of the preceding embodiments, wherein the aerosol-generating material is in the form of a sheet.

39. An aerosol-generating material according to any of the preceding embodiments, the aerosol-generating material being in the form of a film on a support.

40. An aerosol-generating composition comprising an aerosol-generating material according to any of embodiments 1 to 39.

41. An aerosol-generating composition consisting essentially of the aerosol-generating material of embodiments 1 to 39.

42. An aerosol-generating composition consisting of an aerosol-generating material according to any of embodiments 1 to 39.

43. A consumable for use with a non-combustion aerosol-supplying device, the consumable comprising an aerosol-generating composition according to any of embodiments 40 to 42 or an aerosol-generating material according to any of embodiments 1 to 39.

44. A non-combustion aerosol provision system comprising the consumable of embodiment 43 and a non-combustion aerosol provision device, wherein the non-combustion aerosol provision device is configured to generate aerosol from the consumable when the consumable is used with the non-combustion aerosol provision device.

45. The system of embodiment 44, wherein the non-combustion aerosol provision device comprises a heater configured to heat without combusting the consumable.

46. Use of an aerosol-generating material according to any of embodiments 1 to 39 or an aerosol-generating composition according to any of embodiments 41 to 43 for generating an aerosol.

S1, slurry, wherein the slurry comprises the following components:

-an aerosol generator in an amount of about 7wt% to about 13wt% of the slurry on a dry weight basis;

-a binder;

-a flavoring agent in an amount of about 35wt% to about 50wt% of the slurry on a dry weight basis;

-a filler; and

-A solvent.

S2. the slurry of embodiment S1, wherein the flavoring agent comprises menthol.

S3, the slurry of the embodiment S2, wherein the flavoring agent consists of menthol.

S4. the slurry of any of the previous embodiments, wherein the aerosol generating agent comprises one or more of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillin, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixtures, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

S5. the slurry of embodiment S4, wherein the aerosol generating agent consists of one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillin, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixtures, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

S6. the slurry of any of the preceding embodiments, wherein the aerosol generating agent comprises glycerol.

S7. the slurry of embodiment S6, wherein the aerosol generating agent consists of glycerol.

S8. the slurry of any of the preceding embodiments, wherein the slurry comprises aerosol generating agent in an amount of 8wt% -13wt% (dry weight basis).

S9. the slurry of any of the preceding embodiments, wherein the slurry comprises aerosol generating agent in an amount of 9wt% -12wt% (dry weight basis).

S10. the slurry of any of the preceding embodiments, wherein the slurry comprises aerosol generating agent in an amount of 10wt% -12wt% (dry weight basis).

S11. the slurry of any of the preceding embodiments, wherein the slurry comprises an aerosol generating agent in an amount of more than 10wt% to less than 12wt% (on a dry weight basis).

S12. the slurry of any of the preceding embodiments, wherein the slurry comprises aerosol generating agent in an amount of 10.3wt% -11.9wt% (dry weight basis).

S13. the slurry of any of the preceding embodiments, wherein the slurry comprises a flavoring agent in an amount of 35wt% -45wt% (dry weight basis).

S14. the slurry of any of the preceding embodiments, wherein the slurry comprises flavoring agent in an amount of 36wt% -45wt% (dry weight basis).

S15. the slurry of any of the preceding embodiments, wherein the slurry comprises flavoring agent in an amount of 37wt% -43wt% (dry weight basis).

S16. the slurry of any of the preceding embodiments, wherein the binder comprises alginate and/or pectin.

S17. the slurry of any of the preceding embodiments, wherein the binder comprises alginate and pectin.

S18. the slurry of any of embodiments S1-S16, wherein the binder consists of alginate and/or pectin.

S19. the slurry of any of the preceding embodiments, wherein the binder consists of alginate and pectin.

S20. the slurry of any of the preceding embodiments, wherein the slurry is substantially free of cellulosic binders.

S21. the slurry of any of the preceding embodiments, wherein the slurry is substantially free of carboxymethyl cellulose.

S22. the slurry of any of the preceding embodiments, wherein the slurry comprises the binder in an amount of 1wt% -57wt% (dry weight basis).

