KR20240040081A - Consumables for use with aerosol delivery devices - Google Patents

Abstract

A method of manufacturing a consumable (24) for use with a non-flammable aerosol delivery system (2) is provided, wherein the consumable (24) includes a support (30) and an aerosol generating material (32). The method includes (a) providing a support (30); (b) surface treating at least a portion of the first surface 28 of the support 30; and (c) applying an aerosol-generating material (32) to at least a portion of the first surface (28) of the support (30). The surface treatment of step (b) includes altering one or more chemical or physical properties of surface 28, wherein the physical property modifications to surface 28 include perforating or embossing support 30. This is achieved by one or more processes that do not contain

Description

Consumables for use with aerosol delivery devices

The present disclosure relates to the field of non-flammable aerosol delivery systems, particularly including consumables for use with an aerosol delivery device, methods for making consumables for use with an aerosol delivery device, and consumables and aerosol delivery devices. It relates to an aerosol delivery system.

Smoking articles such as cigarettes, cigars, etc. produce tobacco smoke by burning tobacco during use. Alternatives to these types of articles release the compounds from the substrate material by heating without combustion, thereby releasing an inhalable aerosol or vapor. These may be referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol presentation devices.

One example of such a product is a heating device that releases compounds by heating, but not burning, an aerosol-like material, which can be referred to as a solid aerosol-generating material. This solid aerosol-generating material may, in some cases, include tobacco material. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Several different arrangements are known for volatilizing at least one component of a solid aerosol-generating material.

As another example, there are hybrid devices. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further comprises a solid aerosol generating material (which may or may not include tobacco material) whose components are incorporated in an inhalable vapor or aerosol to create an inhaled medium.

According to a first aspect of the present disclosure, there is provided a method of making a consumable for use with a non-flammable aerosol delivery system, wherein the consumable includes a support and an aerosol generating material, the method comprising:

(a) providing a support,

(b) surface treating at least a portion of the first surface of the support, and

(c) applying an aerosol-generating material to at least a portion of the first surface of the support,

The surface treatment of step (b) includes altering one or more chemical or physical properties of the surface, wherein the physical property modifications to the surface are performed by one or more processes that do not involve perforating or embossing the support. achieved.

According to a second aspect of the disclosure, there is provided a consumable comprising an aerosol-generating material and a support made according to the method of the first aspect of the disclosure.

According to a third aspect of the disclosure, there is provided an aerosol-providing device for use with a consumable manufactured by a method according to the first aspect of the disclosure, wherein the device comprises at least a portion of the aerosol-generating material supported on the consumable. It includes a heater assembly configured to heat.

According to a fourth aspect of the disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and consumables manufactured by a method according to the first aspect of the disclosure.

According to a fifth aspect of the disclosure, an aerosol generating device is used to generate an aerosol from a consumable according to the first aspect of the disclosure using an aerosol generating device having at least one aerosol generator positioned to heat, but not combust, the consumable during use. Methods for doing so are provided; Here the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

Additional features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure given by way of example and with reference to the accompanying drawings.

1 shows a schematic diagram of an embodiment of an aerosol delivery device and an embodiment of a consumable manufactured according to an embodiment of the method of the present disclosure;
Figure 2 shows a first embodiment of a support used in the manufacture of the consumable of Figure 1;
Figure 3 shows the support of Figure 2, surface treated according to a first embodiment of the method of the present disclosure;
Figure 4 shows the support of Figure 3 after aerosol-generating material has been applied to the support;
Figure 5 shows the support of Figure 2 after surface treatment according to a second embodiment of the method of the present disclosure;
Figure 6 shows the support of Figure 5 after aerosol-generating material has been applied to the support;
Figure 7 shows the support of Figure 6 separated into two consumables;
Figure 8 shows the support of Figure 2 in a surface treatment process according to a third embodiment of the method of the present disclosure;
Figure 9 shows the support of Figure 5 after aerosol generating material has been applied to the support.

Consumables in this description may alternatively be referred to as articles.

In some embodiments, the consumable includes an aerosol generating material. The consumables include an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one It may include one or more fragrances, one or more aerosol-former materials, and/or one or more other functional materials.

A device for heating the aerosol-generating material with which the consumable will be used is part of a non-flammable aerosol delivery system. Non-flammable aerosol delivery systems are aerosol-generating materials such as electronic cigarettes, tobacco heating products, and hybrid systems for generating aerosols using a combination of aerosol-generating materials to produce compounds from aerosol-generating materials without combustion. emit them.

According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating materials of which the aerosol delivery system (or a component thereof) is non-combustible or combustible to facilitate delivery of at least one substance to a user. It is an unrivaled aerosol delivery system.

In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but the presence of nicotine in the aerosol generating material. Please note that is not a requirement.

In some embodiments, the non-flammable aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. One example of such a system is a tobacco heating system.

In some embodiments, the non-flammable aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of which can be heated. Each of the aerosol-generating materials may be in the form of a solid, liquid, or gel, for example, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with non-flammable aerosol presentation devices. These consumables are sometimes referred to as articles throughout this disclosure.

In some embodiments, a non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device thereof, can include a power source and controller. The power source may be, for example, a power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate that can be energized to distribute power in the form of heat to an aerosol generating material or to a heat transfer material proximate the exothermic power source.

In some embodiments, a non-flammable aerosol delivery system can include a region for receiving consumables, an aerosol generator, and an aerosol generation region, housing, mouthpiece, filter, and/or aerosol modifier.

In some embodiments, consumables for use with a non-flammable aerosol delivery device include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece. , and/or an aerosol modifier.

According to a first aspect of the present disclosure, there is provided a method of manufacturing a consumable for use with an apparatus for heating a non-flammable aerosol delivery system, wherein the consumable includes a support and an aerosol generating material, the method comprising:

(a) providing a support,

(b) surface treating at least a portion of the first surface of the support, and

(c) applying an aerosol-generating material to at least a portion of the first surface of the support,

The surface treatment of step (b) includes altering one or more chemical or physical properties of the surface, wherein the physical property modifications to the surface are performed by one or more processes that do not involve perforating or embossing the support. achieved.

In any of the preceding embodiments, the surface treatment of step (b) is such that the strength of the bond created between the aerosol-generating material and the support is greater than the strength of the bond created between the aerosol-generating material and the untreated portion of the first surface of the support. Provides increased strength of the bond created between the treated portions of the first surface of the.

The strength of the bond between the aerosol-generating material and the surface of the support on which it is applied can be measured by assessing the maximum tensile stress required to separate or tear the aerosol-generating material from that surface when pulled in a direction perpendicular to the surface. there is. The maximum tensile stress is often the tensile stress required to cause the aerosol-generating material to begin to separate from the surface. Once separation begins, the tensile stress required to continue separation of the aerosol-generating material from the surface will be lower than that required to initiate separation.

The increased strength of the bond to the treated portions of the first surface of the support is advantageous because it will result in a reduction in the likelihood of the aerosol-generating material delaminating or unintentionally separating from the surface of the support. . Such reduction in the likelihood of delamination results in an increase in the shelf life or period of time that the consumable product can be stored without delamination of the consumable product.

