US20230413896A1

US20230413896A1 - A plug comprising a combustion retarding additive and uses thereof

Info

Publication number: US20230413896A1
Application number: US18/042,345
Authority: US
Inventors: Walid Abi Aoun; Richard Hepworth
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2020-08-21
Filing date: 2021-08-20
Publication date: 2023-12-28
Also published as: KR20230051695A; IL300226A; JP2023538838A; IL300342A; EP4199756A1; CN116157028A; AU2021329064A1; CA3172455A1; EP4199759A1; GB202109079D0; WO2022038366A1; US20230345999A1; GB202109701D0; WO2022038370A1; JP2023538827A; MX2023002059A; GB202013121D0; BR112023003372A2; CN116157027A; AU2021329063B2

Abstract

An article for use in a non-combustible aerosol provision system, the article including a plug having a combustion retarding additive and related methods for manufacturing and use of said articles.

Description

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No. PCT/GB2021/052159, filed Aug. 20, 2021, which claims priority from GB Application 2013121.5, filed Aug. 21, 2020, GB Application 2109079.0, filed Jun. 24, 2021 and GB Application No. 2109701.9, filed Jul. 5, 2021, each of which hereby fully incorporated herein by reference.

FIELD

The present invention relates to an article for use in a non-combustible aerosol provision system, the article including a plug comprising a combustion retarding additive. The invention further relates to methods for manufacturing and use of said articles.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, smokeable material.

SUMMARY

According to a first aspect of the disclosure herein, there is provided an article for use in a non-combustible aerosol provision system, the article comprising: a rod comprising an aerosol-generating material, and a plug comprising a combustion retarding additive.
In some embodiments, the plug comprising a combustion retarding additive is at the distal end of the article.
In some embodiments, the plug comprising a combustion retarding additive is adjacent to the rod of aerosol generating material.
In some embodiments, the plug comprising a combustion retarding additive is in contact with the rod of aerosol generating material.
In some embodiments, the combustion retarding additive is an alkali metal salt, optionally selected from the group consisting of: sodium chloride, potassium chloride, sodium bromide, potassium bromide, and combinations thereof.
In some embodiments, the plug is formed from a sheet material. In some embodiments, the sheet material is paper or a paper-like material.
In some embodiments, the sheet material comprises an amorphous solid material.
In some embodiments, the combustion retarding additive is incorporated in the sheet material.
In some embodiments, the combustion retarding additive is provided in a coating on a surface of the sheet material.
In some embodiments, the plug comprises a mass of an amorphous solid material.
In some embodiments, the combustion retarding additive is incorporated in the amorphous solid material. In some embodiments, the amorphous solid material comprises from about 3 wt % to about 60 wt % combustion retarding salt (dry weight basis).
In some embodiments, the combustion retarding additive is provided in a coating on a surface of the plug.
In some embodiments, the coating comprising from about 3 wt % to about 70 wt % of at least one combustion retarding additive (dry weight basis).
In some embodiments, the coating comprises a binder. In some embodiments, the binder is selected from one or more of the group consisting of polyvinyl alcohol (PVA), gelatin, gums, acacia gum, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose.
In some embodiments, the coating comprises from about 10 wt % to about 97 wt % of at least one binder.
In some embodiments, the article comprises heating material.
In some embodiments, the heating material is heatable by penetration with a varying magnetic field to heat the aerosol generating material.
In some embodiments, the heating material is in contact with the aerosol generating material.
In some embodiments, the heating material is in contact with the plug comprising a combustion retarding additive.
In some embodiments, the aerosol generating material comprises one or more of tobacco per se, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco or tobacco substitutes.
In some embodiments, the aerosol generating material is in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted smokeable material, liquid, gel, gelled sheet, powder or agglomerates.
In some embodiments, the aerosol generating material comprises non-tobacco material.
In some embodiments, the plug comprising a combustion retarding additive exhibits a pressure drop of from about 5 to about 40 mmWG.
In some embodiments, the plug comprising a combustion retarding additive has a bulk density of between about 0.1 and about 0.3 mg/mm³.
According to a second aspect of the disclosure herein, there is provided a non-combustible aerosol provision system comprising an article according to the first aspect.
According to a third aspect of the disclosure herein, there is provided a method for manufacturing the article according to the first aspect, wherein a combustion retarding additive is incorporated into a plug or is applied to a surface of a plug, and the plug is incorporated into an article with a rod of aerosol generating material.
In some embodiments, the plug is incorporated at the distal end of the article.
In some embodiments, the method comprises gathering one or more sheets into a rod, wrapping the rod and cutting it into discrete sections to form the plug.
In some embodiments, the method comprises crimping the sheet prior to gathering the sheet into a rod.
In some embodiments, the method comprises gathering the sheet around a former to form a hole through the plug.
In some embodiments, the method comprises applying to a surface of the sheet material a coating comprising the combustion retarding additive.
In some embodiments, the method comprises applying to a surface of the plug a coating comprising the combustion retarding additive.
In some embodiments, the coating is formed by applying a precursor material comprising a binder and the combustion retarding additive to a surface.
In some embodiments, the coating is applied to a surface using one or more process selected from the group consisting of: spraying, painting or printing.
According to a fourth aspect of the disclosure herein, there is provided a use of a combustion retarding additive for retarding combustion of a plug in an article for use in a non-combustible aerosol provision system.
According to a fifth aspect of the disclosure herein, there is provided a plug for use in an article for use in a non-combustible aerosol provision system, the plug comprising a combustion retarding additive.
In some embodiments, the plug comprises a combustible material.
In some embodiments, the plug comprises one or more sheet of paper or paper-like material.
In some embodiments, the plug comprises a body of an amorphous solid material.
In some embodiments, the plug is resistant to combustion when exposed to temperatures of up to 300° C.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which:

FIG. 1 is a side-on cross sectional view of a first embodiment of an article comprising a plug comprising a combustion retarding additive; and

FIG. 2 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from the aerosol-generating material of the articles of FIG. 1 .

