NZ771789A - Aerosol generation - Google Patents

Abstract

An aerosol generating article for use in an aerosol generating assembly, the article comprising an aerosol generating material comprising an aerosol-forming layer, and the aerosol forming layer comprising an amorphous solid. The aerosol-forming layer has a thickness of 0.015mm to 0.3mm. The amorphous solid comprises an aerosol generating agent agent selected from erythritol, propylene glycol, glycerol and mixtures thereof. The aerosol generating material does not comprise tobacco fibres. The aerosol generating assembly comprises a heater configured to heat but not burn the aerosol generating material. The aerosol generating material performs particularly well in noncombustible aerosol provision systems where the aerosol generated material is heated without combustion to release aerosol.

Description

An aerosol generating article for use in an aerosol generating assembly, the article comprising an aerosol generating material comprising an aerosol-forming layer, and the aerosol forming layer comprising an amorphous solid. The aerosol-forming layer has a thickness of 0.015mm to 0.3mm. The amorphous solid comprises an aerosol generating agent agent selected from erythritol, propylene glycol, glycerol and mixtures thereof. The aerosol generating material does not comprise tobacco fibres. The aerosol generating assembly comprises a heater configured to heat but not burn the aerosol generating material. The aerosol generating material performs particularly well in noncombustible aerosol provision systems where the aerosol generated material is heated without combustion to release aerosol.

NZ 771789 A2 AEROSOL GENERATION Technical Field The present invention relates to aerosol generation.

Background Smoking articles such as cigarettes, cigars and the like bum tobacco during use to create tobacco smoke. Alteratives to these types of articles release an inhalable aerosol or vapour by releasing compounds fom a substate material by heating without buring. These may be refrred to as non-combustible smoking articles or aerosol generating assemblies.

One example of such a product is a heating device which release compounds by heating, but not buring, a solid aerosolisable material. This solid aerosolisable material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically frming an inhalable aerosol. These products may be refrred to as heat-not-bum devices, tobacco heating devices or tobacco heating products. Various diferent arrangements fr volatilising at least one component of the solid aerosolisable material are known.

As another example, there are e-cig arette / tobacco heating product hybrid devices, also known as electronic tobacco hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additio nally contains a solid aerosolisable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

Summar A first aspect of the invention provides an aerosol generating material compnsmg an aerosol-frming layer, the aerosol-frming layer comprising an amorphous solid, wherein the aerosol-frming layer has a thickness of 0.015mm to 1.0mm. In one embodiment, the aerosol-frming layer has a thickness of fom 0.05mm to 1.0mm.

In one embodiment, the amorphous solid comprises one or more of an active substance, an aerosol generating agent, a favourant and a gelling agent. In a particular embodiment, the amorphous solid comprises one or more of nicotine, a tobacco material, an aerosol generating agent, a favourant and a gelling agent A second aspect of the invention provides an aerosol generating assembly comprising an aerosol generating material according to the frst aspect of the invention and a heater confgured to heat but not bum the aerosol generating material.

A third aspect of the invention provides an aerosol generating article fr use in an aerosol generating assembly, the article comprising an aerosol generating material according to the frst aspect.

A furth aspect of the invention provides a method of making an aerosol generating material according to the frst aspect.

Further aspects of the invention described herein may provide the use of the aerosol generating material, the aerosol generating article or the aerosol generating assembly, in the generation of an inhalable aerosol.

Further fatures and advantages of the invention will become apparent fom the fllowing description, given by way of example only, and with refrence to the accompanying fgures.

Brief Description of the Figures Figure 1 is an exploded schematic diagram of an aerosol generating material.

Figure 2 shows a section view of an example of an aerosol generating article.

Fi re 3 shows a perspective view of the article of Figure 2.

Fi re 4 shows a sectional elevation of an example of an aerosol generating article.

Fi re 5 shows a perspective view of the article of Figure 4.

Fi re 6 shows a perspective view of an example of an aerosol generating assembly.

Fi re 7 shows a section view of an example of an aerosol generating assembly.

Fi re 8 shows a perspective view of an example of an aerosol generating assembly.

Detailed Description The aerosol-frming layer described herein comprises an "amorphous solid", which may alteratively be refrred to as a "monolithic solid" (i.e. non-fbrous), or as a "dried gel". The amorhous solid is a solid material that may retain some fuid, such as liquid, within it. In some cases, the aerosol-frming layer comprises fom about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. In some cases, the aerosol-frming layer consists of amorphous solid.

As described above, the invention provides an aerosol generating material comprising an aerosol-frming layer, the aerosol-frming layer comprising an amorphous solid, and wherein the aerosol-frming layer has a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range ofabout 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. The inventors have fund that a material having a thickness of 0.2mm is particularly suitable. The aerosol-frming layer may comprise more than one layer, and the thickness described herein refrs to the aggregate thickness of those layers.

The inventors have established that if the aerosol-frming layer is too thick, then heating efciency is compromised. This adversely afects the power consumption and the timing of aerosol delivery in use. Conversely, if the aerosol-frming layer is too thin, it is difcult to manufcture and handle; a very thin material is harder to cast and may be fagile, compromising aerosol frmation in use.

The inventors have established that the layer thicknesses stipulated herein optimise the material properties in view of these competing considerations.

The thickness stipulated herein is a mean thickness fr the material. In some cases, the amorhous solid thickness may vary by no more than 25%, 20%, 15%, 10%, % or 1%.

In some cases, the aerosol generating material may comprise embedded heating means, such as resistive or inductive heating elements. For example, the heating means may be embedded in the amorhous solid.