In any of the above embodiments, treating the surface in step (b) provides a treated surface that is less reactive than an untreated surface. In some embodiments, the reactivity results in a reduced likelihood of chemical corrosion of treated portions of the surface. It is advantageous to reduce the reactivity of a treated surface because it reacts with the aerosol-generating material applied to it, the aerosols generated when the aerosol-generating material is heated, or the condensate resulting from the production of the aerosols. Because it is not desirable to do so. Such reactions can lead to chemical corrosion of the first surface of the support. Chemical corrosion of the first surface of the support can be irritating or impair the proper functioning of the consumable and/or non-flammable aerosol delivery system.

In any of the above embodiments, changes in the physical properties of the treated surface resulting from step (b) include changes at a microscopic scale.

In an embodiment of any of the above embodiments, the support is a laminate, the laminate includes at least two layers, and the first layer of the laminate forms a first surface of the support.

In any of the above embodiments, the first surface of the support comprises a metal or metal alloy. In some embodiments, the first surface of the support includes a foil or film of metal or metal alloy.

In any of the above embodiments, the first surface of the support comprises aluminum or an aluminum alloy. In some embodiments, the first surface of the support includes a foil or membrane of aluminum or aluminum alloy.

In any of the above embodiments, the support includes a second layer, and the second layer is formed from a material suitable for forming a substrate. The second layer may be or include, for example, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. .

In any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in a non-flammable aerosol delivery device. In some embodiments, the support includes polyether ether ketone (PEEK). Such embodiments provide that the support can be reused and that the consumables are less affected by any condensation in the non-flammable aerosol delivery device than consumables comprising a support that incorporates the use of an adsorbent material for structural purposes. It has the advantage of receiving

In any of the preceding embodiments, the method includes:

(d) separating the support into two or more smaller parts of the desired shape and size. This step has the advantage that the support can be processed when it has a size that makes it easy to handle and allows processing of the support in an efficient and economical manner. The subsequent separation of the support into a plurality of smaller parts may be separation into parts of appropriate size for use as consumables, or it may be further separated into a plurality of consumables at a later time. .

In any of the above embodiments, the surface treatment of step (b) includes electrostatic coating of at least a portion of the first surface of the support. In some embodiments, the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support using a primer, and the surface treatment of step (b) further comprises (e) curing at least a portion of the primer. , where step (e) is performed subsequent to step (b) and before step (c).

In some embodiments where the electrostatic coating includes electrostatic coating of at least a portion of the first surface of the support using a primer, and the primer is subsequently cured, curing may take the form of baking the support.

Electrostatic coating of at least a portion of a support is a suitable method of processing the support because the support may be configured to be flat or substantially flat and free of surface features that would promote electrostatic deposition of disproportionately or undesirably large amounts. You can. For example, sharp edges promote deposition of disproportionately large amounts of static electricity. In addition, the support may also be constructed to be free of surface features that would promote deposition of disproportionately or undesirably low amounts of electrostatics. For example, recesses promote deposition of disproportionately small amounts of electrostatic charge.

In any of the above embodiments, the surface treatment of step (b) includes chemical treatment of at least a portion of the first surface of the support.

In any of the above embodiments, the chemical treatment of step (b) includes chemically etching at least a portion of the first surface of the support. Chemically etching at least a portion of the support surface has the advantage that, at a microscopic level, the surface area of the etched portion of the first surface of the support is increased. This improves the bond between the aerosol generating material and the surface of the support.

In an embodiment of any of the above embodiments, the surface treatment of step (b) comprises exposing at least a portion of the first surface of the support or at least a portion of the coated first surface of the support to a source of ultraviolet radiation. Includes.

In an embodiment of any of the above embodiments, exposure of at least a portion of the first surface of the support or at least a portion of the coated first surface to the ultraviolet radiation source of step (b) comprises exposing the exposed first surface of the support to the ultraviolet radiation source. Causes modifications to the structure or surface chemistry of the surface. Coating of the first surface of the support may promote or otherwise alter the properties of the surface structure or surface chemistry of the treated portions of the first surface of the support. Such alterations in surface structure or surface chemistry can promote stronger bonding between the aerosol-generating material and the first surface of the support.

In any of the above embodiments, the surface treatment of step (b) includes plasma surface treatment of at least a portion of the first surface of the support.

In an embodiment of any of the above embodiments, the plasma surface treatment of step (b) includes one or more of cleaning the surface of the support, activating the surface of the support, coating the support, and etching the support. Again, such surface treatment promotes a stronger bond between the aerosol-generating material and the first surface of the support.

In any of the above embodiments, step (b) includes applying the aerosol-generating material as two or more separate portions of the aerosol-generating material to the first surface of the support.

In an embodiment of any of the above embodiments, the application of the aerosol-generating material to at least a portion of the support is application of an aerosol-generating material slurry.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated or energized in any other way. For example, aerosol-generating materials can be in the form of solids, liquids or semi-solids (eg gels), which may or may not contain active substances and/or flavorants.

The aerosol-generating material may include one or more active substances and/or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

Aerosol-generating materials may include binders such as gelling agents and aerosol formers. Optionally, substances and/or fillers to be delivered may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol generating material is substantially free of botanical material. In particular, in some embodiments, the aerosol generating material is substantially free of tobacco.

The aerosol-generating material may comprise or be in the form of an aerosol-generating membrane. The aerosol-generating membrane may include an aerosol former and a binder such as a gelling agent. Optionally, substances and/or fillers to be delivered may also be present. The aerosol-generating membrane may be substantially free of botanical material. In particular, in some embodiments, the aerosol generating material is substantially free of tobacco.

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

The aerosol-generating membrane combines a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol former, and one or more substances to be delivered to form a slurry and then heats the slurry to release at least a portion of the solvent. It can be formed by volatilizing to form an aerosol-generating film.

The slurry can be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

In some embodiments, the aerosol-generating material may be or include an “amorphous solid.” In some embodiments, the aerosol-generating material includes an aerosol-generating membrane that is an amorphous solid. Amorphous solids may be “monolithic solids.” Amorphous solids may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid, such as a liquid, inside them. In some embodiments, the amorphous solid may comprise, for example, from about 50%, 60%, or 70% by weight of the amorphous solid to about 90%, 95%, or 100% by weight of the amorphous solid. .

The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

In any of the above embodiments, the method includes:

(g) allowing the aerosol-generating material slurry to harden or causing the aerosol-generating material slurry to harden;

The aerosol-generating slurry is cured to form an aerosol-generating material.

In any of the above embodiments, the aerosol-generating material is an aerosol-generating membrane.

In any of the above embodiments, the surface treatment of step (b) includes surface treating one or more individual portions of the first surface of the support, and the application of the aerosol-generating material in step (c) includes surface treatment. and applying an aerosol-generating material to one or more individual portions of the first surface of the support.