DETAILED DESCRIPTION

The present invention seeks to provide an article for use in a non-combustible aerosol provision system. The article comprises a rod of aerosol-generating material and plug comprising a combustion retarding additive.
In some embodiments, the article has a downstream end, usually connected to or comprising a mouthpiece and/or filter, and an upstream end, also referred to as a distal end. In some embodiments, the article comprises a plug comprising a combustion retarding additive at the distal end of the article. Alternatively or additionally, the plug comprising a combustion retarding additive may be in a different location in the article.
Distal end plugs may serve to prevent the aerosol generating material from being lost from the distal end of the article.
In some embodiments, the plug comprising a combustion retarding additive is adjacent to the rod of aerosol generating material. In some embodiments, the plug comprising a combustion retarding additive is in contact with the aerosol generating material.
In some embodiments, a heating element or heating material may contact the article or may be embedded within the article when the article is in use in a non-combustible aerosol provision system. In some arrangements, the heating element or heating material can expose the plug comprising a combustion retarding additive to high temperatures. In some embodiments, the plug comprising a combustion retarding additive is adjacent to the heating element or heating material. In some embodiments, the plug comprising a combustion retarding additive is in contact with the heating element or heating material.
It is therefore desirable to ensure that the plug can resist combustion. Where the plug is formed from a material that may combust or degrade upon exposure to high temperatures, one or more combustion-retarding additive is added to prevent such combustion and/or degradation.
Advantageously, the plug comprising a combustion retarding additive may be formed from a non-plastic material, for example, a cellulosic material such as paper or a sheet material comprising an amorphous solid.
The inventors have found that combustion retarding properties are afforded by adding at least one combustion retarding additive to the plug. The presence of the plug comprising a combustion retarding additive makes it much harder to light the article and hinders combustion of the article.
The invention enjoys the advantage that the article is capable of withstanding higher temperatures without burning, which in turn can allow for the release of more volatiles. This is desirable for the end user of the non-combustible aerosol provision system. In addition, this invention has the additional advantage that this is safer if the consumer attempts to ignite the article as the invention reduces the combustion of the article.
In addition, plugs disclosed herein provide an environmentally friendly alternative to other plugs currently used, which may, for example, comprise cellulose acetate or other plastic materials.
As described herein, the combustion retarding properties may be achieved with a salt such as NaCl, a sustainable and accessible resource. In addition, the plug may comprise paper or a paper-like material, or an amorphous solid material, as described herein. These materials may be sustainably sourced, and are biodegradable. The biodegradability of the wrapper is environmentally friendly and an attractive feature to consumers.
The plug can have an axial length of, for instance, about 5 mm to about 20 mm, for instance about 5 mm to about 15 mm or about 5 mm to about 12 mm.
The plug can have a circumference of about 17 mm to about 25 mm, for instance about 19 mm to about 24 mm or about 20 mm to about 23 mm.
The pressure drop across the plug can be at least about 5 mmWG, at least about 7 mmWG, at least about to mmWG, at least about 12 mmWG, or at least about 15 mmWG. Alternatively or additionally, the pressure drop across the plug can be less than about 60 mmWG, less than about 50 mmWG, or less than about 40 mmWG. For instance, the pressure drop across the plug can be in the range of 10 to 50 mmWG, for instance in the range of 12 to 40 mmWG or 15 to 30 mmWG. In some embodiments, the plug comprising a combustion retarding additive may exhibit a pressure drop of from about 12 to about 40 mmWG.
In some embodiments, the pressure drop across the plug is at least about 1 mmWG per mm axial length of the plug, for instance at least about 1.2, 1.5, 1.8, or 2 mmWG per mm axial length of the plug. In some embodiments, the pressure drop across the plug is less than about 4 mmWG per mm axial length of the plug, for instance less than about 3.5, 3.2, 3, or 2.5 mmWG per mm axial length of the plug. For instance, the pressure drop across the plug can be in the range of 1.0 to 4.0, or 1.5 to 3.5, or 2.0 to 3.0 mmWG per mm axial length of the plug.
The plug can have a bulk density of at least about 0.05 mg/mm³, for instance, a bulk density of at least about 0.07 mg/mm³, at least about 0.1 mg/mm³or at least about 0.12 mg/mm³. Alternatively or additionally, the plug can have a bulk density of less than about 0.3 mg/mm³, less than about 0.27 mg/mm³or less than about 0.25 mg/mm³. For instance the plug can have a bulk density between about 0.05 and about 0.35 mg/mm³, between about 0.1 and about 0.3 mg/mm³or between about 0.15 and about 0.25 mg/mm³. The plug can have a bulk density of about 0.2 mg/mm³.