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

The carrier fnctions as a support on which the amorphous solid layer frms, easing manufcture. The carrier may provide tensile strength to the amorphous solid layer, easing handling.

The carrier may be any suitable material which can be used to support an amorphous solid. In some cases, the carrier may be frmed fom materials selected fom metal fil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be frmed fom materials selected fom metal fil, paper, cardboard, wood or combinations thereof. In some cases, the carrier itself be a laminate structure comprising layers of materials selected fom the preceding lists. In some cases, the carrier may also fnction as a favour carrier. For example, the carrier may be impregnated with a favourant or with tobacco extract.

In some cases, the carrier may be magnetic. This fnctionality may be used to fsten the carrier to the assembly in use, or may be used to generate particular amorphous solid shapes. In some cases, the aerosol generating material may comprise one or more magnets which can be used to fsten the material to an induction heater in use.

In some cases, the carrier may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the carrier layer, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use on, fr example, the surfce of a heater provided in an aerosol generating assembly. Thus, consumption efciency and hygiene can be improved in some cases.

In one case, the surfce of the carrier that abuts the amorphous solid may be porous. For example, in some cases, the carrier comprises paper. The inventors have fund that a porous carrier such as paper is particularly suitable fr the present invention; the porous layer abuts the amorphous solid layer and frms a strong bond.

The amorphous solid is frmed by drying a gel and, without being limited by theory, it is thought that the slurry fom which the gel is frmed partially impregnates the porous carrier (e.g. paper) so that when the gel sets and frms cross-links, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier ( and between the dried gel and the carrier). The porous layer ( e.g. paper) may also be used to carry favours. In some cases, the porous layer may comprise paper, suitably having a porosity of 0-300 Coresta Units (CU), suitably 5-100 CU or 25-75 CU.

Additionally, surfce roughness may contribute to the strength of bond between the amorphous material and the carrier. The inventors have fund that the paper roughness (fr the surfce abutting the carrier) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surfce, in which air at a specifed pressure is leaked between a smooth glass surfce and a paper sample, and the time (in seconds) fr a fxed vol ume of air to seep between these surfces is the "Bekk smoothness".) Conversely, the surfce of the carrier fcing away fom the amorphous solid may be arranged in contact with the heater, and a smoother surfce may provide more efcient heat transfr. Thus, in some cases, the carrier is disposed so as to have a rougher side abutting the amorphous material and a smoother side fcing away fom the amorphous material.

In one particular case, the carrier may be a paper-backed fil; the paper layer abuts the amorhous solid layer and the properties discussed in the previous paragraphs are aforded by this abutment. The fil backing is substantially impermeable, providing control of the aerosol flow path. A metal fil backing may also serve to conduct heat to the amorphous solid.

In another case, the fil layer of the paper-backed fil abuts the amorphous solid. The fil is substantially impermeable, thereby preventing water provided in the amorphous solid to be absorbed into the paper which coul d weaken its structural integrity.

In some cases, the carrier is frmed fom or comprises metal fil, such as aluminium fil. A metallic carrier may allow fr better conduction of thermal energy to the amorphous solid. Additionally, or alt eratively, a metal fil may fnction as a susceptor in an induction heating system. In particular embodiments, the carrier compnses a metal fil layer and a support layer, such as cardboard. In these embodiments, the metal fil layer may have a thickness of less than 20µm, such as fom about lµm to about IOµm, suitably about 5µm.

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

AEROSOL-FORMING MATERIAL COMPOSITION In some cases, the amorphous solid may comprise 1-60wt% of a gelling agent wherein these weights are calculated on a dry weight basis.

Suitably, the amorphous solid may comprise fom about 1 wt%, 5wt%, 1 0wt¾, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 27wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50wt%, 5-40wt%, 10-30wt% or 15-27wt% of a gelling agent.

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected fom the group comprising alginates, pectins, starches ( and derivatives), celluloses ( and derivatives), gums, silica or silicones compounds, clays, pol inyl alcohol and combinations thereof For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fmed silica, PDMS, sodium silicate, kaolin and pol inyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during frmation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorhous solid in an amount of fom 10-30wt% of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one frther gelling agent, such as pectin.

In some embodiments the amorphous solid may include gelling agent compnsmg carrageenan.

Suitably, the amorhous solid may comprise fom about 5wt%, 10wt%, 15wt%, or 20wt% to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the amorphous solid may comprise 10-60wt%, 15-50wt% or 20-40wt% of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compound selected fom erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol. The inventors have established that if the content of the plasticiser is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. The inventors have established that if the plasticiser content is too low, the amorphous solid may be brittle and easily broken.

The plasticiser content specifed herein provides an amorphous solid fexibil ity which allows the amorphous solid sheet to be wound onto a bobbin, which is usefl in manufcture of aerosol generating articles.

In some cases, the amorphous solid may comprise a favour. Suitably, the amorphous solid may comprise up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%, 1 0wt¾ or 5wt% of a favour. In some cases, the amorphous solid may comprise at least about 0.lwt¾, 0.5wt%, I wt%, 2wt%, 5wt% 10wt%, 20wt% or 30wt% of a favour (all calculated on a dry weight basis). For example, the amorhous solid may comprise 0 .1- 60wt%, 1-60wt%, 5-60wt%, 10-60wt%, 20-50wt% or 30-40wt% of a favour. In some cases, the favour (if present) comprises, consists essentially of or consists of menthol.

In some cases, the amorphous solid does not comprise a favour.

In some cases, the amorphous solid additionally comprises an active substance.