In any of the above embodiments, the surface treatment of step (b) includes surface treating substantially all of the first surface of the support, and the application of the aerosol-generating material in step (c) includes treating the first surface of the support. 1 Involves application of an aerosol-generating material to one or more separate portions of a surface.

In any of the above embodiments, the application of the aerosol-generating material in step (c) includes application of the aerosol-generating material to three or more separate portions of the first surface of the support, the individual portions being adjacent to the first surface of the support. It is arranged in a grid pattern on the first surface.

In any of the above embodiments, one or more of the individual portions of the aerosol-generating material applied in step (c) have substantially circular, longitudinally extending stripes in the plane of the first surface of the support. These are stripes that contain at least one curve or angle, or are stripes that form a mosaic-like shape.

In any of the above embodiments, the at least two individual parts of the aerosol-generating material applied in step (c) have different compositions. This has the advantage that the user of the consumable may have different experiences from different individual parts of the aerosol-generating material on the consumable. This may make the use of the consumable more satisfying and/or more interesting than the use of a consumable with only one composition of aerosol-generating material.

In any of the above embodiments, the application of the aerosol-generating material is performed two or more times. This can have the effect of producing a thicker aerosol-generating material on the support than a single application of the aerosol-generating material. The increased thickness may result in a greater amount of aerosol being generated by the aerosol-generating material and/or providing the aerosol for a longer period of time than if only one application of the aerosol-generating material occurred.

In any of the above embodiments, at least one individual portion of the aerosol-generating material applied in step (c) has a shape and/or color indicative of the composition of the aerosol-generating material forming the individual portion.

In any of the above embodiments, the method includes the additional method step of (f) subjecting the support to further processing, wherein the further processing includes perforating or embossing at least a portion of the support.

In any of the above embodiments, the support includes a susceptor. In some embodiments, the support is a laminate, at least one layer of the laminate is a susceptor, and the treated first surface of the support is a susceptor.

A susceptor is a material that can be heated by penetration by a changing magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that its penetration by a changing magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor material may be a magnetic material, whereby penetration by a changing magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor can be both electrically conductive and magnetic, so that the susceptor can be heated by both heating mechanisms. A device configured to generate a changing magnetic field is referred to as a magnetic field generator.

The susceptor may comprise steel or an iron alloy such as an iron nickel alloy or a ferromagnetic metal such as iron. Some exemplary ferromagnetic metals are grade 410 stainless steel, or grade 420 stainless steel, or 400 series stainless steel, such as grade 430 stainless steel, or similar grades of stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, especially paramagnetic, conductive material such as aluminum. In paramagnetic conducting materials, inductive heating occurs only by resistive heating due to eddy currents. Alternatively, the susceptor may include a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated only by hysteresis losses. The susceptor was either Phytherm 230 (having a composition (wt% = wt%) of 50 wt% Ni, 10 wt% Cr and the remainder Fe) or Pytherm 260 (50 wt% Ni, 9 wt% Cr and the remainder It may include commercial alloys such as those having a composition containing Fe.

The susceptor, in any of the above embodiments, may be a metal or metal alloy. The susceptor may be a metal foil, optionally an aluminum foil or an iron foil, in some embodiments of any of the above embodiments. Alternatively, the susceptor may be any conductor that can be sprayed or vapor deposited onto the material forming the support, in some embodiments of any of the above embodiments.

In any of the above embodiments, the aerosol generating material comprises an active agent.

As used herein, the active agent may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substances may be selected from, for example, nutraceuticals, nootropics, and psychoactives. The active substances may occur naturally or be obtained synthetically. The active substances are, for example, nicotine, caffeine, taurine, terpenes from non-cannabinoids, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or It may include constituents, derivatives, or combinations thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other botanicals.

The active substance may include one or more components, derivatives or extracts of cannabis, such as cannabinoids or terpenes.

In some embodiments, the active substance includes nicotine. In some embodiments, the active agent includes caffeine, melatonin, or vitamin B12.

The active substance may comprise or be derived from one or more herbal medicines or their components, derivatives or extracts. As used herein, the term "herbal medicine" means extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk. , shells, etc., but are not limited to any material derived from plants. Alternatively, the material may contain active compounds naturally present in herbal medicines obtained synthetically. This material may be in the form of liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, etc. Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, and flax. ), ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin ), papaya, rose, sage, tea (e.g. green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaf. (bay leaves), cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elder. Elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom. blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm ), lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine ( theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v. (Mentha piperita citrata c.v.), Mentha piperita c.v. (Mentha piperita c.v.), Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suablens Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is tobacco.

In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from rooibos and fennel.

In some embodiments, the aerosol generating material includes a flavor or flavoring agent.

As used herein, the terms “flavour” and “flavourant” refer to the taste, aroma, or aroma desired in a product for adult consumers, when local regulations permit. ) or other somatosensorial sensations. These include naturally occurring flavoring ingredients, plants, extracts of plants, synthetically obtained ingredients, or combinations thereof (e.g. tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen. , cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumbers, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery. , cascarilla, nutmeg, sandalwood oil, bergamot, geranium, khat, naswar, betel nut, hookah, pine, honey essence, rose oil, vanilla, lemon. Oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, Coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnuts, hibiscus. , bay, mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano. ), paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, cassis, valerian. , pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena. (verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or irritants, sugars and/or Sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives , such as charcoal, chlorophyll, minerals, herbal medicines, or breath fresheners. These may be imitation, synthetic or natural components or blends thereof. These may be in any suitable form, for example liquids such as oils, solids such as powders or gases.

In some embodiments, the flavor includes menthol, spearmint, and/or peppermint. In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus, and/or red berry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

In some embodiments, flavor is a sensation intended to achieve a somatosensory sensation that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the scent or taste nerves. These may include agents that provide heating, cooling, tingling, and numbing effects. A suitable thermogenic agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

Aerosol-generating materials include aerosol-generating agents. In some embodiments, an aerosol generating agent may include one or more ingredients capable of forming an aerosol. In some embodiments, the aerosol generating agent is glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillatate, ethyl lau. One or more of nitrate, diethyl subrate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. It can be included. In particular examples, the aerosol generating agent includes glycerol.

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

In some embodiments, the aerosol generating material is from about 0.1%, 0.5%, 1%, 3%, 5%, 7% or 10% to about 50%, 45%, 40% by weight. , may contain 35%, 30% or 25% by weight of aerosol generating agent (all calculated on a dry weight basis). Aerosol generating agents can act as plasticizers. For example, the aerosol-generating material may include 0.5 to 40%, 3 to 35%, or 10 to 25% by weight of aerosol generating agent.

In some embodiments, the aerosol generating material is from about 5%, 10%, 20%, 25%, 27%, or 30% by weight to about 60%, 55%, 50%, 45% by weight. %, 40% or 35% by weight of aerosol generating agent (DWB). For example, the aerosol-generating material may include 10 to 60 weight percent, 20 to 50 weight percent, 25 to 40 weight percent, or 30 to 35 weight percent aerosol generating agent.