Body of the Plug

In some embodiments, the plug is formed from a biodegradable and sustainable material. In some embodiments, the plug comprising a combustion retarding additive does not include a material which is considered to be a plastic material, including bioplastics such as cellulose acetate.
In some embodiments, the plug comprising a combustion retarding additive is formed from a sheet material. In particular, the plug may be at least partially formed from a gathered sheet, or a gathered and crimped sheet. The plug comprising a combustion retarding additive may also be formed by cutting sheet material into longitudinal strips which are gathered into a rod.
In some embodiments, the plug may be formed from a combination of sheet material comprising a combustion retarding additive and sheet material that does not comprise the additive.
In some embodiments, the sheet material comprises cellulosic material. In some embodiments, the cellulosic material makes up at least 20%, 30%, 40% or 50% of the sheet material.
In some embodiments, the sheet may comprise or consist substantially of paper or a paper-like material. Said paper or paper-like material may be between about 20 gsm and about 150 gsm or from about 20 gsm to about 120 gsm. In some embodiments, the paper or paper-like material may be between about 25 gsm and about 35 gsm, or between about 55 gsm and 65 gsm.
In some embodiments, the sheet material may be formed from plant material, including from tobacco material. For example the sheet material may be a reconstituted tobacco material, or a similar material formed from other types of plants or plant matter.
In some embodiments, the plug comprising a combustion retarding additive is formed from a fibrous material. In some embodiments, the fibrous material is a non-plastic material, for example, the plug is not formed from cellulose acetate. The combustion retarding additive may be added to the fibrous material before it is formed into the plug. Alternatively or additionally, the combustion retarding additive may be added to the fibrous material after it is formed into the plug. For example, the combustion retarding additive may be added to one or more surfaces of the plug.
In some embodiments, an aerosol-modifying agent as described herein and/or an aerosol-former material as described herein is/are included in the plug, for instance when the plug is formed from a sheet material such as a cellulose-based material such as paper. In some embodiments, the aerosol-modifying agent and/or the aerosol-former material may be applied to the material forming the plug before the plug is formed. Alternatively or additionally, the aerosol-modifying agent and/or aerosol-former material may be applied to the formed plug.
The aerosol-former material can include one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. At least 0.02 mg of aerosol-former material can be applied to the plug per 1 mm axial length of the plug, for instance at least 0.03, 0.04 or 0.05 mg of aerosol-former material per 1 mm axial length of the plug. Less than 0.5 mg of aerosol-former material can be applied to the plug per 1 mm axial length of the plug, for instance less than 0.4 mg, less than 0.3 mg, less than 0.2 mg, or less than 0.1 mg. For instance, between about 0.02 and 0.5 mg of aerosol-former material can be applied to the plug per 1 mm of axial length of the plug, or between about 0.05 mg and about 0.4 mg. For instance, between about 0.02 and 0.5 mg of glycerine or propylene glycol can be applied to the plug per 1 mm of axial length of the plug, or between about 0.05 mg and about 0.4 mg.
In some embodiments, the plug comprising a combustion retarding additive is formed from an “amorphous solid material”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid material may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
The amorphous solid material may comprise from about 0.1 wt %, 0.5 wt %, 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt % or 35 wt % of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50 wt %, 5-45 wt %, 10-40 wt % or 20-35 wt % 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 from the group comprising polysaccharides such as alginates, pectins, starches (and derivatives), and celluloses (and derivatives); gums, silica or silicones compounds; clays; polyvinyl 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, chitosan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation 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. In an embodiment, the alginate is present in the amorphous solid in an amount of from 1-30 wt % 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 further gelling agent, such as pectin.
In some embodiments the plug comprising a combustion retarding additive may comprise an amorphous solid which may include gelling agent comprising carrageenan.
Suitably, the amorphous solid may comprise at least about 0.1 wt %, 0.5 wt %, 1 wt %, 3 wt %, 5 wt %, 7 wt %, 10 wt %, 15 wt %, 20 wt %, 25 wt %, 30 wt %, 35 wt % or 40%, and/or up to about 75 wt %, 70 wt %, 65 wt %, 60 wt %, 55 wt % or 50 wt % of an aerosol-former material (all calculated on a dry weight basis). For example, the amorphous solid may comprise 5-10 wt %, 20-70 wt %, 40-60 wt % or 50-60 wt % of an aerosol-former material.
As used herein, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
In some cases, the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, vegetable glycerine (VG), triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of or consists of glycerol.
The aerosol-former material may act as a plasticiser. For example, the amorphous solid material may comprise 0.5-40 wt %, 3-35 wt % or 10-25 wt % of an aerosol-former material. In some cases, the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of or consists of glycerol. The plasticiser content specified herein provides an amorphous solid flexibility which allows the amorphous solid sheet to be wound onto a bobbin, which is useful in manufacture of a plug for inclusion in aerosol-generating articles.
In some embodiments, the amorphous solid material is a hydrogel and comprises less than about 20 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15 wt %, 12 wt % or 10 wt % of 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 % of water (WWB).
In some embodiments, the plug comprising a combustion retarding additive is formed from a sheet of amorphous solid material. In particular, the plug may be formed from a gathered sheet, or a gathered and crimped sheet comprising an amorphous solid material. The plug may also be formed by cutting one or more sheets of amorphous solid material into longitudinal strips which are gathered into a rod.
In other embodiments, plug comprising a combustion retarding additive may be formed as a solid mass comprising an amorphous solid material. For example, the plug may be a cylindrical mass or portion of an amorphous solid material.
In some circumstances, and particularly if the plug is made of relatively dense material or is tightly compressed or gathered into a rod, the plug may restrict air flow through it. To mitigate this, it is possible to provide perforations or holes. In some embodiments, the perforations or holes are provided in the article downstream of the plug comprising a combustion retarding additive, so that air can be drawn into the consumable, and into the aerosol-generating material, through the perforations. Alternatively or in addition, holes or perforations may be provided that allow air being drawn into the consumable through the plug comprising a combustion retarding additive.