For example, in some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. For example, the amorphous solid may additionally comprise powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the amorphous solid may comprise fom about 1 wt%, 5wt%, 1 0wt¾, 15wt%, 20wt% or 25wt% to about 70wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of active substance. In some cases, the amorphous solid may comprise fom about lwt¾, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine.

In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60wt% ( calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise fom about 1 wt%, 5wt%, 1 0wt¾, 15wt%, 20wt% or 25wt% to about 55wt%, 50wt%, 45wt% or 40wt% ( calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 5-60wt%, 10-55wt% or 25- 55wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises 1 wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results fom the tobacco extract.

In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise fom about lwt¾, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, 10wt% or 5wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-20wt% or 2-5wt% of nicotine.

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

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

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

The amorphous solid may be made fom a gel, and this gel may additionally comprise a solvent, included at 0.1-50wt%. However, the inventors have established that the inclusion of a solvent in which the favour is soluble may reduce the gel stability and the favour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the favour is soluble.

In some embodiments, the amorphous solid comprises less than 60wt% of a fller, such as fom I wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.

In other embodiments, the amorphous solid comprises less than 20wt%, suitably less than 1 0wt¾ or less than 5wt% of a fller. In some cases, the amorhous solid comprises less than 1 wt% of a fller, and in some cases, comprises no fller.

The fller, if present, may comprise one or more inorganic fller materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The fller may comprise one or more organic fller materials such as wood pulp, cellulose and cellulose derivatives. In particular, in some cases, the amorhous solid comprises no calcium carbonate such as chalk.

In particular embodiments which include fller, the fller is fbrous. For example, the fller may be a fbrous organic fller material such as wood pulp, hemp fbre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fbrous fller in an amorphous solid may increase the tensile strength of the material. This may be particularly advantageous m examples wherein the amorphous solid is provided as a sheet, such as when an amorphous solid sheet circumscribes a rod of aerosolisable material.

In some embodiments, the amorphous solid does not comprise tobacco fbres.

In particular embodiments, the amorphous solid does not comprise fbrous material.

In some embodiments, the aerosol generating material does not compnse tobacco fbres. In particular embodiments, the aerosol generating material does not comprise fbrous material.

In some embodiments, the aerosol generating substrate does not compnse tobacco fbres. In particular embodiments, the aerosol generating substrate does not comprise fbrous material.

In some embodiments, the aerosol generating article does not comprise tobacco fbres. In particular embodiments, the aerosol generating article does not comprise fbrous material.

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

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

The aerosol generating material comprising the amorhous solid may have any suitable area density, such as fom 30 g/m to 120 g/m . In some embodiments, aerosol generating material may have an area density of fom about 30 to 70 g/m , or about 40 to 60 g/m . In some embodiments, the amorphous solid may have an area density of fom about 80 to 120 g/m , or fom about 70 to 110 g/m , or particularly fom about 90 to 110 g/m . Such area densities may be particularly suitable where the aerosol­ generating material is included in an aerosol generating article/assembly in sheet frm, or as a shredded sheet (described frther hereinbelow).

AEROSOL GENERATNG ARTCLE AND ASSEMBLY A second aspect of the invention provides an aerosol generating assembly comprising an aerosol generating material according to the frst aspect of the invention and a heater confgured to heat but not bum the aerosol generating material.

In some cases, the heater may heat, without buring, the aerosolisable material(s) to between 120 C and 350 C in use. In some cases, the heater may heat, without buring, the aerosolisable material(s) to between 140 C and 250 C in use. In some cases in use, substantially all of the amorphous solid is less than about 4mm, 3mm, 2mm or Imm fom the heater. In some cases, the amorphous solid is disposed between about 0.017mm and 2.0mm fom the heater, suitably between about 0.1mm and 1.0mm. In some cases, a surfce of the amorphous solid may directly abut the heater.

The heater is confgured to heat not bum the aerosol generating material. The heater may be, in some cases, a thin flm, electrically resistive heater. In other cases, the heater may comprise an induction heater or the lie. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to product heat in use. The aerosol generating assembly may comprise a plurality of heaters. The heater(s) may be powered by a battery.

The aerosol generating assembly may additio nally comprise a cooling element and/or a flt er. The cooling element, if present, may act or fnction to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to frm an aerosol. It may also act to space the very hot parts of the apparatus fom the user. The flter, if present, may comprise any suitable flter known in the art such as a cellulose acetate plug.

In some cases, the aerosol generating assembly may be a heat-not-bum device.

That is, it may contain a solid tobacco-containing material (and no liquid aerosolisable material). In some cases, the amorphous solid may comprise the tobacco material. A heat-not-bum device is disclosed in A2, which is incorporated by refrence in its entirety.

In some cases, the aerosol generating assembly may be an electronic tobacco hybrid device. That is, it may contain a solid aerosolisable material and a liquid aerosolisable material. In some cases, the amorphous solid may comprise nicotine. In some cases, the amorphous solid may comprise a tobacco material. In some cases, the amorphous solid may comprise a tobacco material and a separate nicotine source. The separate aerosolisable materials may be heated by separate heaters, the same heater or, in one case, a downstream aerosolisable material may be heated by a hot aerosol which is generated fom the upstream aerosolisable material. An electronic tobacco hybrid device is disclosed in Al, which is incorporated by refrence in its entirety.

The invention also provides an aerosol generating article fr use in an aerosol generating assembly comprising an aerosol generating material according to the frst aspect of the invention. The article (which may be refrred to herein as an aerosol generating article, a cartridge or a consumable) may be adapted fr use in a THP, an electronic tobacco hybrid device or another aerosol generating device. In some cases, the article may additionally comprise a flter and/or cooling element (which have been described above). In some cases, the aerosol generating article may be circumscribed by a wrapping material such as paper.

