WO2023118223A1 - Procédé de fabrication d'un consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol - Google Patents

Procédé de fabrication d'un consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol Download PDF

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Publication number
WO2023118223A1
WO2023118223A1 PCT/EP2022/087111 EP2022087111W WO2023118223A1 WO 2023118223 A1 WO2023118223 A1 WO 2023118223A1 EP 2022087111 W EP2022087111 W EP 2022087111W WO 2023118223 A1 WO2023118223 A1 WO 2023118223A1
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WO
WIPO (PCT)
Prior art keywords
aerosol generating
generating material
support
material slurry
aerosol
Prior art date
Application number
PCT/EP2022/087111
Other languages
English (en)
Inventor
Robert Press
Richard Hepworth
John Richardson
Original Assignee
Nicoventures Trading Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nicoventures Trading Limited filed Critical Nicoventures Trading Limited
Publication of WO2023118223A1 publication Critical patent/WO2023118223A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/42—Cartridges or containers for inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/20—Devices using solid inhalable precursors

Definitions

  • This disclosure relates to the field of non-combustible aerosol-provision systems, in particular to a method of manufacturing a product comprising aerosol generating material for use as a consumable for use with an aerosol provision device, a method for manufacturing consumables for use with an aerosol provision device, and an aerosol provision system including a consumable and an aerosol provision device.
  • Aerosol-generating articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible articles, aerosol generating assemblies, or aerosol provision devices.
  • a heating device which release compounds by heating an aerosolisable material, which may be referred to as a solid aerosolgenerating material.
  • the heating volatilises at least one component of the material, typically forming an inhalable aerosol.
  • These products may be referred to as heat- not-burn devices.
  • hybrid devices there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain an active) which is vaporised by heating to produce an inhalable vapour or aerosol.
  • the device additionally contains a solid aerosol-generating material (which may or may not contain a botanical material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.
  • a method of manufacturing an product in which the product comprises aerosol generating material and a support, in which the method comprises providing a support, applying aerosol generating material slurry to the support, and the aerosol generating material slurry is applied to the support using a silk screen or rotary screen printing technique.
  • a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision system in which the product is the product of the method according to the first aspect of the present disclosure.
  • a consumable for use with a non-combustible aerosol provision system in which the consumable is a portion of an product according to the second aspect of the present disclosure in which the portion of the product has been shaped and dimensioned to a desired configuration.
  • an aerosol provision device for use with a consumable according to the third aspect of the present disclosure, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.
  • an aerosol provision system comprising an aerosol provision device according to the fourth aspect of the present disclosure and a consumable according to the third aspect of the present disclosure.
  • Figure 1 shows a schematic view of a first embodiment of an product according to the present disclosure
  • Figure 2 shows a schematic view of a detail of the product of Figure 1 ;
  • Figure 3 shows a schematic view of an embodiment of a second detail of the product of Figure 1;
  • Figure 4 shows a sectional view along the section line A-A of the detail of Figure 3;
  • Figure 5 shows a schematic view of a second embodiment of a second detail of the product of Figure 1;
  • Figure 6 shows a sectional view along the section line B-B of the detail of Figure 5;
  • Figure 7 shows a schematic view of an embodiment of a consumable of the present disclosure
  • Figure 8 shows a schematic view of an embodiment of the method of manufacture of the product of Figure 1 ;
  • Figure 9 shows a schematic view of a second embodiment of an product according to the present disclosure.
  • Figure 10 shows a flow chart of the steps of an embodiment of the method of manufacture of the product of Figure 9.
  • the consumable of the present description may be alternatively referred to as an article.
  • the consumable comprises aerosol-generating material.
  • the consumable may comprise an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
  • Non-combustible aerosol provision systems release compounds from an aerosolgenerating 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.
  • 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.
  • the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
  • 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 aerosolgenerating material is not a requirement.
  • END electronic nicotine delivery system
  • the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system.
  • An example of such a system is a tobacco heating system.
  • 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.
  • 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.
  • the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.
  • the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
  • 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.
  • the exothermic power source comprises a carbon substrate which may be energised 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.
  • 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.
  • the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
  • a method of manufacturing a product in which the product comprises aerosol generating material and a support, in which the method comprises providing a support, applying aerosol generating material slurry to the support, and the aerosol generating material slurry is applied to the support using a silk screen or rotary screen printing technique.