The Combustion Retarding Additive

The combustion retarding additive is an additive that, when added to or incorporated into a plug, can reduce the tendency of the plug to combust when exposed to high temperatures.
The combustion retarding additive may be added to the plug before, during or after the plug is formed or assembled. Thus, for example, the combustion retarding additive may be added to or incorporated into the material from which the plug is formed.
In some embodiments, the combustion retarding additive is added to or applied to a sheet material which is used to form the plug. The combustion retarding additive may be incorporated into the sheet material, for example during the manufacture of the sheet material. Alternatively or additionally, the combustion retarding additive may be applied to the sheet material, for example in the form of a coating comprising the additive, as discussed in greater detail below.
In some embodiments, the combustion retarding additive is added to or applied to an amorphous solid material which is used to form the plug. The combustion retarding additive may be incorporated into the amorphous solid material, for example during the manufacture of the amorphous solid material. Alternatively or additionally, the combustion retarding additive may be applied to the amorphous solid material, whether this is in the form of a sheet or a mass. For example, the combustion retarding additive may be added in a coating that is applied to the surface of the amorphous solid material, as discussed in greater detail below.
In some embodiments, the plug comprising a combustion retarding additive comprises one or more combustion retarding additive in a total amount of at least about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt % about, about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, and/or in an amount of no more than about 70 wt %, about 65 wt %, about 60 wt %, about 55 wt %, or about 50 wt % of the plug (all calculated on a dry weight basis). The quantity of combustion retarding additive is selected to provide the desired combustion retarding effect.
In some embodiments, the coating on or in the plug comprising a combustion retarding additive comprises one or more combustion retarding additive in a total amount of at least about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt % about, about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, and/or in an amount of no more than about 70 wt %, about 65 wt %, about 60 wt %, about 55 wt %, or about 50 wt % of the coating (all calculated on a dry weight basis). The quantity of combustion retarding additive is selected to provide the desired combustion retarding effect.
For the avoidance of doubt, any reference to the amount of combustion retarding salt in the plug is a reference to the amount of added salt, and does not include any salt that may be present in the plug without the addition of the combustion retarding salt as described herein.
The combustion-retarding salt used herein is a chemical compound consisting of an ionic assembly of cation and anions. The salts used herein are those whose anion and/or whose cation may be effective in retarding combustion. In some embodiments, the salt is an inorganic salt.
In some embodiments, the salt is a halide salt, i.e. has a halide anion. In some embodiments, the salt is a chloride salt or a bromide salt. The presence of high concentrations of chloride or bromide has been shown to retard combustion, as discussed further below.
In some embodiments, the salt may be an alkali metal salt, i.e. has an alkali metal cation. In some embodiments, the salt has an alkaline earth metal cation. In some embodiments, the salt has a zinc cation or an iron cation, such as a ferric or ferrous cation. In some embodiments, the salt has an ammonium cation or a phosphonium cation.
In some embodiments, the salt may be an alkali metal halide, such as sodium chloride or potassium chloride. The salt may be an alkaline earth metal halide, such as magnesium chloride, calcium chloride. The salt may be another metal halide, such as zinc chloride or sodium bromide.
In some embodiments, the salt has a carboxylate anion. For example, the salt may be an alkali metal carboxylate, such as potassium citrate, potassium succinate, potassium malate, potassium acetate, potassium tartrate, potassium oxalate, sodium citrate, sodium succinate, sodium acetate, or sodium malate.
In other embodiments, the salt has an anion selected from: borate, carbonate, phosphate, sulphate or sulphamate.
Factors that may influence the selection of salt will include, for example, melting point, which will preferably be at least 450° C. In some embodiments, the salt is soluble in water. In some embodiments, the salt is selected to provide a desired pH to the material it is added to. In some embodiments, the salt will not significantly change the pH of the material.
In some embodiments, sodium chloride (NaCl) is the salt used. It has been demonstrated that wrapper with a high chloride content is difficult to combust. Further, sodium chloride is neutral, highly soluble and does not affect pH of the wrapper.
The combustion retarding salt may be one salt or a combination of any number of salts disclosed herein or known in the art, and is referred to as “combustion retarding salt” herein. The combustion retarding salt(s) may be advantageously selected to give the combustion retarding material desired characteristics.
In some embodiments, the combustion retarding salt comprises, consists essentially of, or consists of sodium chloride, potassium chloride, sodium bromide and/or potassium bromide.
Depending on the combustion retarding or other physical properties desired, the components of the salt may be in free base form, salt form, or as a complex, or as a solvate. The combustion retarding salt may be of any density and any crystalline structure.

Binder

In some embodiments, the combustion retarding additive is added to the plug in the form of a coating comprising a combustion retarding additive and a binder. The coating may be added to the sheet material used to form the body of the plug. In some embodiments, the coating is added to the sheet before it is gathered to form a plug. In other embodiments, the coating is added to the formed plug.
The binder may be a film-forming material, which forms the basis of the coating comprising the combustion retarding additive. The combustion retarding additive may be located in or on the film formed from the binder. In some embodiments, the salt is mixed with the binder and applied to the wrapper, as discussed in greater detail below.
The binder may adhere the combustion retarding additive to the sheet material or plug. It may also be used to adhere the sheet or plug to itself and/or to other components of the article.
Suitable binders include, for example, film-forming agents such as polyvinyl alcohol (PVA), gelatin, gums such as acacia gum, starches and derivatives thereof, polysaccharides, pectins, alginates, wood pulp, celluloses, cellulose derivatives such as carboxymethylcellulose, silica or silicones compounds, clays, and combinations thereof. Suitable binders include, for example, gelling agents such as one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, chitosan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder may include alginate and/or pectin, and the precursor material may further comprise a setting agent (such as a calcium source) which may aid formation of the amorphous solid. In some cases, the binder may include a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the coating comprises at least about 0.1 wt %, about 0.2 wt %, about 0.3 wt %, about 0.4 wt %, about 0.5 wt %, about 0.6 wt %, about 0.7 wt %, about 0.8 wt %, about 0.9 wt %, about 1 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt % or at least about 50 wt % of a binder (all calculated on a dry weight basis). In some cases, the coating comprises no more than about 70 wt %, about 65 wt %, about 60 wt %, about 55 wt %, about 50 wt %, about 45 wt %, about 40 wt %, about 35 wt %, or about 30 wt % of a binder (all calculated on a dry weight basis).