The aerosol generating article may additionally comprise ventilation apertures.

These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the flter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilised components fom the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet fr mation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by frther condensation of the heated volatilised components and by coagulation of newly frmed droplets fom the heated volatilised components.

In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilatio n ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibil ity of the heated volatilised components enables the user to identif that the volatilised components have been generated and adds to the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to provide additi onal cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.

In some cases, the aerosol generating material may be included in the article/assembly in sheet frm. In some cases, the aerosol generating material may be included as a planar sheet. In some cases, the aerosol generating material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the frm of a tube). In some such cases, the amorhous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolisable material ( e.g. tobacco). In some other cases, the aerosol generating material may be frmed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with cut rag tobacco and incororated into the article.

In some examples, the amorphous solid in sheet frm may have a tensile strength of fom around 200 Nim to around 900 Nim. In some examples, such as where the amorphous solid does not comprise a fller, the amorphous solid may have a tensile strength of fom 200 Nim to 400 Nim, or 200 Nim to 300 Nim, or about 250 N/m. Such tensile strengths may be particularly suitable fr embodiments wherein the aerosol generating material is frmed as a sheet and then shredded and incororated into an aerosol generating article. In some examples, such as where the amorphous solid comprises a fller, the amorphous solid may have a tensile strength of fom 600 Nim to 900 Nim, or fom 700 Nim to 900 Nim, or around 800 Nim. Such tensile strengths may be particularly suitable fr embodiments wherein the aerosol generating material is included in an aerosol generating article/assembly as a rolled sheet, suitably in the frm of a tube.

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

The article 101 of one example is in the frm of a substantially cylindrical rod that includes a body of aerosol generating material 103 and a flter assembly 105 in the frm of a rod. The aerosol generating material comprises a 0.2mm thick layer of aerosol-fr ming amorphous solid. In the illustrated embodiment, the aerosol generating material has been incororated as a rolled sheet (i.e. in tube frm). In other embodiments, the aerosol generating material may be incorporated in other frms as described above, including without limitation, as a fat sheet, as a bunched or gathered sheet, as a crimped sheet or in shredded frm.

The flter assembly 105 includes three segments, a cooling segment 107, a flter segment 109 and a mouth end segment 111. The article 101 has a frst end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol generating material 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol generating material 103 between the body of aerosol generating material 103 and the flter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol generating material 103 and the flter segment 103. In other examples, there may be a separation between the body of aerosol generating material 103 and the cooling segment 107 and between the body of aerosol generating material 103 and the flter segment 109. The flter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article 101, adjacent the flter segment 109. In one example, the flter segment 109 is in an abutting relationship with the mouth end segment 111. In one embodiment, the total length of the flter assembly 105 is between 37mm and 45mm, more prefrably, the total length of the flter assembly 105 is 41mm.

In one example, the rod of aerosol generating material 103 is between 34mm and 50mm in length, suitably between 38mm and 46mm in length, suitably 42mm in length.

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

An axial end of the body of aerosol generating material 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) covering the axial end of the body of aerosol generating material 103.

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

In one example, the cooling segment 107 is an annular tube and is located around and defnes an air gap within the cooling segment. The air gap provides a chamber fr heated volatilised components generated fom the body of aerosol generating material 103 to flow. The cooling segment 107 is hollow to provide a chamber fr aerosol accumulation yet rigid enough to withstand axial compressive frces and bending moments that might arise during manufcture and whilst the article 101 is in use during insertion into the device 51. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29mm.

The cooling segment 107 provides a physical displacement between the aerosol generating material 103 and the flter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is confgured to provide a temperature diferential of at least 40 degrees Celsius between a heated volatilised component entering a frst end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is confgured to provide a temperature diferential of at least 60 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature diferential across the length of the cooling element 107 protects the temperature sensitiv e flter segment 109 fom the high temperatures of the aerosol generating material 103 when it is heated by the device 51.

If the physical displacement was not provided between the flter segment 109 and the body of aerosol generating material 103 and the heating elements of the device 51, then the temperature sensitiv e flter segment may 109 become damaged in use, so it would not perfrm its required fnctions as efectiv ely.

In one example the length of the cooling segment 107 is at least 15mm. In one example, the length of the cooling segment 107 is between 20mm and 30mm, more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.

The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concer, fr example, toxic compounds when in use adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufctured fom a spirally wound paper tube which provides a hollow interal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufcturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created fom stif plug wrap or tipping paper. The stif plug wrap or tipping paper is manufctured to have a rigidity that is sufcient to withstand the axial compressive frces and bending moments that might arise during manufcture and whilst the article 101 is in use during insertion into the device 51.

The flter segment 109 may be frmed of any flter material sufcient to remove one or more volatilised compounds fom heated volatilised components fom the aerosol generating material. In one example the flter segment 109 is made of a mono­ acetate material, such as cellulose acetate. The flter segment 109 provides cooling and irritation-reduction fom the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfctory level fr a user.

In some embodiments, a capsule (not illustrated) may be provided in flter segment 109. It may be disposed substantially centrally in the flter segment 109, both across the flter segment 109 diameter and along the flter segment 109 length. In other cases, it may be ofset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a favourant or aerosol generating agent.

The density of the cellulose acetate tow material of the flter segment 109 controls the pressure drop across the flter segment 109, which in tum contols the draw resistance of the article 101. Therefre the selection of the material of the flter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the flter segment perfrms a fltration fnction in the article 101.

In one example, the flter segment 109 is made of a 8Y15 grade of flter tow material, which provides a fltration efect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result fom the heated volatilised material.