  • An advantage of the present disclosure is that by using a silk screen or rotary screen printing technique the layer of aerosol generating material slurry is sufficiently thin for the aerosol generating material slurry to at least partially set in a short time period.
  • the thinness of the aerosol generating material slurry has an additional advantage that the aerosol generating material slurry is less likely to crack or form splits in the aerosol generating material whilst it is setting.
  • the application of aerosol generating material slurry is the application of one or more discrete portions of aerosol generating material slurry.
  • the one or more discrete portions of aerosol generating material slurry are applied at predetermined positions on the support.
  • the at least two discrete portions of aerosol generating material slurry are applied to the support at predetermined positions relative to each other.
  • the discrete portions are applied to the support in a grid pattern or other regular pattern.
  • the discrete portions of aerosol generating material slurry there are two or more discrete portions of aerosol generating material slurry, at least one of the discrete portions of aerosol generating material slurry is formed from an aerosol generating material slurry of a first composition, at least one of the discrete portions of aerosol generating material slurry is formed from an aerosol generating material slurry of a second composition, and the first and second compositions are different.
  • This has the effect that the different discrete portions may give rise to different sensory experiences for the user of the consumable.
  • the different discrete portions may be of different flavours.
  • there are two or more discrete portions of aerosol generating material slurry at least one of the discrete portions of aerosol generating material slurry is of a first size, at least one of the discrete portions of aerosol generating material slurry is second size, and the first and second sizes are different.
  • At least one of the discrete portions of aerosol generating material slurry is of a first shape
  • at least one of the discrete portions of aerosol generating material slurry is second shape
  • the first and second shapes are different.
  • a stencil is used in the silk screen or rotary screen printing technique, and the stencil is so configured that it determines the position and size of the one or more discrete portions of the aerosol generating material slurry when application of the aerosol generating material occurs.
  • the silk screen or rotary screen printing techniques include use of a screen or mesh through which the aerosol generating material slurry is forced by a squeegee or equivalent.
  • the mesh count (the number of threads crossing per inch or centimetre) of the screen may be chosen so as not to prevent any constituent of the aerosol generating material slurry from passing through the screen.
  • the mesh size may be chosen on the basis of the desired shape and size of the aerosol generating material slurry that will be applied to the support.
  • the mesh of the screen can be made of wires or filaments formed from metal, fabric, woven or non-woven materials, or plastics. For example, and without limitation, monofilament polyester or stainless steel.
  • the screen of the screen printing apparatus has a mesh count of between 80 threads per inch (about 32 threads per centimetre) and 325 threads per inch (about 128 threads per centimetre).
  • the aerosol generating material slurry is applied to the support in the form of a plurality of microdots of aerosol generating material.
  • the application of the aerosol generating material slurry as microdots comprises application using a screen with a mesh count of at lest 200 threads per inch (about 79 threads per centimetre).
  • the stencil is so configured that only a small number of holes in the mesh are not blocked and aerosol generating material slurry can be pushed through those holes.
  • the distance between adjacent wires or filaments is about 0.074 mm.
  • the plurality of microdots may be placed adjacent to each other or they may be at least partially overlapping.
  • the application of the microdots may be continued until sufficient aerosol generating material has been applied to form the discreet portion of aerosol generating material and that portion includes a predetermined quantity of aerosol generating material.
  • At least one of the microdots of aerosol generating material slurry is formed from an aerosol generating material slurry of a first composition
  • at least one of the microdots of aerosol generating material slurry is formed from an aerosol generating material slurry of a second composition
  • the first and second compositions are different.
  • the method further comprises filtering the aerosol generating material slurry before applying the aerosol generating material slurry to the support. This is advantageous because the filtration will remove any solids in the aerosol generating material which will block the screen of the silk screen or rotary screen apparatus.
  • the support is orientated at an angle to horizontal when the aerosol generating material slurry is applied to the support.
  • the support is orientated at an angle of one of at least 30 degrees, at least 40 degrees, at least 50 degrees, at least 60 degrees, at least 70 degrees or at least 80 degrees to horizontal when the aerosol generating material slurry is applied to the support.
  • the support is orientated at an angle of between 70 and 90 degrees to horizontal when the aerosol generating material slurry is applied to the support.