The Precursor Material

In some embodiments, the combustion retarding additive is incorporated into or added to the precursor material which is used to form the coating.
In some embodiments, the combustion retarding additive is suspended in the precursor material. In some embodiments, the combustion retarding additive is dissolved in the precursor material, optionally in the presence of a solvent. The solvent may be an aqueous or organic liquid, and may be polar or non-polar depending on the materials that are to be dissolved and the extent to which they are to be dissolved.
The precursor material may comprise from about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt %, about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, or about 50 wt % of the combustion retarding additive (all calculated on a dry weight basis).
The precursor material may comprise from about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt %, about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, or about 50 wt % of a combustion retarding salt (all calculated on a dry weight basis).
In some embodiments, a precursor material comprising the combustion retarding additive is applied to the surface of the sheet or plug. This deposits the combustion retarding additive on the surface of the sheet or plug and provides a coating on the surface of the sheet or plug.
In some embodiments, the sheet or plug is contacted with the precursor material such as a solution or a suspension comprising the combustion retarding additive. This technique may be used to form a coating comprising the combustion retarding additive on the surface or a portion of the surface of the sheet or plug. In some embodiments, precursor material may be sprayed, printed, painted or otherwise locally applied onto the sheet or plug. This is advantageous because it can result in the formation of a coating of the combustion retarding additive evenly distributed over the sheet or plug. Some methods of application, such as spraying, printing and painting, may be more precise, providing a localised coating or capable of applying a higher concentration of combustion retarding additive onto the sheet or plug.
The sheet or wrapper may be contacted with the precursor material comprising the combustion retarding additive multiple times to form one or more layers comprising the combustion retarding additive. In some embodiments, one layer may be allowed to dry before the next layer is applied. In some embodiments, the composition of the layers may be different, for example comprising different combustion retarding additives and/or other components such as binders. This may provide a specific combustion—retarding profile or make use of different adhesive properties of the binder. This process may also be repeated to provide a desired thickness of the layer of combustion retarding additive, and/or a desired amount or concentration of combustion retarding additive, which is a further advantage. The additional thickness where the coating has been added to the sheet or plug may contribute to improved structural rigidity or increase its tensile strength.
In some embodiments, the precursor material and/or subsequent coating comprises or is in the form of an amorphous solid which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the precursor material or coating may be in the form of a dried gel. An amorphous solid is a solid material that may retain some fluid, such as liquid, within it. The precursor material or coating in the form of an amorphous solid may comprise a binder consisting of at least one gelling agent as described herein. A precursor material or coating which comprises an amorphous solid enjoys the advantage of providing increased tensile strength and rigidity to the sheet or plug.
In some embodiments, the precursor material used to form one layer may be in the form of a liquid in one layer and the precursor material used to form another layer may be in the form of a solid or an amorphous solid. In an exemplary embodiment, a precursor material in the form of a liquid and comprising a binder such as PVA may provide a first layer. A precursor material in the form of an amorphous solid may provide a second layer. The second layer may be in the form of the sheet. Such an embodiment provides a sheet or plug to which an amorphous solid sheet is adhered via the first layer. The layer(s) may be located on a specific portion of the sheet or plug and thus provide the advantages of the form of an amorphous solid locally. The amorphous solid may comprise additional components as described herein and advantageously provide the additional components locally to a portion of the sheet or plug.
The layers may comprise the same combustion retarding additive or different combustion retarding additives. Additionally, the proportion of the combustion retarding additive in the precursor material may be altered to provide the layer(s) on sheet or plug with desired properties.
In some embodiments, the coating comprising the combustion retarding additive is applied to a portion of the sheet or plug, for example a patch or section of the sheet or plug. The coating may be applied to the inner and/or outer surface of the wrapper.
In some embodiments, the coating is on the surface of the plug which is positioned adjacent to the aerosol-generating material in the article.
In another embodiment of the invention, the precursor material may be applied in the form of a printed patch. In this embodiment, the precursor material may have properties that are tailored to this method of application, for example, the precursor material may have a suitable viscosity or may comprise a higher concentration of the combustion retarding additive. The advantage of this method of application is that the print patch may be of a precise size, shape and location on the sheet or plug and the method provides a more controlled application of the salt onto the sheet or plug. The print patch may be located on a portion or all of the sheet of plug.