The presence of the filter segment 109 provides an insulating efect by providing frther cooling to the heated volatilised components that exit the cooling segment 107.

This frther cooling efect reduces the contact temperature of the user's lips on the surfce of the flter segment 109.

In one example, the flter segment 109 is between 6mm to 10mm in length, suitably 8mm.

The mouth end segment 111 is an annular tube and is located around and defnes an air gap within the mouth end segment 111. The air gap provides a chamber fr heated volatilised components that flow fom the flter segment 109. The mouth end segment 111 is hollow to provide a chamber fr aerosol accumulation yet rigid enough to withstand axial compressive frces and bending moments that might arise during manufcture and whilst the article is in use during insertion into the device 51. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29mm. In one example, the length of the mouth end segment 111 is between 6mm to 10mm, suitably 8mm.

The mouth end segment 111 may be manuf ctured fom a spirally wound paper tube which provides a hollow interal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufcturing processes with respect to tube length, outer diameter, roundness and straightn ess.

The mouth end segment 111 provides the fnction of preventing any liquid condensate that accumulates at the exit of the flter segment 109 fom coming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be frmed of a single tube and the flter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment Refrring to Figures 4 and 5, there are shown a partially cut-away sect ion and perspective views of an example of an article 301. The refrence signs shown in Figures 4 and 5 are equivalent to the refrence signs shown in Figures 2 and 3, but with an increment of 200.

In the example of the article 301 shown in Figures 4 and 5, a ventilation region 317 is provided in the article 301 to enable air to fow into the interior of the article 301 fom the exterior of the article 301. In one example the ventilation region 317 takes the frm of one or more ventilation holes 317 frmed through the outer layer of the article 301. The ventilation holes may be located in the cooling segment 307 to aid with the cooling of the article 301. In one example, the ventil ation region 317 comprises one or more rows of holes, and prefrably, each row of holes is arranged circumfrentially around the article 301 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 301.

In one example, there are between one to fur rows of ventilation holes to provide ventilation fr the article 301. Each row of ventilation holes may have between 12 to 36 ventilation holes 317. The ventilation holes 317 may, fr example, be between 100 to 500µm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.

In one example, the ventilation holes 317 are of unifrm size. In another example, the ventilation holes 317 vary in size. The ventilation holes can be made using any suitable technique, fr example, one or more of the fllowing techn iques: laser technology, mechanical perfrat ion of the cooling segment 307 or pre-perfration of the cooling segment 307 befre it is frmed into the article 301. The ventilation holes 317 are positioned so as to provide efective cooling to the article 301.

In one example, the rows of ventilation holes 317 are located at least 11mm fom the proximal end 313 of the article, suitably between 17mm and 20mm fom the proximal end 313 of the article 301. The location of the ventilation holes 317 is positioned such that user does not block the ventilation holes 317 when the article 301 1s muse.

Providing the rows of ventilation holes between 17mm and 20mm fom the proximal end 313 of the article 301 enables the ventilation holes 317 to be located outside of the device 51, when the article 301 is flly inserted in the device 51, as can be seen in Figures 7 and 8. By locating the ventilation holes outside of the device, non­ heated air is able to enter the article 301 through the ventilation holes fom outside the device 51 to aid with the cooling of the article 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 51, when the article 301 is flly inserted into the device 51. The length of the cooling segment 307 provides a frst fnction of providing a phy sical gap between the heater arrangement of the device 51 and the heat sensitive flter arrangement 309, and a second fnction of enabling the ventilation holes 317 to be located in the cooling segment, whilst also being located outside of the device 51, when the article 301 is flly inserted into the device 51. As can be seen fom Figures 7 and 8, the majority of the cooling element 307 is located within the device 51.

However, there is a portion of the cooling element 307 that extends out of the device 51. It is in this portion of the cooling element 307 that extends out of the device 51 in which the ventilation holes 317 are located.

Refrring now to Figures 6 to 8 in more detail, there is shown an example of a device 51 arranged to heat aerosol generating material to volatilise at least one component of said aerosol generating material, typically to frm an aerosol which can be inhaled. The device 51 is a heating device which releases compounds by heating, but not buring, the aerosol generating material.

A frst end 53 is sometimes refrred to herein as the mouth or proximal end 53 of the device 51 and a second end 55 is sometimes refrred to herein as the distal end 55 of the device 51. The device 51 has an on/of button 57 to allow the device 51 as a whole to be switched on and of as desired by a user.

The device 51 compnses a housing 59 fr locating and protecting various interal components of the device 51. In the example shown, the housing 59 comprises a uni-body sleeve 11 that encompasses the perimeter of the device 51, capped with a top panel 17 which defnes generally the 'top' of the device 51 and a bottom panel 19 which defnes generally the 'bottom' of the device 51. In another example the housing comprises a font panel, a rear panel and a pair of opposite side panels in addition to the top panel 1 7 and the bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably fxed to the uni­ body sleeve 11, to permit easy access to the interior of the device 51, or may be "permanently" fxed to the uni-body sleeve 11, fr example to deter a user fom accessing the interior of the device 51. In an example, the panels 17 and 19 are made of a plastics material, including fr example glass-flled nylon frmed by injection moulding, and the uni-body sleeve 11 is made of aluminium, though other materials and other manufcturing processes may be used.

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

The housing 59 has located or fxed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed fom an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, conf red and arranged to control the heating of the aerosol generating material in the article 101, 301 as discussed frther below.