In some embodiments, the aerosol generating material comprises up to about 80% by weight of aerosol generating agent, such as about 40 to 80%, 40 to 75%, 50 to 70%, or 55 to 65% by weight. You can do it (DWB).

Aerosol-generating materials may also include gelling agents. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, gelling agents include alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. It contains one or more compounds selected from the group comprising: For example, in some embodiments, the gelling agent is alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, gum acacia, fumed Contains one or more of silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin and can be combined with a curing agent (e.g., a calcium source) while forming the aerosol-generating material. In some cases, the aerosol generating material may include calcium-crosslinked alginate and/or calcium-crosslinked pectin.

In some embodiments, the gelling agent includes one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

In some embodiments, the cellulose gelling agent is hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CAB), It is selected from the group consisting of cellulose acetate butyrate (CAP), cellulose acetate propionate (CAP), and combinations thereof.

In some embodiments, the gelling agent includes (or is one or more of) hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent is agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan. , starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

In some embodiments, the gelling agent includes alginate, and the alginate is present in the aerosol-generating material in an amount of 10 to 30% by weight of the aerosol-generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent includes alginate and at least one additional gelling agent, such as pectin.

In some embodiments, the aerosol generating material is from about 1%, 5%, 10%, 15%, 20% or 25% by weight to about 60%, 50%, 45%, 40% by weight. % or 35% by weight of gelling agent (all calculated on dry weight basis). For example, the aerosol-generating material may include 1 to 50%, 5 to 45%, 10 to 40%, or 20 to 35% by weight of gelling agent.

In some embodiments, the aerosol-generating material comprises from about 20%, 22%, 24%, or 25% to about 30%, 32%, or 35% by weight of a gelling agent (all on a dry weight basis). calculated). For example, the aerosol-generating material may include 20 to 35 weight percent or 25 to 30 weight percent of a gelling agent.

In some cases, the aerosol generating material is from about 1%, 5%, 10%, 15% or 20% by weight to about 60%, 50%, 40%, 30% or 25% by weight. It may contain a gelling agent (DWB). For example, the aerosol-generating material may include 10 to 40%, 15 to 30% or 20 to 25% by weight of gelling agent (DWB).

In examples, the aerosol-generating material includes a gelling agent and a filler, wherein the gelling agent and filler comprise from about 10%, 20%, 25%, 30% or 35% to about 60% by weight of the aerosol-generating material; Taken together in amounts of 55% by weight, 50% by weight or 45% by weight. In examples, the aerosol-generating material includes a gelling agent and a filler, the gelling agent and filler being in an amount of about 20 to 60%, 25 to 55%, 30 to 50%, or 35 to 45% by weight of the aerosol-generating material. are taken together as

In some examples, the aerosol-generating material (i.e., without considering the amount of filler) is about 5%, 10%, 15%, 20%, 25%, 30%, or 35% by weight of the aerosol-generating material. % to about 60%, 55%, 50% or 45% by weight of gelling agent. In examples, the aerosol-generating material (i.e., without considering the amount of filler) is about 5 to 60%, 20 to 60%, 25 to 55%, 30 to 50%, or 35 to 35% by weight of the aerosol-generating material. It contains a gelling agent in an amount of 45% by weight.

In some examples, the alginate comprises the gelling agent in an amount of about 5 to 40%, or 15 to 40%, by weight of the aerosol generating material. That is, the aerosol-generating material includes alginate in an amount of about 5 to 40% by weight, or 15 to 40% by weight, based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes alginate in an amount of about 20 to 40%, or about 15% to 35% by weight of the aerosol-generating material.

In some examples, pectin is included in the gelling agent in an amount of about 3 to 15% by weight of the aerosol generating material. That is, the aerosol-generating material includes pectin in an amount of about 3 to 15% by weight based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes pectin in an amount of about 5 to 10% by weight of the aerosol-generating material.

In some examples, guar gum is included in the gelling agent in an amount of about 3 to 40% by weight of the aerosol generating material. That is, the aerosol-generating material includes guar gum in an amount of about 3 to 40% by weight based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes guar gum in an amount of about 5 to 10% by weight of the aerosol-generating material. In some examples, the aerosol-generating material includes guar gum in an amount of about 15 to 40%, or about 20 to 40%, or about 15 to 35% by weight of the aerosol-generating material.

In examples, the alginate is present in an amount of at least about 50 wt% of the gelling agent. In examples, the aerosol-generating material includes alginate and pectin, with a ratio of alginate to pectin from 1:1 to 10:1. The ratio of alginate to pectin is typically >1:1, i.e., alginate is present in greater amounts than pectin. In examples, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

The aerosol-generating material can (a) form a slurry comprising the components of the aerosol-generating material or their precursors, (b) form a layer of the slurry, (c) cure the slurry to form a gel, and (d) dry. It can be formed in a way to form an aerosol generating material.

(b) Forming a layer of slurry typically involves spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting slurry.

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

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

In examples, the slurry includes a gelling agent, an aerosol former material, and an active agent. The slurry may include these ingredients in any of the ratios given herein in relation to the composition of the aerosol generating material. For example, the slurry may include (on a dry weight basis):

Gelling agent and, optionally, filler - the amount of gelling agent and filler taken together is about 10 to 60 wt% of the slurry;

aerosol former material in an amount of about 40 to 80% by weight of the slurry; and

Optionally, the active material in an amount of up to about 20% by weight of the slurry.

c) Curing the gel may include adding a setting agent to the slurry. For example, the slurry can include sodium, potassium, or ammonium alginate as a gel-precursor, and a curing agent comprising a calcium source (e.g., calcium chloride) can be added to the slurry to form a calcium alginate gel. there is.

In examples, the curing agent is calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, Or it includes or consists of a combination thereof. In some examples, the curing agent includes or consists of calcium formate and/or calcium lactate. In certain instances, the curing agent includes or consists of calcium formate. The present inventors have found that, typically, using calcium formate as a curing agent results in an aerosol-generating material with greater tensile strength and greater resistance to elongation.

The total amount of hardener, such as calcium source, may be 0.5 to 5 wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1 wt%, 2.5 wt% or 4 wt% to about 4.8 wt% or 4.5 wt%. The inventors have discovered that adding too little curing agent may result in an aerosol-generating material in which the aerosol-generating material components are not stabilized and these components are shed from the aerosol-generating material. The inventors have discovered that adding too much curing agent makes the aerosol-generating material very sticky and consequently poor handling.

If the aerosol-generating material does not contain tobacco, larger amounts of hardener may need to be applied. Accordingly, in some cases the total amount of curing agent may be 0.5 to 12 wt%, such as 5 to 10 wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 5 wt%, 6 wt% or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol generating material will generally not contain any tobacco.

In examples, supplying the curing agent to the slurry includes spraying the curing agent onto the slurry, such as the top surface of the slurry.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10 to 600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. am. By adding calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with high G monomer content form gels more easily upon addition of a calcium source. Accordingly, in some cases, the gel-precursor is an alginate wherein at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units. May contain salt.