Components of the Precursor Material

In some embodiments, the precursor material comprises a binder and the combustion retarding additive.
In some cases, the precursor material comprises at least about 0.1 wt %, about 1 wt %, about 10 wt %, about 20 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt % or at least about 50 wt % of a binder (all calculated on a dry weight basis). In some cases, the precursor material comprises no more than about 70 wt %, about 65 wt %, about 60 wt %, about 55 wt %, about 50 wt %, about 45 wt %, about 40 wt %, about 35 wt %, or about 30 wt % of a binder (all calculated on a dry weight basis).
The precursor material may comprise the appropriate amount of binder in order to provide an advantageous viscosity. For example, the precursor material must be viscous enough to form a film and provide a coating having the desired thickness or other physical characteristics. However, if the viscosity of the precursor material is too great, the material may be difficult to apply to the sheet or plug.
In some embodiments, the precursor material comprising a binder provides an adhesive quality to the precursor material. The precursor material may be a viscous composition with adhesive or “glue-like” qualities. In some embodiments, the precursor material, and the subsequent coating, may advantageously be used to secure the sheet or plug in place.
In some embodiments, the precursor material comprises one or more solvents. The solvent may be included to dissolve one or more components of the precursor material. Additionally or alternatively, the solvent may be included to control the properties of the precursor material, such as its viscosity or its drying behavior under certain conditions. The viscosity of the precursor material can be reduced, for example, to facilitate its application to a wrapper, whilst maintaining the desired binder and additive content.
The solvent may comprise one or more liquid, including aqueous liquid and non-aqueous liquid. For example, the solvent may be selected from the group consisting of: water (such as distilled water), benzyl alcohol, ethanol, methanol, triacetin, glycerol, propylene glycol, or combinations thereof. In some embodiments, the solvent is distilled water.
The solvent may be advantageously selected to be readily removed following application of the precursor material onto the sheet or plug to form a (dry) coating comprising the combustion retarding salt on the surface of the sheet or plug. In some embodiments, the solvent may be removed as a result of a treatment step, as discussed in more detail below. In some embodiments, the liquid carrier is a volatile solvent, which may be advantageously be removed by evaporation.

Treating the Precursor Material

The precursor material, once applied to the surface of a sheet or plug, may optionally be treated to provide the coating. The treatment may include a step comprising drying, curing, cross-linking of alginates or polymers, heating or any other suitable treatment. This provides the advantage that the coating may have different properties to the precursor material. For example, the precursor material may be a liquid but may hardened on the sheet or plug during a treatment step, providing a coating with a suitable rigidity. In a further example, the precursor material may be “sticky” prior to treatment, and may not be sticky after treatment in order to prevent the sheet or plug adhering to surfaces unintentionally.
The precursor material may be treated differently in different locations of the sheet or plug. This provides the advantage that the combustion retarding additive and properties may be provided in distinct sections of the sheet or plug.
In some embodiments, some components of the precursor material are removed, for example via evaporation, to leave the combustion retarding additive (and other non-volatile components) deposited on the sheet or plug in the coating.
In some embodiments, the precursor material or components of the precursor material may remain in the coating formed on the sheet or plug, and may provide the coating with additional combustion retardant, taste, flavor and/or physical characteristics.
In some embodiments the precursor material is not treated, and forms the coating without further processing.

The Coating

In some embodiments, the coating may have a thickness of from about 0.2 μm to about 50 μm. The coating may have a thickness of at least about 0.2 μm, about 0.3 m, about 0.4 μm, about 0.5 μm, about 0.6 μm, about 0.7 μm, about 0.8 μm, about 0.9 μm, about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm. The coating may have a thickness of no more than about 50 μm, about 45 μm, about 40 μm, about 35 μm, about 30 μm, about 25 μm, about 20 μm, about 15 μm, about 10 μm or about 5 μm.
The combustion retarding additive coating may comprise more than one layer, and the coating thickness described herein refers to the aggregate thickness of those layers. The coating may also contain other additives in addition to the combustion retarding additive(s) as disclosed herein. The coating may also be very thin, and inconsistent across the surface of the sheet or plug. The thickness of the coating may be selected to provide desirable combustion retarding characteristics, and to provide the coated sheet with satisfactory rigidity and structural integrity.
The thickness of the coating of combustion retarding salt may be measured using a microscope such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.
In some cases, the coating thickness may vary by no more than about 25%, about 20%, about 15%, about 10%, about 5% or about 1% across its area. This has the advantage that the coated sheet has a consistent thickness, and/or a plug formed from the coated sheet or having a coating has consistent dimensions so that the plug may fit with the other components of the article and so that the article may fit more easily into the non-combustible aerosol provision system.
In some embodiments of the invention, only a portion of the total area of a surface of a sheet for inclusion in a plug comprises the coating comprising the combustion retarding additive. In other embodiments, all of a surface of the sheet comprises the coating comprising the combustion retarding additive.
In an article comprising the coating described herein, a portion of the plug towards or adjacent to an end of the rod of aerosol generating material may comprise the coating comprising the combustion retarding additive. This embodiment enjoys the advantage of preventing the plug combusting if the aerosol-generating material or heating material located therein is heated to a high temperature.

Methods

The articles described herein may be manufactured by a method wherein a combustion retarding additive is incorporated into a plug or is applied to a surface of a plug, and then the plug is incorporated into an article with a rod of aerosol generating material.
In some embodiments, the plug is incorporated at the distal end of the article.
In some embodiments, the method comprises gathering one or more sheets into a rod, wrapping the rod and cutting it into discrete sections to form the plug. The method may comprise crimping the sheet prior to gathering the sheet into a rod.
The method may comprise gathering the sheet around a former to form a hole through the plug.
In some embodiments where the plug is formed from a sheet, the combustion retarding additive is included when the sheet material is made.
In some embodiments where the plug is formed from a sheet, the combustion retarding additive is incorporated into a coating that is applied to a surface of the sheet material.
In some embodiments, the combustion retarding additive is applied to at least part of a surface of the formed plug. In some embodiments, the combustion retarding additive is incorporated into a coating that is applied to a surface of the plug.
In some embodiments, the coating is formed by applying a precursor material comprising a binder and the combustion retarding additive to a surface.