  • the thickness of the aerosol generating material slurry that needs to be initially applied to the support, it has been found that it is necessary for the surface of the support to which the aerosol generating material slurry is applied to be horizontal at the time of application and until the aerosol generating material has set sufficiently for it not to flow across the surface of the support if the support ceases to be horizontal. It has been found that by using silk screen printing techniques and I or rotary screen printing techniques, the aerosol generating material slurry does not flow across the surface of the support irrespective of the angle of the surface of the support to horizontal at the time of application of the aerosol generating material slurry to the support.
  • the manufacturing path can be configured not to be a straight and unbending manufacturing path.
  • the manufacturing path can, in the direction perpendicular to the major surfaces of the sheet, include one or more bends or curves, for example the manufacturing path may be serpentine.
  • the manufacturing apparatus used to apply the aerosol generating material slurry to the support may have a smaller footprint in the manufacturing location than known manufacturing apparatus without shortening the length of the manufacturing path.
  • the same size apparatus as is currently used may include a longer manufacturing path.
  • the method further comprises allowing or causing the aerosol generating material slurry applied to the support to at least partially set, in which the aerosol generating material slurry at least partially sets as an aerosol generating material film.
  • the setting of the aerosol generating material may also be known as curing.
  • the method further comprises measuring the thickness of the aerosol generating material after the aerosol generating material slurry is applied to the support.
  • the thickness measurement is performed after the aerosol generating material slurry has set or at least partially set.
  • the application of aerosol generating material slurry to the support is repeated at least once.
  • aerosol generating material slurry to the support is application of aerosol generating material slurry to the surface of the support, or to the surface of aerosol generating material which has been already applied to the support.
  • each application of aerosol generating material slurry to the support is application of aerosol generating material slurry to the same location or locations on the support.
  • At least two applications of aerosol generating material slurry to the support is application of aerosol generating material slurry to the surface of the support
  • each application of aerosol generating material slurry to the support is performed using a different silk screen or rotary screen printing apparatus.
  • This has an advantage that the aerosol generating material slurry can at least partially set as the support or portion of support to which aerosol generating material has been applied moves between the different silk screen or rotary screen printing apparatus.
  • the stencils used in connection with each of the different silk screen or rotary screen printing apparatus are of the same configuration. This allows accurate application of each application of aerosol generating material slurry to the support and that each second and subsequent application is on top of a previous application of aerosol generating material.
  • the method further comprises moving the support along a manufacturing path, in which the manufacturing path comprises two or more silk screen apparatus, two or more rotary screen printing apparatus, or at least one silk screen apparatus and at least one rotary screen printing apparatus.
  • the aerosol generating material slurry applied to the support is allowed to or caused to at least partially set or cure whilst the support moves between each silk screen and I or rotary screen printing apparatus.
  • the thickness measurement is performed whilst the support moves between a silk screen and I or rotary screen printing apparatus.
  • the support is a longitudinally extending material extending in a direction X
  • at least two groups of aerosol generating material slurry are applied to the support
  • each group of aerosol generating material slurry is comprised of at least one discrete portion of aerosol generating material slurry
  • the groups of aerosol generating material slurry are spaced from each other in one or both of direction X or direction Y where direction Y is perpendicular to direction X.
  • the manufacturing path extends in the direction X.
  • At least one of the repetitions of the application of the aerosol generating material slurry to the support comprises the application of aerosol generating material slurry of a first composition
  • at least one of the repetitions of the application of the aerosol generating material slurry to the support comprises the application of aerosol generating material slurry of a second composition
  • At least one of the discrete portions of aerosol generating material slurry comprises aerosol generating material slurry of a first composition, and at least one of the discrete portions of aerosol generating material slurry comprises aerosol generating material slurry of a second composition.
  • causing the aerosol generating material slurry applied to the support to at least partially set comprises exposing the aerosol generating material slurry to electromagnetic radiation with wavelengths in the range of 700 nanometres to 1 millimetre, that is radiation in the infrared part of the electromagnetic spectrum.
  • the method further comprises forcibly cooling the at least partially set aerosol generating material, in which the cooling is performed after the aerosol generating material slurry applied to the support is allowed to or caused to at least partially set.
  • the aerosol generating material slurry may be exposed to radiation from other parts of the electromagnetic spectrum, at least partial vacuum, directly heated, or exposed other conditions that cause the aerosol generating material slurry to set at an increased rate relative to the setting rate of aerosol generating material at ambient conditions.
  • the support comprises a flexible sheet material. In an embodiment of any of the above embodiments, the support comprises one or more of a metallic foil, a metallic film, or a plastics film.