S23. the slurry of any of the preceding embodiments, wherein the slurry comprises the binder in an amount of 5wt% -50wt% (dry weight basis).

S24. the slurry of any of the preceding embodiments, wherein the slurry comprises the binder in an amount of 15wt% -35wt% (dry weight basis).

S25. the slurry of any of the preceding embodiments, wherein the slurry comprises the binder in an amount of 20wt% -30wt% (dry weight basis).

S26. the slurry of any of the preceding embodiments, wherein the slurry comprises the binder in an amount of 20wt% -25wt% (dry weight basis).

S27. the slurry of any of the preceding embodiments, wherein the filler comprises wood pulp.

S28. the slurry of any of the preceding embodiments, wherein the filler consists of wood pulp.

S29. the slurry of any of the preceding embodiments, wherein the slurry comprises filler in an amount of 5wt% -45wt% (dry weight basis).

S30. the slurry of any of the preceding embodiments, wherein the slurry comprises filler in an amount such as 10wt% -40wt% (dry weight basis).

S31. the slurry of any of the preceding embodiments, wherein the slurry comprises filler in an amount of 18wt% -35wt% (dry weight basis).

S32. the slurry of any of the preceding embodiments, wherein the slurry comprises filler in an amount of 20wt% -30wt% (dry weight basis).

S33. the slurry of any of the preceding embodiments, wherein the slurry further comprises a cross-linking agent.

S34. the slurry of embodiment S33, wherein the cross-linking agent includes calcium ions.

S35. the slurry of embodiment S34, wherein the cross-linking agent comprises calcium lactate and/or calcium acetate.

S36. the slurry of embodiment S35, wherein the cross-linking agent is composed of calcium lactate and/or calcium acetate.

S36a. the slurry of any of the preceding embodiments, wherein the slurry comprises 1wt% to 10wt% cross-linking agent (on a dry weight basis).

S36b. the slurry of any of the preceding embodiments, wherein the slurry comprises 3wt% to 8wt% cross-linking agent (on a dry weight basis).

S36c. the slurry of any of the preceding embodiments, wherein the slurry comprises 5wt% to 7wt% cross-linking agent (on a dry weight basis).

S37. the slurry of any of the preceding embodiments, wherein the slurry is substantially free of tobacco.

S38. the slurry of any of the preceding embodiments, wherein the solvent comprises water.

S39. the slurry of any of the preceding embodiments, wherein the solvent is water.

Embodiment 47. A method of manufacturing an aerosol-generating material, the method comprising:

(a) Forming a slurry of any of embodiments S1-S39;

(b) Forming a layer of slurry;

(c) Optionally curing the slurry; and

(D) The slurry is dried to form an aerosol-generating material.

Embodiment 48 the method of embodiment 47, wherein the aerosol-generating material is the aerosol-generating material of any of embodiments 1 to 39.

Embodiment 49 the method of embodiment 47 or 48, wherein less than or equal to about 15wt% of the flavoring added to the slurry is lost in steps (a) - (d).

Embodiment 50 the method of embodiment 49, wherein less than or equal to about 10wt% of the flavoring added to the slurry is lost in steps (a) - (d).

Embodiment 51 the method of embodiment 50, wherein less than or equal to 5wt% of the flavoring added to the slurry is lost in steps (a) - (d).

Embodiment 52 an aerosol-generating material obtainable by the method of any of embodiments 47-51.

Embodiment 53. An aerosol-generating material obtained by the method of any one of embodiments 47-51.

Examples

Gas chromatography measurement method

Reagent(s)

A1.1 solvent: methanol- (HPLC grade or the like)

A1.2 Internal Standard (ISTD): n-heptane or anethole (purity > 99.0%)

A1.3 control: menthol- (purity > 99.0%)

A1.4 carrier gas: high purity helium (at least 99.995%)

A1.5 assist gas: flame Ionization Detectors (FID) use air, FID uses high purity (at least 99.995%) hydrogen,

A1.6 other reagents: ultrapure water

A1.7 extraction solution: extraction solvent (A1.1) containing internal standard (A1.2)

A1.8.1 extraction solution

(2.5.+ -. 0.01) G of n-heptane (ISTD) was weighed into a weighing vessel and added to a 5L volumetric flask containing 400-500mL of methanol. Mix well to dissolve n-heptane overnight. After dissolution, the correct volume was made up with methanol.