Consumables

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
A consumable is an article comprising aerosol-generating material, part or all of which is intended to be consumed during use by a user, as well as a plug comprising a combustion retarding additive, as described herein. The article has a downstream end, usually connected to or comprising a mouthpiece and/or filter, and an upstream end, also referred to as a distal end. In some embodiments, the article comprises a plug comprising a combustion retarding additive at the distal end of the article.
A consumable may further comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.
A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator herein.
In some embodiments, the heating material may comprise a metal or a metal alloy. In some embodiments, the heating material may comprise one or more materials selected from the group consisting of: aluminium, gold, iron, nickel, cobalt, conductive carbon, graphite, plain-carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. Other heating material(s) may be used in other embodiments. In some embodiments, the heating material may be magnetic. It has also been found that, when magnetic electrically-conductive material is used as the heating material, magnetic coupling between the magnetic electrically-conductive material and an electromagnet of the apparatus may be enhanced in use. In addition to potentially enabling magnetic hysteresis heating, this can result in greater or improved Joule heating of the heating material, and thus greater or improved heating of the smokeable material.
In some embodiments, the heating material comprises a plate or strip or ribbon. In some embodiments, the heating material comprises a mesh or expanded metal.
In some embodiments, the heating material is in contact with the aerosol generating material when the article is in use. In some embodiments, the heating material is incorporated into the article. In other embodiments, the heating material is inserted into the article when the article is inserted into the non-combustible aerosol provision device.
Where the article includes heating material, such as a susceptor, the heating material may be included in the rod of aerosol generating material. In some embodiments, the heating material is distributed within the aerosol generating material. In some embodiments, a sheet or mesh of heating material extends through the rod of aerosol generating material. In some embodiments, the heating material extends to the end of the rod of aerosol generating material that abuts the plug comprising a combustion retarding additive. In some embodiments the plug comprising a combustion retarding additive abuts the upstream end of the rod of aerosol generating material, and is optionally at the distal end of the article.
The heating material may be in contact with the plug comprising a combustion retarding additive. In some embodiments, the heating material may extend through the plug comprising a combustion retarding additive and into the aerosol generating material. In such embodiments, the plug comprising a combustion retarding additive may be upstream of the rod of aerosol generating material, and is optionally at the distal end of the article.
An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavorants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50 wt %, about 60 wt % or about 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.
In some embodiments, the article comprises a wrapper that circumscribes the rod of aerosol generating material and the plug, wherein at least a portion said wrapper comprises a combustion retarding additive. In some embodiments, the combustion retarding additive is provided in the form of a coating on at least a portion of the surface of the wrapper.
The wrapper may comprise a combustion retarding additive, and the coating comprising it as described herein with respect to the plug. The combustion retarding additive may be incorporated into the wrapper in a manner as described herein with respect to the plug.
The inventors have found that combustion retarding properties are afforded by adding at least one combustion retarding additive to the coating which is provided on a surface of the wrapper. The presence of the coating comprising a combustion retarding salt makes it much harder to light the article and hinders combustion of the article.
In addition, this wrapper provides an environmentally friendly alternative to other wrappers known to perform a combustion-retarding role. For example, it is common to use aluminium as a wrapper to retard combustion in aerosol-generating articles. As aluminium is energy-intensive to produce and challenging to recycle after use, the wrapper described herein is a more sustainable alternative.
As used herein, the wrapper is an integral part of the article or consumable, and the term is not used to refer to any packaging of the article that is removed before use of the article.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energized so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the article, wrapper, carrier, amorphous solid, aerosol-generating material or any component of the article may further comprise one or more of aerosol-former material(s), functional material(s), flavor(s), botanical(s), active substance(s) or aerosol-modifying agent.
The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
As used herein, the terms “flavor” and “flavorant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavor 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, fenugreek, 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 fruits, 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, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.
In some embodiments, the flavor may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth 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 effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
In some embodiments, the substance to be delivered comprises a flavor.
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 for example be selected from nutraceuticals, nootropics, and psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the substance to be delivered comprises an active substance.
In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, 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.
As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term “botanical” includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, 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 from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component that is operable to selectively release the aerosol-modifying agent
The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of aflavorant, acolorant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.
In some embodiments, the article comprises a substrate. The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.
In some embodiments, the non-combustible aerosol provision system comprises an aerosol generator. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.
FIG. 1 is a side-on cross sectional view of a consumable or article 1 for use in an aerosol delivery system. The article 1 comprises a mouthpiece segment 2, and an aerosol generating segment 3.
The aerosol generating segment 3 is in the form of a cylindrical rod and comprises an aerosol-generating material 4 comprising, in this example, cut rag reconstituted tobacco. The aerosol-generating material can be any suitable material.
The mouthpiece segment 2, in the illustrated embodiment, includes a body of material 5 such as gathered paper or a fibrous or filamentary tow.
The rod-shaped consumable 1 further comprises a wrapper 6 circumscribing the mouthpiece segment 2 and aerosol generating segment 3, such as a paper wrapper. The consumable 1 also includes a plug 7 comprising a combustion retarding additive at the distal end.
FIG. 2 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating medium/material such as the aerosol-generating material of a consumable 110, as described herein. In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating medium, for instance an article 1 as illustrated in FIG. 1 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article 110 together form a system.
The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In FIG. 2 , the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow “B”.
The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.
The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

EXAMPLES

Sheets including a combustion retarding salt were tested to assess their resistance to burning. For testing, the sheets were exposed to a naked flame to see whether they would combust.

Example 1

In a first example, various coatings on paper sheets were prepared by applying two layers of a precursor material. The different tests used different concentrations of combustion retarding salt and binder, as shown in Table 1. The combustion retarding salt was NaCl, and the binder was PVA glue. None of the treated sheets ignited upon attempted combustion.