In examples, d) drying removes from about 50 wt %, 60 wt %, 70 wt %, 80 wt % or 90 wt % to about 80 wt %, 90 wt % or 95 wt % (WWB) of water in the slurry.

In examples, d) drying reduces the casting material thickness by at least 80%, suitably by 85% or 87%. For example, the slurry is cast to a thickness of 2 mm, resulting in a thickness of 0.2 mm of dried aerosol generating material.

In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry includes about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% (WWB) of solvent.

In instances where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol-generating material. Accordingly, the discussion herein regarding solid compositions is explicitly disclosed in combination with the slurry embodiment of the invention.

Aerosol-generating materials may include flavors. Suitably, the aerosol generating material may comprise up to about 80%, 70%, 60%, 55%, 50% or 45% by weight of flavor. In some cases, the aerosol-generating material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% (all calculated on a dry weight basis) of flavoring agent. For example, the aerosol generating material may include 1 to 80%, 10 to 80%, 20 to 70%, 30 to 60%, 35 to 55%, or 30 to 45% by weight of flavor. . In some cases, the flavor includes, consists essentially of, or consists essentially of menthol.

Aerosol-generating materials may include fillers.

In some embodiments, the aerosol-generating material is less than 60% by weight, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 10% by weight. Contains 20% by weight of filler.

In other embodiments, the aerosol-generating material includes less than 20% filler, suitably less than 10% or less than 5% filler. In some cases, the aerosol-generating material includes less than 1% by weight filler, and in some cases, no filler.

In some such cases, the aerosol-generating material contains at least 1% filler, such as at least 5%, at least 10%, at least 20%, at least 30%, at least 40%, or at least 50% by weight. Contains % filler. In some embodiments, the aerosol-generating material includes 5 to 25 weight percent filler.

The filler (if present) may be one or more suitable inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. May contain adsorbents. The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

In certain embodiments involving filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

Without being bound by theory, it is believed that including fibrous fillers in an aerosol generating material can increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided in a sheet, for example where the sheet of aerosol-generating material surrounds a rod of aerosolizable material.

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

The aerosol-generating material may include one or more active substances and/or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

In some embodiments, the aerosol-generating material additionally includes an active agent. For example, in some cases, the aerosol-generating material additionally includes tobacco material and/or nicotine. In some embodiments, the aerosol generating material includes powdered tobacco and/or nicotine and/or tobacco extract.

In some cases, the aerosol-generating material may include 5 to 60% tobacco material and/or nicotine by weight (calculated on a dry weight basis). In some cases, the aerosol generating material is from about 1%, 5%, 10%, 15%, 20% or 25% by weight to about 70%, 60%, 50%, 45% by weight. , may contain 40%, 35% or 30% by weight of active substance (calculated on dry weight basis). In some cases, the aerosol generating material is from about 1%, 5%, 10%, 15%, 20% or 25% by weight to about 70%, 60%, 50%, 45% by weight. , may contain 40%, 35% or 30% by weight of tobacco material (calculated on dry weight basis). For example, the aerosol-generating material may include 10 to 50 weight percent, 15 to 40 weight percent, or 20 to 35 weight percent tobacco material. In some cases, the aerosol-generating material may include from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% nicotine by weight ( Calculated on dry weight basis). For example, the aerosol-generating material may include 1 to 20%, 2 to 18%, or 3 to 12% nicotine by weight.

In some cases, the aerosol-generating material includes an active agent such as tobacco extract. In some cases, the aerosol-generating material may include 5 to 60% tobacco extract by weight (calculated on a dry weight basis). In some cases, the aerosol generating material is from about 5%, 10%, 15%, 20% or 25% by weight to about 60%, 50%, 45%, 40%, 35% by weight. or 30% by weight tobacco extract (calculated on dry weight basis). For example, the aerosol-generating material may include 10 to 50 weight percent, 15 to 40 weight percent, or 20 to 35 weight percent tobacco extract. Tobacco extract may be used wherein the aerosol generating material comprises from 1% 1.5%, 2% or 2.5% to about 6%, 5%, 4.5% or 4% nicotine by weight (calculated on a dry weight basis). ) may contain nicotine in concentration. In some cases, the aerosol-generating material may be free of nicotine other than the nicotine produced from tobacco extract.

In some embodiments, the aerosol-generating material does not include tobacco material but includes nicotine. In some such cases, the aerosol-generating material may include from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% nicotine by weight. (Calculated on dry weight basis). For example, the aerosol-generating material may include 1 to 20%, 2 to 18%, or 3 to 12% nicotine by weight.

In some cases, the total content of active material and/or flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of active substance and/or flavor may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine and flavor may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavor may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

The aerosol-generating component may include one or more active substances. In examples, the aerosol-generating material includes one or more active substances, for example, up to about 20% by weight of the aerosol-generating material. In examples, the aerosol-generating material comprises the active agent in an amount from about 1%, 5%, 10%, or 15% to about 20%, 15%, 15%, or 5% by weight of the aerosol-generating material. It can be included.

Active substances may include physiologically and/or olfactory active substances that are included in the aerosol-generating composition to achieve a physiological and/or olfactory response.

The tobacco material may be present in the aerosol-generating composition in an amount of about 50 to 95 wt%, or about 60 to 90 wt%, or about 70 to 90 wt%, or about 75 to 85 wt%.

Tobacco material can be in any form but is typically fine-cut (e.g., cut into narrow shreds). The finely chopped tobacco material can advantageously be blended with the aerosol-generating material to provide an aerosol-generating composition in which the tobacco material and aerosol-generating material are evenly dispersed throughout the aerosol-generating composition.

In examples, the tobacco material is one of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and/or tobacco extract. It may include more. Surprisingly, the inventors have found that it is possible to use relatively large amounts of lamina tobacco in an aerosol generating composition and also provide an acceptable aerosol when heated by a non-flammable aerosol delivery system. Lamina tobacco typically provides excellent organoleptic properties. In examples, the tobacco material includes lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material includes cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

In some embodiments, one or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some cases, the aerosol generating material may further include an emulsifying agent to emulsify the molten flavor during manufacturing. For example, the aerosol-generating material may comprise from about 5% to about 15% by weight emulsifier (calculated on a dry weight basis), suitably about 10% by weight. Emulsifiers may include acacia gum.

In some embodiments, the aerosol-generating material is a hydrogel and contains less than about 20% water, calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15 wt%, 12 wt%, or 10 wt% water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

The aerosol-generating material may have any suitable moisture content, for example, from 1% to 15% by weight. Suitably, the moisture content of the aerosol-generating material is from about 5%, 7% or 9% by weight to about 15%, 13% or 11% by weight (WWB), most suitably about 10%. The moisture content of the aerosol-generating material can be determined, for example, by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

In some cases, the aerosol-generating material may consist or consist essentially of a gelling agent, water, an aerosol-generating agent, flavor, and, optionally, an active agent.