  • the support comprises aluminium foil.
  • each application of the aerosol generating material slurry to the support is performed using silk screen printing apparatus.
  • each application of the aerosol generating material slurry to the support is performed using rotary screen printing apparatus.
  • the product comprises at least one further material
  • the method comprises applying the aerosol generating material slurry to the support followed by applying a first further material to at least a portion of the aerosol generating material previously applied to the support, and the first further material is applied to the aerosol generating material using a silk screen or rotary screen printing technique.
  • the further material is a material that has a different composition to that of the aerosol generating material slurry I aerosol generating material.
  • the further material is a material that gives rise to a different sensory experience for a user of a product made using the method of the present disclosure to that of the aerosol generating material slurry I aerosol generating material.
  • the further material is a material that has one or more different physical characteristics to that of the aerosol generating material slurry I aerosol generating material.
  • the use of a silk screen or rotary screen printing technique for the application of the further material is advantageous because of the accuracy of placement of the further material that such techniques allow.
  • a second or subsequent further material is, after the application of the first or a second or subsequent further material, applied to at least a portion of one or more of the aerosol generating material, the first further material, and the second and subsequent further materials.
  • the second further material is a material that has a different composition to that of the aerosol generating material slurry I aerosol generating material and the first further material.
  • the second further material is a material that gives rise to a different sensory experience for a user of a product made using the method of the present disclosure to that of the aerosol generating material slurry I aerosol generating material and the first further material.
  • the second further material is a material that has one or more different physical characteristics to that of the aerosol generating material slurry I aerosol generating material and the first further material.
  • one or more of the aerosol generating material slurry applied to the support and a further material is allowed to or caused to at least partially set before the subsequent application of a further material.
  • At least one of the first, second or subsequent further material wholly overlies the aerosol generating material or further material to which the first, second or subsequent further material is applied. In an embodiment of any of the above embodiments, at least one of the first, second or subsequent further material overlies less than all of the aerosol generating material or further material to which the first, second or subsequent further material is applied.
  • the support comprises a support material and at least one base further material, in which the base further material is applied to the support material before the aerosol generating material is applied to the support, and the base further material is applied to the support material using a silk screen or rotary screen printing technique.
  • the base further material is a material that has a different composition to that of the aerosol generating material slurry I aerosol generating material, the first further material and the second and subsequent further materials.
  • the base further material is a material that gives rise to a different sensory experience for a user of a product made using the method of the present disclosure to that of the aerosol generating material slurry I aerosol generating material, the first further material, and the second and subsequent further materials.
  • the base further material is a material that has one or more different physical characteristics to that of the aerosol generating material slurry I aerosol generating material, the first further material, and the second and subsequent further materials.
  • the product is larger than is compatible for use with a non-combustible aerosol provision system, and the method further comprises configuring the product for storage.
  • configuring the product for storage comprises rolling the product onto a bobbin, or folding the product into a concertina. In an embodiment of any of the above embodiments, configuring the product for storage further includes slitting the product into two or more longitudinally extending strips.
  • the product is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises separating the product into two or more product portions, in which each product portion is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system.
  • the consumable is a substantially flat consumable.
  • the product portion is formed into a tube.
  • the tube is substantially cylindrical.
  • the tube is not cylindrical, for example, but without limitation, the tube is triangular, rectangular, square or polyhedral in cross section.
  • At least one of the discrete portions of aerosol generating material faces the hollow defined by the tube.
  • the hollow extends along the length of the tube.
  • the hollow formed by the tube is at least partially filled with material that adds to the sensory experience of a user of the consumable.
  • the hollow formed by the tube my be at least partially filled with rag tobacco.
  • 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 semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
  • the aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
  • the aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former.
  • a substance to be delivered and/or filler may also be present.
  • a solvent such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent.
  • the aerosol-generating material is substantially free from botanical material.
  • the aerosolgenerating material is substantially tobacco free.
  • the aerosol-generating material may comprise or be in the form of an aerosolgenerating film.
  • the aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former.
  • a substance to be delivered and/or filler may also be present.
  • the aerosol-generating film may be substantially free from botanical material.
  • the aerosol-generating material is substantially tobacco free.
  • the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1 ,5mm or 0.05mm to about 1.0mm.
  • the thickness may be in the range of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.
  • the aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.