A1.8.2 calibration Stock (SA)

About (8.0.+ -. 0.01) g menthol is accurately weighed and directly put into a 200mL volumetric flask. After each compound was weighed, the weighing vessel was rinsed into a volumetric flask with the extraction solution. Make up to volume with the extraction solution and mix the contents of the volumetric flask by repeatedly inverting the flask.

Instrument and equipment

Gas chromatograph equipped with split/no split injection system, one analytical column, flame Ionization (FID) detector and data analysis system.

GC column: phenomenex ZB WAXplus (or equivalent); 30m 0.53mm inner diameter 1.00 μm

Analytical balance (precision 0.1 mg)

Capacity glassware

150ML Erlenmeyer flask with stopper

Capped amber vials (60 mL and 40 mL) for storing the solutions in a refrigerator

GC vial and cap

Pressure sealing tool (crimping tool)

Magnetic stirrer

Rail type/horizontal shaking flask bed

Glass pipette class A

Scheme for the production of a semiconductor device

A calibration graph of menthol analyte is constructed by diluting a calibration stock (A1.8.2) to provide a series of calibration standards and analyzing the calibration standards by gas chromatography.

The dried aerosol-generating material was extracted according to the following protocol. The extract was then analyzed by gas chromatography. The peak area is used as a measure of the analyte concentration.

Weigh 0.25g of a sample of dry aerosol-generating material into a 150mL Erlenmeyer flask

Add 50mL of extraction solution using a calibrated dispenser.

Plug volumetric flask.

Set on an orbital/horizontal shake flask shaker at 150rpm for 3h.

Some of the extract was filtered through a 0.45 μm PTFE filter into a 2mL amber GC vial using a 5mL plastic syringe.

The vials were pressure sealed and labeled.

Chromatographic column parameters

Inlet/injector parameters

	Front-MNPH
		Mode	Without split flow
Temperature (. Degree. C.)	270
		Pressure (psi)	5.1
Split ratio	N/A
		Flow split (mL/min)	N/A
Total flow (mL/min)	48
		Injection volume (mu L)	1
Carrier saving mode (Gas Saver)	Opening the valve

Detector parameters

Oven parameters

Initial temperature	120℃
		Initial time of	4min
Rate of temperature rise	20℃/min
		End point temperature	230℃
Endpoint time	2.5min

In order to be able to convert the concentration to a dry weight basis, the water concentration of the aerosol-generating material was also measured by karl-fischer titration.

Example 1 (reference)

The reference aerosol-generating material is made by forming a slurry comprising water, menthol, glycerol, alginate, pectin, and wood pulp, casting the slurry, applying calcium lactate to the casting slurry and drying the slurry. The amounts of the components added to the slurry were as follows (all on a dry weight basis):

Then, the amount of menthol in the dry aerosol-generating material was measured using gas chromatography according to the protocol described above. The average menthol content measured in the dry material was about 28.5wt% (compared to 40wt% in the initial slurry) in 45 samples. Thus, the samples showed significant menthol loss (about 29% loss rate) during the production process.

Example 2

The aerosol-generating material according to the invention was prepared by forming a slurry comprising water, menthol, glycerol, alginate, pectin and wood pulp, casting the slurry, applying calcium lactate to the cast slurry (in the same amount as in example 1) and drying the slurry. The menthol and glycerol content of the aerosol-generating material was then measured using gas chromatography according to the protocol described above.

The amounts of the components added to the slurry were as follows (all on a dry weight basis):

The amount of menthol in the dry aerosol-generating material was then measured on two different samples of the composition, found to be 39.85wt% (sample 1) and 38.74wt% (sample 2). Thus, the samples showed less than 5% menthol loss rate during the production process.

From this example, it can be seen that the reduction in the amount of glycerol unexpectedly reduces menthol loss in the aerosol-generating material as compared to reference example 1.

Claims

1. An aerosol-generating material comprising:

-about 7wt% to about 13wt% of an aerosol generator;

-a binder;

-about 35wt% to about 50wt% of a flavoring agent; and

-A filler.