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

In examples, the aerosol-generating material consists or consists essentially of a gelling agent, an aerosol-generating agent, an active agent, and water. In examples, the aerosol-generating material consists of or consists essentially of a gelling agent, an aerosol-generating agent, and water.

In examples, the aerosol-generating material does not include flavoring agents; In certain instances, the aerosol-generating material does not include an active agent.

In some embodiments, the aerosol generating material includes:

- 1 to 60% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol generating agent; and

- 0.1 to 80% by weight of flavor;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material includes 1 to 80% flavor by weight (dry weight basis).

In some embodiments, the aerosol generating material includes:

- 1 to 50% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol generating agent; and

- 30 to 60% by weight of flavor;

These weights are calculated on a dry weight basis.

In alternative embodiments of the aerosol-generating material, the aerosol-generating material includes:

- 1 to 60% by weight of gelling agent;

- 5 to 60% by weight of aerosol generator; and

- 10 to 60% by weight of tobacco extract;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material includes:

- 1 to 60% by weight of gelling agent;

- 20 to 60% by weight of aerosol generator; and

- 10 to 60% by weight of tobacco extract;

These weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material includes 20 to 35 weight percent of a gelling agent; 10 to 25% by weight of aerosol former material; Filler comprising 5 to 25% by weight of fibers; and 35 to 50% by weight of flavoring agent and/or active substance.

In some cases, the aerosol-generating material may consist or consist essentially of a gelling agent, an aerosol-generating agent, tobacco extract, water and, optionally, flavor. In some cases, the aerosol generating material may consist or consist essentially of glycerol, alginates and/or pectins, tobacco extract and water.

In some embodiments, the aerosol-generating material may have the following composition (DWB): a gelling agent (preferably (including alginate); Tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%; An aerosol generator (preferably comprising glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

In one embodiment, the aerosol generating material includes about 20% alginate gelling agent, about 48% Virginia tobacco extract, and about 32% glycerol by weight (DWB).

The “thickness” of an aerosol-generating material refers to the shortest distance between the first and second surfaces. In embodiments where 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 opposite the first planar surface of the sheet.

In some cases, the aerosol-forming aerosol-generating material layer has a thickness of about 0.015 mm to about 1.5 mm, suitably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Suitably, the thickness may range from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.

In some cases, the aerosol-generating material can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

Materials with a thickness of 0.2 mm are particularly suitable. The aerosol-generating material may include more than one layer, and the thickness described herein refers to the collective thickness of these layers.

If the aerosol generating material is too thick, heating efficiency is reduced. This adversely affects power consumption during use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; Very thin materials are difficult to cast and brittle, which can adversely affect aerosol formation when used.

The thickness specified herein is the average thickness of the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some examples, the aerosol-generating material in sheet form can have a tensile strength of about 200 N/m to about 900 N/m. In some instances, for example where the aerosol-generating material does not include filler, the aerosol-generating material has a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. It may be N/m.

These tensile strengths may be particularly suitable for embodiments where the aerosol-generating material is formed into a sheet and then broken and incorporated into the aerosol-generating article. In some instances, such as when the aerosol-generating material includes a filler, the aerosol-generating material has a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m. You can. These tensile strengths may be particularly suitable for embodiments in which the aerosol-generating solid is included in the aerosol-generating article/assembly as a rolled sheet, suitably in the form of a tube.

In some examples, the aerosol-generating material in sheet form can have a tensile strength of about 200 N/m to about 2600 N/m. In some examples, the aerosol-generating material can have a tensile strength of 600 N/m to 2000 N/m, or 700 N/m to 1500 N/m, or about 1000 N/m. These tensile strengths may be particularly suitable for embodiments where the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

The aerosol-generating material can have any suitable areal density, such as from 30 g/m2 to 120 g/m2. In some cases, the sheet has a density similar to cut rag tobacco, and such that the mixture of these materials cannot be easily separated) from 80 to 120 g/m2, or about 70 to 110 g/m2. m2, or in particular about 90 to 110 g/m2, or suitably about 100 g/m2. In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25 to 60 g/m2 and may be used to wrap an aerosolable material such as a cigarette.

All weight percentages (expressed in wt%) described herein are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. The weight presented on a dry weight basis refers to the extract or slurry or the entire material other than water, and may include components that are liquid themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages given on a wet weight basis refer to all ingredients including water.

Aerosol-generating materials may include colorants. The addition of colorants can change the visual appearance of the aerosol-generating material. The presence of colorants in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched with other components of the aerosol-generating material or with other components of the article comprising the aerosol-generating material.

Various colorants can be used depending on the desired color of the aerosol generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown or black. Other colors are also envisioned. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which can impart the aerosol generating material with a brown appearance. In these embodiments, the color may be similar to that of other components of the aerosol-generating material (e.g., tobacco material). In some embodiments, the addition of a colorant to the aerosol-generating material renders the aerosol-generating material visually indistinguishable from other components of the aerosol-generating material.

The colorant can be incorporated during forming the aerosol-generating material (e.g., when forming a slurry comprising the materials forming the aerosol-generating material) or while forming the aerosol-generating material (e.g., by spraying onto the aerosol-generating material). It may later be applied to aerosol-generating materials.

In any or some of the above embodiments, talcum powder, calcium carbonate powder, or other powder is applied to the exposed surface of at least one individual portion of the aerosol-generating material. This can reduce the level of tackiness or adhesion of the aerosol-generating material.

In the following discussions of the accompanying drawings, where the same element is present in more than one embodiment, the same reference numerals are used for that element throughout, wherein where similar elements are present, like reference numerals (same numerals (a number plus a multiple of 100) is used.

Referring to Figure 1, the aerosol presentation device 2 includes a casing 4 within which a heater assembly 6 is located. The heater assembly (6) consists of a heating chamber (8) and an aerosol generator (10). The aerosol generator 10 may be an electrical resistance heater or a magnetic field generator for use with a susceptor.

The heating chamber 8 defines an opening or mouth 12 at the first end of the heating chamber 8 . At the opposite end of the heating chamber 8 there is an aperture 14. Aperture 14 is in fluid communication with mouthpiece 16 via conduit 18.

Also located inside the casing 4 is a controller 20 that is in electronic communication with the aerosol generator 10 and controls the functions of the aerosol generator 10. Controller 20 may include memory (not shown) in which one or more tables related to the operation of heater 10 may be stored. Aerosol generator 10 and controller 20 are powered by a power source 22. Power source 22 is a rechargeable battery. In other embodiments, the power source may be other suitable sources of power.

The aerosol delivery device (2) is suitable for use with consumables (24). Consumable 24 includes one or more individual portions of aerosol-generating material 32 supported on a first surface 28 of consumable 24 . Individual portions of aerosol-generating material 32 are supported in a square grid pattern on first surface 28. Other non-illustrated embodiments of consumable 24 include more or fewer individual pieces of aerosol-generating material 32 than shown in FIG. 1 , including a single piece of aerosol-generating material 32 . and those parts may be distributed in an arbitrary pattern on the first surface 28. Although individual portions of aerosol-generating material 32 are shown in FIG. 1 as having an approximately circular shape, they may have other shapes in other embodiments. Examples of methods for producing or manufacturing consumables 24 are described below.