The power source 27 may be fr example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include fr example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/ or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under contol of the control circuitry 25 to heat the aerosol generating material in the article ( as discussed, to volatilise the aerosol generating material without causing the aerosol generating material to bum).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 51 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, ofen measured in Amp-hours or the like) and thus the battery lif fr the device 51 can be longer.

In one example, the heater arrangement 23 is generally in the frm of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101, 301 comprising the aerosol generating material is inserted fr heating in use. Diferent arrangements fr the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be frmed of plural heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least part-annular or part­ tubular around its circumfrence. In an example, the or each heating element may be a thin flm heater. In another example, the or each heating element may be made of a ceramics material. Examples of suitable ceramics materials include alumina and aluminium nit ride and silicon nitride ceramics, which may be laminated and sintered.

Other heating arrangements are possible, including fr example inductive heating, infared heater elements, which heat by emitting infared radiation, or resistive heating elements frmed by fr example a resistive electrical winding.

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

The or each heating element may be arranged so that selected zones of the aerosol generating material can be independently heated, fr example in tum (over time, as discussed above) or together (simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing fom the heater arrangement 23 to the exterior of the device 51. This helps to keep down the power requirements fr the heater arrangement 23 as it reduces heat losses generally.

The insulator 31 also helps to keep the exterior of the device 51 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve which provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 may be fr example a "vacuum" tube, i.e. a tube that has been at least partially evacuated so as to minimise heat transfr by conduction and/or convection. Other arrangements fr the insulator 31 are possible, including using heat insulating materials, including fr example a suitable fam-type material, in addition to or instead of a double-walled sleeve.

The housing 59 may frther comprises various interal support structures 37 fr supporting all interal components, as well as the heating arrangement 23.

The device 51 frther comprises a collar 33 which extends around and projects fom the opening 20 into the interior of the housing 59 and a generally tubular chamber which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 frther comprises a cooling stucture 35f, which in this example, comprises a plural ity of cooling fns 35f spaced apart along the outer surfce of the chamber 35, and each arranged circumfrentially around outer surfce of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 101,301 when it is inserted in the device 51 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumfrence of the article 101, 301 over at least part of the cooling segment 307.

The collar 33 comprises a plural ity of ridges 60 arranged circumfrentially around the periphery of the opening 20 and which project into the opening 20. The ridges 60 take up space within the opening 20 such that the open span of the opening at the locations of the ridges 60 is less than the open span of the opening 20 at the locations without the ridges 60. The ridges 60 are confgured to engage with an article 101, 301 inserted into the device to assist in securing it within the device 51. Open spaces (not shown in the Figures) defned by adjacent pairs ofridges 60 and the article 101, 301 frm ventilation paths around the exterior of the article 101, 301. These ventilation paths allow hot vapours that have escaped fom the article 101, 301 to exit the device 51 and allow cooling air to flow into the device 51 around the article 101, 301 in the air gap 36.

In operation, the article 101, 301 is removably inserted into an insertion point of the device 51, as shown in Figures 6 to 8. Refrring particularly to Fi re 7, in one example, the body of aerosol generating material 103, 303, which is located towards the distal end 115, 315 of the article 101, 301, is entirely received within the heater arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends fom the device 51 and acts as a mouthpiece assembly fr a user.

In operation, the heater arrangement 23 will heat the article 101, 301 to volatilise at least one component of the aerosol generating material fom the body of aerosol generating material 103, 303.

The primary fow path fr the heated volatilised components fom the body of aerosol generating material 103,303 is axially through the article 101,301, through the chamber inside the cooling segment 107, 307, through the flter segment 109, 309, through the mouth end segment 111, 313 to the user. In the illustrated example, the fow path also passes through the tube frmed by the rolled aerosol generating material 103, 303.

In one example, the temperature of the heated volatilised components that are generated fom the body of aerosol generating material is between 60 C and 250 C, which may be above the acceptable inhalation temperature fr a user. As the heated volatilised component travels through the cooling segment 107, 307, it will cool and some volatilised components will condense on the inner sufce of the cooling segment 107, 307.

In the examples of the article 301 shown in Figures 4 and 5, cool air will be able to enter the cooling segment 307 via the ventilation holes 317 frmed in the cooling segment 307. This cool air will mix with the heated volatilised components to provide additi onal cooling to the heated volatilised components.

METHOD OF MANUFACTURE A furth aspect of the invention provides a method of making an aerosol generating material according to the frst aspect.

The method may comprise (a) frming a slurry comprising components of the amorphous solid or precursors thereof, (b) frming a layer of the slurry, and ( c) setting the slurry to frm a gel and ( d) drying to frm an amorphous solid.

The step (b) of frming a layer of the slurry may comprise spraying, casting or extuding the slurry, fr example. In some cases, the layer is frmed by electrospraying the slurry. In some cases, the layer is frmed by casting the slurry.

In some cases, the slurry is applied to a carrier.

In some examples, the slurry has a viscosit y of fom about 10 to about 20 Pa·s at 46.5 °C, such as fom about 14 to about 16 Pa·s at 46.5 °C.

In some cases, the steps (b) and/or ( c) and/or ( d) may, at least partially, occur simultaneously (fr example, during electrospraying). In some cases, these steps may occur sequentially.

The step ( c) of setting the gel may comprise the addition of a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to frm a calcium alginate gel.

The total amount of the setting agent, such as a calcium source, may be 0.5- 5wt% (calculated on a dry weight basis). The inventors have fund that the addition of too little setting agent may result in an amorphous solid which does not stabilise the amorphous solid components and results in these components dropping out of the amorphous solid. The inventors have fund that the addition of too much setting agent results in an amorphous solid that is very tacky and consequently has poor handleability.