TABLE 1

	Combustion		First	Second	Total
	retarding salt	Binder:distilled	layer	layer	Coating
Test	(%)	water	(g)	(g)	(g)

1	5.0	50:50	0.0156	0.0132	0.0288
2	7.0	25:75	0.0207	0.0148	0.0355
3	7.5	50:50	0.0161	0.0137	0.0298

Example 2

A sheet of an amorphous material comprising a combustion retarding salt was formed from a slurry having the following make up:

- 43 g alginate (2.7%)
- 100 g sodium chloride (6.3%)
- 50 g glycerol (3.1%)
- 1400 ml water (87.9%)

The slurry was dried in an oven and the resulting sheet was tested by trying to light the sheet using a naked flame. The sodium chloride content of the dried sheet was 52 wt % (dry weight basis), and the amount of alginate binder was 22.3 wt % (DWB).
Tests showed that the amorphous solid material comprising sodium chloride resisted combustion well.
In addition, a further sheet was formed from a slurry having the following make up:

- 21.5 g alginate
- 21.5 g wood pulp
- 120 g sodium chloride
- 30 g glycerol
  - 1400 ml water

The slurry was dried in an oven to form a sheet. The sheets that were obtained also did not combust when exposed to a naked flame from a lighter. The sodium chloride content of the dried sheet was 62.2 wt % (dry weight basis), and the amount of alginate binder was 11.1 wt % (DWB).
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and 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 comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. An article for use in a non-combustible aerosol provision system, the article:

a rod comprising an aerosol-generating material,

and a plug comprising a combustion retarding additive.

2. The article as claimed in claim 1, wherein the plug comprising a combustion retarding additive is;

(i) at the distal end of the article;

(ii) adjacent to the rod of aerosol generating material; and/or

(iii) in contact with the rod of aerosol generating material.

3. (canceled).

4. (canceled).

5. The article as claimed in claim 1, wherein the combustion retarding additive is an alkali metal salt, optionally selected from the group consisting of: sodium chloride, potassium chloride, sodium bromide, potassium bromide, and combinations thereof.

6. The article as claimed in claim 1, wherein the plug is formed from a sheet material, optionally wherein the sheet material is paper or paper-like material or wherein the sheet material comprises an amorphous solid, optionally wherein the combustion retarding additive is incorporated in the amorphous solid material.

7. (canceled)

8. (canceled)

9. The article as claimed in claim 6, wherein the combustion retarding additive is incorporated in the sheet material; and/or wherein the combustion retarding additive is provided in a coating on a surface of the sheet material.

10. (canceled)

11. The article as claimed in claim 1, wherein the plug comprises a mass of an amorphous solid material, optionally wherein the combustion retarding additive is incorporated in the amorphous solid material.

12. (canceled)

13. The article as claimed in claim 11, wherein the amorphous solid material comprises from about 3 wt % to about 60 wt % combustion retarding salt (dry weight basis).

14. The article as claimed in claim 1, wherein the combustion retarding additive is provided in a coating on a surface of the plug, the coating optionally comprising from about 3 wt % to about 70 wt % of at least one combustion retarding additive (dry weight basis), and/or optionally comprising a binder.

15. (canceled)

16. (canceled)

17. The article as claimed in claim 14, wherein the binder is selected from one or more of the group consisting of polyvinyl alcohol (PVA), gelatin, gums, acacia gum, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose, optionally wherein the coating comprises from about 10 wt % to about 97 wt % of at least one binder.

18. (canceled)

19. The article as claimed in claim 1, comprising

heating material, optionally wherein the heating material is:

(i) heatable by penetration with a varying magnetic field to heat the aerosol generating material; and/or

(ii) in contact with the aerosol generating material; and/or

(iii) in contact with the plug comprising a combustion retarding additive.

20. (canceled)

21. (canceled)

22. (canceled)

23. The article as claimed in claim 1, wherein the aerosol generating material:

(i) comprises one or more of tobacco per se, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenised tobacco or tobacco substitutes;

(ii) is in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted smokeable material, liquid, gel, gelled sheet, powder or agglomerates; and/or

(iii) comprises non-tobacco material.

24. (canceled)

25. (canceled)

26. The article as claimed in claim 1, wherein the plug comprising a combustion retarding additive;

(i) exhibits a pressure drop of from about 5 to about 40 mmWG; and/or

(ii) has a bulk density of between about 0.1 and about 0.3 mg/mm3.

27. (canceled)

28. A non-combustible aerosol provision system comprising an article as claimed in claim 1.

29. A method for manufacturing the article as claimed in claim 1, wherein a combustion retarding additive is incorporated into a plug or is applied to a surface of a plug, and the plug is incorporated into an article with a rod of aerosol generating material, optionally wherein the plug is incorporated at the distal end of the article.

30. (canceled)

31. The method as claimed in claim 29, comprising gathering one or more sheets into a rod, wrapping the rod and cutting it into discrete sections to form the plug, optionally crimping the sheet prior to gathering the sheet into a rod, and/or gathering the sheet around a former to form a hole though the plug.

32. (canceled)

33. (canceled)

34. The method as claimed in claim 31, comprising applying to a surface of the sheet material a coating comprising the combustion retarding additive or comprising applying to a surface of the plug a coating comprising the combustion retarding additive.

35. (canceled)

36. The method as claimed in claim 34, wherein the coating is formed by applying a precursor material comprising a binder and the combustion retarding additive to a surface, optionally wherein the coating is applied to a surface using one or more processes selected from the group consisting of: spraying, painting or printing.

37. (canceled)

38. Use of a combustion retarding additive for retarding combustion of a plug in an article for use in a non-combustible aerosol provision system.

39. A plug for use in an article for use in a non-combustible aerosol provision system, the plug comprising a combustion retarding additive.

40. The plug as claimed in claim 39, wherein the plug;

(i) comprises a combustible material;

(ii) comprises one or more sheets of paper or paper-like material or comprises a body of an amorphous solid material; and/or

(iii) is resistant to combustion when exposed to temperatures up to 300° C.

41. (canceled)

42. (canceled)

43. (canceled)