Referring to Figure 2, to begin the production of consumables 24, a support 30 is provided. Support 30 comprises a longitudinally extending sheet of flexible laminate material comprising first and second layers 36, 38. The first layer 36 has a surface that is the first surface 28 and is composed of a sheet of aluminum foil. The first layer is less than 0.025 mm thick. In other non-illustrated embodiments, the material of first layer 36 may be an aluminum alloy or another suitable material, such as a different metal or metal alloy.

The second layer 38 is formed of card. The second layer 38 is sufficiently rigid to support the first layer and provide a support with a fixed configuration.

The length and width of support 30 as shown in FIGS. 1 and 2 are for illustrative purposes only. Support 30 may have different lengths and widths without departing from the scope of the present disclosure.

3, substantially all of first surface 28 (area 40) is electrostatically coated with a primer using known electrostatic coating techniques. In this technique, the primer has a negative electrostatic charge and the first layer 36 is grounded and has a positive electrostatic charge. The primer is sprayed towards the first surface 28 and the primer is attracted to the first surface 28 . The support 30 is then baked at an appropriate temperature for an appropriate amount of time to allow the primer applied to the area 40 to cure.

The primer modifies at least one or more of the chemical and/or physical properties of region 40 of first surface 28. For example, the primer may be used to determine the strength at which the aerosol-generating material will bind to the surface of area 40 compared to the strength with which the aerosol-generating material would have bonded to surface 28 before the surface of area 40 was treated by application of the primer. Strength can be increased.

Additionally or alternatively, the primer of at least the region 40 may be configured to (aerosol-generating material and the foil, the foil and the aerosol to be generated within the heating chamber 8 of the aerosol providing device 2, or the foil and the aerosol within the heating chamber 8). This will make the aluminum foil of the first layer 36 less likely to corrode (as a result of reactions between any condensates) than the foil of the first layer 36 that has not been primed.

Referring to Figure 4, once the primer of at least area 40 has cured, individual portions of aerosol-generating material 32, in the form of a slurry of aerosol-generating material, are applied to the surface of area 40 in a grid pattern. The slurry is applied to surface 40 using known aerosol-generating material slurry application techniques, for example, from an aerosol-generating material slurry reservoir (not shown) through one or more nozzles (not shown).

The individual portions of the aerosol-generating material 32 are all substantially circular, in the plane of the first surface of the support. In other non-illustrated examples of the method of the present disclosure, one or more of the individual portions of the aerosol-generating material 32 have longitudinally extending stripes, the shape of the stripes comprising at least one curve or angle. and/or may have a tessellate shape.

The individual portions of aerosol-generating material 32 are then allowed to dry, resulting in a slurry of aerosol-generating material of aerosol-generating material of more or less fixed dimensions and shape. The consumables 24 are then ready for use in the aerosol delivery device 2. If the aerosol-providing device 2 is an aerosol-providing device in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 36 serves as a susceptor for heating the aerosol-generating material portions 32 .

Referring to Figure 5, support 130 is a laminate having first and second layers 136 and 138. The first layer 136 has a surface that is the first surface 128 and is composed of a sheet of aluminum foil. The first layer is less than 0.015 mm thick.

The second layer 138 is formed of polyetheretherketone (PEEK). The second layer 138 is sufficiently rigid to support the first layer 136 and provide a support with a fixed configuration.

The length and width of support 130 as shown in Figure 5 are for illustrative purposes only. Support 130 may have different lengths and widths without departing from the scope of the present disclosure.

Three areas 142 , 144 , 146 of first surface 128 of support 130 are chemically treated using a chemical material that chemically etches the surface of first surface 128 . The etching of regions 142, 144, 146 is on a microscopic scale, but at the microscopic scale, the remainder of first surface 128 (of first surface 128 that is not within regions 142, 144, 146) is etched. This has the effect of making the first surface 128 rougher in areas 142, 144, and 146 than in portions 142, 144, and 146. Etching increases the strength of the bond between the aerosol-generating material and the surface 128 in regions 142 , 144 , and 146 compared to the bond between the aerosol-generating material and the remainder of first surface 128 .

Referring to Figure 6, individual portions of first aerosol-generating material 132A and second aerosol-generating material 132B, both in the form of an aerosol-generating material slurry, are arranged into regions in a grid pattern as shown in Figure 6. 142, 144, 146) is applied to the surface. The slurry is applied, for example, from first and second reservoirs (not shown) of aerosol-generating material slurry (132A, 132B) through at least two nozzles (not shown). It is applied to the surfaces of areas 142, 144, and 146 using a technique. The first and second aerosol generating materials 132A, 132B have different compositions. For example, they contain different flavoring agents which, when heated, result in the creation of aerosols with different scents.

The individual portions of the first aerosol-generating material 132A are all substantially circular in the plane of the first surface 128 of the support 130, and the individual portions of the second aerosol-generating material 132B are formed on the first support 132B. In plane the first surface 128 of 130 is all substantially square. Accordingly, the shapes of the first and second portions of aerosol-generating material 132A, 132B represent different compositions of the aerosol-generating materials comprising those portions. Optionally, the first aerosol-generating material 132A has a different color relative to the second aerosol-generating material 132B.

The individual portions of the first and second aerosol-generating materials 132A, 132B are then allowed to dry, such that the slurries of aerosol-generating materials 132A, 132B form aerosols of more or less fixed dimensions and shapes. They become creation materials.

Next, the support 130 is separated along a separation line 148 to form a pair of consumables 124 as shown in FIG. 7 . Consumables 124 are ready for use in the aerosol delivery device 2. If the aerosol presentation device 2 is an aerosol presentation device in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 136 is used to heat the first and second aerosol generating material portions 132A, 132B. It acts as a susceptor.

Referring to Figure 8, support 230 is a laminate having first and second layers 236 and 238. The first layer 236 has a surface that is the first surface 228 and is composed of a sheet of aluminum alloy foil. The first layer is less than 0.020 mm thick.

The length and width of support 230 as shown in Figure 8 are for illustrative purposes only. Support 230 may have different lengths and widths without departing from the scope of the present disclosure.

The second layer 238 is formed of polyetheretherketone (PEEK). The second layer 238 is about 1.0 mm thick and sufficiently rigid to support the first layer 236 and provide support 230 with a fixed configuration.

A mask 250 is placed over the first surface 228 . Mask 250 includes four apertures 252 that leave four areas 254 on first surface 228 uncovered. Mask 250 is formed from a material that is not damaged by exposure to strong ultraviolet (UV) light (electromagnetic radiation with a wavelength between 10 nm and 400 nm).

The masks and areas 254 on first surface 228 are exposed to intense UV light from a UV light source (not shown). This cleans the areas 254 of the first surface 228, thereby binding the aerosol-generating material to the areas 254 of the surface when applied to the first surface 228, and consequently causing the areas to Enhancing the strength of the bond of the aerosol generating material to the first surface 228 at 254.