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

The drying step may cause the cast material thickness to reduce by at least 80%, suitably 85% or 87%. For instance, the slurry may be cast at a thickness of 2mm, and the resulting dried amorphous solid material may have a thickness of 0.2mm.

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

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

EXEMPLARY EMBODIMENTS In some embodiments, the amorphous solid comprises menthol.

Particular embodiments comprising a menthol-containing amorphous solid may be particularly suitable fr including in an aerosol generating article/assembly as a shredded sheet. In these embodiments, the amorphous solid may have the fllowing composition (DWB): gelling agent (refrably comprising alginate, more prefrably comprising a combination of alginate and pectin) in an amount of fom about 20wt% to about 40wt%, or about 25wt% to 35wt%; menthol in an amount of fom about 35wt% to about 60wt%, or fom about 40wt% to 55wt%; aerosol generating agent (prefrably comprising glycerol) in an amount of fom about 1 0wt¾ to about 30wt%, or fom about 15wt% to about 25wt% (DWB).

In one embodiment, the amorphous solid comprises about 32-33wt% of an alginate/pectin gelling agent blend; about 47-48wt% menthol favourant; and about 19- 20wt% glycerol aerosol generating agent (DWB).

As noted above, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a shredded sheet. The shredded sheet may be provided in the article/assembly blended with cut tobacco. Alteratively, the amorphous solid may be provided as a non-shredded sheet. Suitably, the shredded or non-shredded sheet has a thickness of fom about 0.015mm to about Imm, prefrably fom about 0.02mm to about 0.07mm.

Particular embodiments of the menthol-containing amorphous solid may be particularly suitable fr including in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolisable material ( e.g. tobacco). In these embodiments, the amorphous solid may have the fllowing composition (DWB): gelling agent (prefrably comprising alginate, more prefrab ly comprising a combination of alginate and pectin) in an amount of fom about 5wt% to about 40wt%, or about 1 0wt¾ to 30wt%; menth ol in an amount of fom about 1 0wt¾ to about 50wt%, or fom about 15wt% to 40wt%; aerosol generating agent (refrab ly comprising glycerol) in an amount of fom about 5wt% to about 40wt%, or fom about 10wt% to about 35wt%; and optionally fller in an amount of up to 60wt% - fr example, in an amount of fom 5wt% to 20wt%, or fom about 40wt% to 60wt% (DWB).

In one of these embodiments, the amorphous solid comprises about 11 wt% of an alginate/pectin gelling agent blend, about 56wt% woodpulp fller, about 18% menthol favourant and about 15wt% glycerol (DWB).

In another of these embodiments, the amorhous solid comprises about 22wt% of an alginate/pectin gelling agent blend, about 12wt% woodpulp fller, about 36% menthol favourant and about 30wt% glycerol (DWB).

As noted above, the amorhous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is provided on a carrier comprising paper. In one embodiment, the sheet is provided on a carrier comprising metal fil, suitably aluminium metal fil. In this embodiment, the amorhous solid may abut the metal fil.

In one embodiment, the sheet frms part of a laminate material with a layer (refrably comprising paper) attached to a top and bottom surfce of the sheet.

Suitably, the sheet of amorphous solid has a thickness of fom about 0.015mm to about In some embodiments, the amorphous solid comprises a favourant which does not comprise menthol. In these embodiments, the amorphous solid may have the fllowing composition (DWB): gelling agent (refrably comprising alginate) in an amount of fom about 5 to about 40wt%, or fom about 1 0wt¾ to about 35wt%, or fom about 20wt% to about 35wt%; favourant in an amount of fom about 0.lwt¾ to about 40wt%, of fom about 1 wt% to about 30wt%, or fom about 1 wt% to about 20wt%, or fom about 5wt% to about 20wt%; aerosol generating agent (refrably comprising glycerol) in an amount of fom 15wt% to 75wt%, or fom about 30wt% to about 70wt%, or fom about 50wt% to about 65wt%; and optionally fller (suitably woodpulp) in an amount of less than about 60wt%, or about 20wt%, or about 1 0wt¾, or about 5wt% (prefrably the amorphous solid does not comprise fller) (DWB).

In one of these embodiments, the amorphous solid comprises about 27wt% alginate gelling agent, about 14wt% favourant and about 57wt% glycerol aerosol generating agent (DWB).

In another of these embodiments, the amorphous solid comprises about 29wt% alginate gelling agent, about 9wt% favourant and about 60wt% glycerol (DWB).

The amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a shredded sheet, optionally blended with cut tobacco.

Alteratively, the amorhous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolisable material ( e.g. tobacco). Alteratively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a layer portion disposed on a carrier.

In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may have the fllowing composition (DWB): gelling agent (refrably comprising alginate) in an amount of fom about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of fom about 30wt% to about 60wt%, or fom about 40wt% to 55wt%, or fom about 45wt% to about 50wt%; aerosol generating agent (prefrably comprising glycerol) in an amount of fom about 1 0wt¾ to about 50wt%, or fom about 20wt% to about 40wt%, or fom about 25wt% to about 35wt% (DWB).

In one embodiment, the amorphous solid comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).

The amorphous solid of these embodiments may have any suitable water content. For example, the amorphous solid may have a water content of fom about 5wt% to about 15wt%, or fom about 7wt% to about 13wt%, or about 10wt%.

The amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a shredded sheet, optionally blended with cut tobacco.

Alteratively, the amorhous solid of these embodiments may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of aerosolisable material ( e.g. tobacco). Alteratively, the amorphous solid of these embodiments may be included in an aerosol generating article/assembly as a layer portion disposed on a carrier. Suitably, in any of these embodiments, the amorphous solid has a thickness of fom about 50 µm to about 200 µm, or about 50 µm to about 100 µm, or about 60 µm to about 90 µm, suitably about 77 µm.