2. An aerosol-generating material according to claim 1, comprising:

-about 7wt% to about 13wt% of an aerosol generator;

-from about 1wt% to about 57wt% of a binder;

-about 35wt% to about 50wt% of a flavoring agent; and

-From about 1wt% to about 50wt% of a filler;

Wherein these amounts are calculated on a dry weight basis.

3. An aerosol-generating material according to claim 1 or claim 2, wherein the flavouring agent comprises menthol.

4. An aerosol-generating material according to any preceding claim, wherein the aerosol-generating agent comprises one or more of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixtures, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

5. An aerosol-generating material according to any preceding claim, wherein the aerosol-generating agent comprises glycerol.

6. An aerosol-generating material according to any of the preceding claims, wherein the aerosol-generating material comprises an aerosol-generating agent in an amount of about 8wt% to about 13 wt%.

7. An aerosol-generating material according to any preceding claim, wherein the aerosol-generating material comprises a flavouring in an amount of from about 35wt% to about 45 wt%.

8. An aerosol-generating material according to any of the preceding claims, wherein the binder comprises alginate and/or pectin.

9. An aerosol-generating material according to any preceding claim, wherein the aerosol-generating material is substantially free of cellulosic binder.

10. An aerosol-generating material according to any one of the preceding claims, wherein the aerosol-generating material is substantially free of carboxymethyl cellulose.

11. An aerosol-generating material according to any of claims 1-8, wherein the binder comprises a cellulosic binder and a non-cellulosic binder.

12. An aerosol-generating material according to claim 11, wherein the cellulosic binder comprises carboxymethyl cellulose; and/or wherein the non-cellulosic binder comprises alginate and/or guar gum.

13. An aerosol-generating material according to any of the preceding claims, wherein the aerosol-generating material comprises a binder in an amount of about 1wt% to about 57 wt%.

14. An aerosol-generating material according to any preceding claim, wherein the filler comprises wood pulp.

15. An aerosol-generating material according to any of the preceding claims, wherein the aerosol-generating material comprises filler in an amount of about 5wt% to about 45 wt%.

16. An aerosol-generating material according to any of the preceding claims, wherein the aerosol-generating material further comprises a cross-linking agent.

17. An aerosol-generating material according to claim 16, wherein the cross-linking agent comprises calcium ions, such as wherein the cross-linking agent comprises calcium lactate and/or calcium acetate.

18. An aerosol-generating material according to any preceding claim, wherein the aerosol-generating material is substantially free of tobacco.

19. An aerosol-generating composition comprising an aerosol-generating material according to any preceding claim.

20. A consumable for a non-combustion aerosol-supplying device, the consumable comprising an aerosol-generating composition according to claim 19.

21. A non-combustion aerosol provision system comprising the consumable of claim 20 and a non-combustion aerosol provision device, wherein the non-combustion aerosol provision device is configured to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol provision device.

22. The system of claim 21, wherein the non-combustion aerosol provision device comprises a heater configured to heat without combusting the consumable.

23. Use of an aerosol-generating material according to any of claims 1 to 18 or an aerosol-generating composition according to claim 19 for generating an aerosol.

24. A slurry, comprising:

-about 7wt% to about 13wt% of an aerosol generator;

-a binder;

-about 35wt% to about 50wt% of a flavoring agent; and

-A filler;

Wherein these weights are calculated on a dry weight basis, and

-A solvent.

25. A method of manufacturing an aerosol-generating material, the method comprising:

(a) Forming a slurry comprising

-About 7wt% to about 13wt% of an aerosol generator;

-a binder;

-about 35wt% to about 50wt% of a flavoring agent; and

-A filler;

Wherein these weights are calculated on a dry weight basis, and

-A solvent;

(b) Forming a layer of the slurry;

(c) Optionally curing the slurry; and

(D) Drying the slurry to form the aerosol-generating material.

26. The method of claim 25, wherein the flavoring added to the slurry loses less than or equal to about 15wt%, such as less than or equal to 10wt% or less than or equal to 5wt%, of the flavoring added to the slurry in steps (a) - (d).

27. The slurry of claim 24 or the method of claim 25 or 26, wherein the solvent is water.

28. An aerosol-generating material obtainable by a method according to any one of claims 25 to 27.