In some embodiments, first layer 236 is coated with a layer of material activated by UV light, which in turn enhances binding of the aerosol-generating material to regions 254 of first surface 228. .

9, once areas 254 have been exposed to UV light for a sufficient period of time, mask 250 is removed from first surface 250, and then an aerosol-generating material slurry is applied to the first surface. It is applied to areas 254 of 228 to form aerosol generating material portions 232 .

The individual portions of the aerosol-generating materials 232 are then allowed to dry, resulting in the slurry of aerosol-generating material 232 becoming an aerosol-generating material of more or less fixed dimensions and shapes. The consumables 224 are then ready for use in the aerosol delivery device 2. If the aerosol-providing device 2 is an aerosol-providing device in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 236 serves as a susceptor for heating the aerosol-generating material portions 232 .

8 and 9, mask 250 is an etch mask for use in a plasma etch process. The exposed surfaces 254 of first surface 228 are etched using known plasma etch techniques until the desired depth of etch is achieved. This creates a rough surface of the foil in areas 254 which creates an improved strength of bond between the aerosol generating material and the surface 228 of areas 254 . Support 230 is then further processed as described above to produce consumable 224.

The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These examples are provided merely as a representative sample of examples and are not exhaustive and/or exclusive. The advantages, embodiments, examples, functions, features, structures and/or other aspects described herein do not extend to the scope of the invention as defined by the limitations on the claims or equivalents to the claims. It should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include suitable combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, or It may consist of this, or it may consist essentially of this. Additionally, the present disclosure may include other inventions that are not currently claimed, but may be claimed in the future.

Claims (34)

A method of manufacturing a consumable for use with a non-flammable aerosol delivery system, comprising:
The consumables include a support and an aerosol generating material,
The above method is,
(a) providing a support,
(b) surface treating at least a portion of the first surface of the support, and
(c) applying an aerosol-generating material to at least a portion of the first surface of the support,
The surface treatment of step (b) includes altering one or more chemical or physical properties of the surface, wherein the physical property modifications to the surface do not include perforating or embossing the support. Achieved by processes,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 1,
The surface treatment of step (b) is such that the adhesive strength of the bond created between the aerosol-generating material and the first surface of the support is relative to the adhesive strength of the bond created between the aerosol-generating material and the first surface of the support. providing increased strength of the bond created between treated parts,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 1 or 2,
Treating the surface in step (b) provides a treated surface, the treated surface having reduced reactivity compared to an untreated surface,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to clause 4,
The reactivity results in chemical corrosion of the surface,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to any one of claims 1 to 4,
The changes in the physical properties of the treated surface resulting from step (b) include changes at a microscopic scale.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to any one of claims 1 to 5,
wherein the support is a laminate, the laminate comprising at least two layers, the first layer of the laminate forming a first surface of the support,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 6,
The first surface of the support comprises a metal or metal alloy,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to clause 7,
wherein the first surface of the support comprises a foil or film of metal or metal alloy,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 7 or 8,
The metal or metal alloy is aluminum or aluminum alloy,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 9,
The above method is
(d) separating the support into two or more smaller units of the desired shape and size,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 10,
The surface treatment of step (b) comprises electrostatic coating of at least a portion of the first surface of the support.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 11,
wherein the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support using a primer,
The surface treatment in step (b) is
(e) further comprising curing at least a portion of the primer,
Step (e) is performed subsequent to step (b) and before step (c),
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 12,
Step (e) comprises baking the support to cure the primer,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to any one of claims 1 to 13,
The surface treatment of step (b) comprises chemical treatment of at least a portion of the first surface of the support,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 14,
The chemical treatment of step (b) comprises chemically etching at least a portion of the first surface of the support.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 15,
The surface treatment of step (b) comprises exposing at least a portion of the first surface of the support or at least a portion of the coated first surface to a source of ultraviolet radiation.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to claim 16,
The exposure of at least a portion of the first surface or at least a portion of the coated first surface to the ultraviolet radiation source of step (b) causes the structure or surface chemistry of the exposed first surface of the support to change. causing modifications to,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 17,
The surface treatment of step (b) comprises plasma surface treatment of at least a portion of the first surface of the support,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to clause 18,
The plasma surface treatment of step (b) includes one or more of cleaning the surface of the support, activating the surface of the support, coating the support, and etching the support.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 19,
The aerosol generating material is a slurry comprising a binder and an aerosol former,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 20,
The surface treatment of step (b) comprises surface treating one or more individual portions of the first surface of the support, and the application of the aerosol-generating material of step (c) includes surface treating the first surface of the support. comprising application of an aerosol-generating material to one or more separate portions of a surface,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 20,
Wherein the surface treatment of step (b) comprises surface treating substantially all of the first surface of the support, and the application of the aerosol-generating material of step (c) includes treating one or more of the first surfaces of the support. comprising application of an aerosol-generating material to individual parts,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method of claim 21 or 22,
The application of the aerosol-generating material of step (c) comprises application of the aerosol-generating material to three or more individual portions on the first surface of the support, wherein the individual portions are aligned with the first surface of the support in a grid pattern. placed on the surface,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 21 to 23,
One or more of the individual portions of the aerosol-generating material applied in step (c) are substantially circular in the plane of the first surface of the support and have longitudinally extending stripes, at least one curve or Stripes containing angles, or having a tessellate shape,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 21 to 24,
At least two separate parts of the aerosol-generating material applied in step (c) have different compositions from each other,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 21 to 25,
At least one individual portion of the aerosol-generating material applied in step (c) has a shape and/or color indicative of the composition of the aerosol-generating material forming the individual portion,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 26,
The above method is
(f) comprising an additional method step of processing the support using an additional treatment,
The additional processing includes perforating or embossing at least a portion of the support.
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 27,
said application of an aerosol-generating material to at least a portion of said first surface of said support in step (c) is application of an aerosol-generating material slurry,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. According to clause 28,
The above method is
(g) allowing said aerosol-generating material slurry to harden or causing said aerosol-generating material slurry to harden;
wherein the aerosol-generating slurry is cured to form an aerosol-generating material,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. The method according to any one of claims 1 to 29,
The aerosol-generating material is an aerosol-generating membrane,
Method for manufacturing consumables for use with non-flammable aerosol delivery systems. As a consumable for use with a non-flammable aerosol delivery system,
The consumable product includes a support and an aerosol generating material, and the consumable product is manufactured according to the method of any one of claims 1 to 30,
Consumables for use with non-flammable aerosol delivery systems. According to claim 31,
wherein the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.
Consumables for use with non-flammable aerosol delivery systems. An aerosol delivery system comprising an aerosol delivery device according to claim 32 and a consumable according to claim 31. Generating an aerosol from a consumable manufactured according to any one of claims 1 to 30 using an aerosol generating device having at least one aerosol generator arranged to heat, but not combust, the consumable during use. As a method,
wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor,
How to create an aerosol.