The slurry fr frming this amorhous solid may also frm part of the invention.

In some cases, the slurry may have an elastic modulus of fom about 5 to 1200 Pa (also refrred to as storage modulus); in some cases, the slurry may have a viscous modulus of about 5 to 600 Pa ( also refrred to as loss modulus).

DEFINITIONS The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may fr example be selected fom nutraceuticals, nootropics, psychoactives.

The active substance may be naturally occurring or synthetically obtained. The active substance may comprise fr example nicotine, cafeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine.

In some embodiments, the active substance comprises cafeine, melatonin or vitamin B12.

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

Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CBI and CB2) in cells that repress neurotransmitter release in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) fom plants such as cannabis, fom animals ( endocannabinoids ), or artifcially manufctured (synthetic cannabinoids). Cannabis species express at least 85 diferent phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidio ls, tetrahydrocannabino ls, cannabino ls and cannabinodiols, and other cannabinoids. Cannabinoids fund in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

As noted herein, the active substance may comprise or be derived fom one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived fom plants including, but not limited to, extracts, leaves, bark, fbres, stems, roots, seeds, fowers, fuits, pollen, husk, shells or the like. Alteratively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the frm ofliquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fnnel, lemongrass, peppermint, spearmint, rooibos, chamomile, fax, ginger, ginkgo bilo ba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, cofee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, safron, lavender, lemon peel, mint, juniper, elderfower, vanilla, wintergreen, beefteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, maroram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen fom the fllowing mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c. v. and Mentha suaveolens.

In some embodiments, the botanical is selected fom eucalyptus, star anise, cocoa and hemp.

In some embodiments, the botanical is selected fom rooibos and fnnel.

As used herein, the terms "favour" and "favourant" refr to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product fr adult consumers. They may include naturally occurring favour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof ( e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fnugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fuits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fnnel, wasabi, piment, ginger, coriander, cofee, hemp, a mint oil fom any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, fax, ginkgo bilo ba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderfower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffon, lemon peel, mint, beefteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), favour enhancers, bitteress receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes ( e.g., sucralose, acesulfme potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath feshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable frm, fr example, liquid such as an oil, solid such as a powder, or gas.

The favour may suitably comprise one or more mint-favours suitably a mint oil fom any species of the genus Mentha. The favour may suitably comprise, consist essentially of or consist of men tho 1.

In some embodiments, the favour compnses menthol, spearmint and/or peppermint.

In some embodiments, the favour comprises favour components of cucumber, blueberry, citrus fu its and/or redberry.

In some embodiments, the favour comprises eugenol.

In some embodiments, the favour comprises favour components extracted fom tobacco.

In some embodiments, the favour comprises favour components extracted fom cannabis.

In some embodiments, the favour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the ffh cranial nerve ( trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing efect. A suitable heat efect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.

As used herein, the term "aerosol generating agent" refrs to an agent that promotes the generation of an aerosol. An aerosol generating agent may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol.

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

As used herein, the term "tobacco material" refrs to any material comprising tobacco or derivatives therefre. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fbre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

The tobacco used to produce 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. It may also be tobacco particle 'fnes' or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fbres, and may be frmed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.

All percentages by weight described herein ( denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refrs to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol.

Conversely, a weight percentage quoted on a wet weight basis refrs to all components, including water.

For the avoidance of doubt, where in this specifcation the term "comprises" is used in defning the invention or fatures of the invention, embodiments are also disclosed in which the invention or fature can be defned using the terms "consists essentially of' or "consists of' in place of "comprises". Refrence to a material "comprising" certain fatures means that those fatures are included in, contained in, or held within the material.

The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any fature described in relation to any one embodiment may be used alone, or in combination with other fatures described, and may also be used in combination with one or more fatures of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifcations not described above may also be employed without departing fom the scope of the invention, which is defned in the accompanying claims.

Claims (8)

1. An aerosol generating article for use in an aerosol generating assembly, the article comprising an aerosol generating material comprising an aerosol-forming layer, the aerosol- forming layer comprising an amorphous solid, wherein the aerosol-forming layer has a thickness of 0.015mm to 0.3mm, wherein the amorphous solid comprises an aerosol generating agent selected from erythritol, propylene glycol, glycerol and mixtures thereof, and wherein the aerosol generating material does not comprise tobacco fibres, and wherein the aerosol generating assembly comprises a heater configured to heat but not burn the aerosol generating material.

2. An aerosol generating article according to claim 1, comprising a carrier on which the amorphous solid is provided.

3. An aerosol generating article according to claim 1 or claim 2, wherein the amorphous solid comprises one or more of an active substance, a flavourant and a gelling agent.

4. An aerosol generating article according to claim 3, wherein the material comprises a gelling agent selected from cross-linked pectin, cross-linked alginate and mixtures thereof.

5. An aerosol generating article according to any preceding claim, wherein the amorphous solid comprises 1-60 wt% of a gelling agent on a dry weight basis.

6. An aerosol generating assembly comprising an aerosol generating article according to any preceding claim and a heater configured to heat but not burn the aerosol generating material.

7. An aerosol generating assembly according to claim 6, wherein the assembly is a heat- not-burn device.

8. An aerosol generating assembly according to claim 6, wherein the assembly is an electronic tobacco hybrid device. Fi re 1 111 1 9 lOT_, Fi re 2 --?--- 5 Fi re 3 .. .