  • a binder such as a gelling agent
  • a solvent such as water
  • an aerosol-former such as one or more other components, such as one or more substances to be delivered
  • the slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
  • the aerosol-generating material may comprise or be an “amorphous solid”.
  • the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid.
  • the amorphous solid may be a “monolithic solid”.
  • the amorphous solid may be substantially non-fibrous.
  • 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.
  • the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
  • the amorphous solid may be substantially free from botanical material.
  • the amorphous solid may be substantially tobacco free.
  • 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 susceptor by resistive heating as a result of electric eddy currents.
  • the susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor.
  • 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.
  • the susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron nickel alloy.
  • ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades.
  • the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents.
  • the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses.
  • the aerosol-generating material comprises an active substance.
  • 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, psychoactives.
  • the active substance may be naturally occurring or synthetically obtained.
  • the active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, 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.
  • the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
  • the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
  • the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
  • botanical includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
  • 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
  • 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, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
  • the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
  • 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.
  • 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.
  • the aerosol-generating material comprises a flavour or flavourant.
  • flavour and “flavourant” 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 flavour 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,
  • the flavour comprises menthol, spearmint and/or peppermint.
  • the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
  • the flavour comprises eugenol.
  • the flavour comprises flavour components extracted from tobacco.
  • the flavour comprises flavour components extracted from cannabis.
  • the flavour 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.
  • the aerosol generating material comprises an aerosol generating agent.
  • the aerosol generating agent may comprise one or more constituents capable of forming an aerosol.
  • the aerosol generating agent may comprise one or more of 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 aerosol generating agent comprises glycerol.
  • the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin
  • esters of polyhydric alcohols such as glycerol mono-, di- or triacetate
  • aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
  • the aerosol generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis).
  • the aerosol generating agent may act as a plasticiser.
  • the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10- 25wt% of an aerosol generating agent.
  • the aerosol generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt% or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% of an aerosol generating agent (DWB).
  • the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30- 35wt% of an aerosol generating agent.
  • the aerosol generating material may comprise up to about 80wt%, such as about 40 to 80wt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt% of an aerosol generating agent (DWB).
  • DWB aerosol generating agent
  • the aerosol generating material may also comprise a gelling agent.
  • the gelling agent comprises a hydrocolloid.
  • the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.
  • the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
  • 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 aerosol generating material.
  • the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
  • the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.
  • the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.
  • the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.
  • the gelling agent comprises (or is) one or more non- cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof.
  • the non-cellulose based gelling agent is alginate or agar.
  • the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
  • the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis).
  • the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent.
  • the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis).
  • the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.
  • the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB).
  • the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).
  • the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material.
  • the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
  • the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material.
  • the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
  • alginate is comprised in the gelling agent in an amount of from about 5 to 40wt% of the aerosol generating material, or 15 to 40wt%. That is, the aerosol generating material comprises alginate in an amount of about 5 to 40wt% by dry weight of the aerosol generating material, or 15 to 40wt%. In some examples, the aerosol generating material comprises alginate in an amount of from about 20 to 40wt%, or about 15wt% to 35wt% of the aerosol generating material.
  • pectin is comprised in the gelling agent in an amount of from about 3 to 15wt% of the aerosol generating material. That is, the aerosol generating material comprises pectin in an amount of from about 3 to 15wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises pectin in an amount of from about 5 to 10wt% of the aerosol generating material.
  • guar gum is comprised in the gelling agent in an amount of from about 3 to 40wt% of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10wt% of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40wt% of the aerosol generating material, or from about 20 to 40wt%, or from about 15 to 35wt%.
  • the alginate is present in an amount of at least about 50wt% of the gelling agent.
  • the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1.
  • the ratio of the alginate to the pectin is typically >1 :1 , i.e. the alginate is present in an amount greater than the amount of pectin.
  • the ratio of alginate to pectin is from about 2:1 to 8:1 , or about 3:1 to 6:1, or is approximately 4:1.
  • the aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.
  • the (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry.
  • the slurry layer is formed by electrospraying the slurry.
  • the slurry layer is formed by casting the slurry.
  • (b) and/or (c) and/or (d) at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.
  • the slurry is applied to a support.
  • the layer may be formed on a support.
  • the slurry comprises gelling agent, aerosol-former material and active substance.
  • the slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material.
  • the slurry may comprise (on a dry weight basis): gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry; aerosol-former material in an amount of about 40 to 80wt% of the slurry; and optionally, active substance in an amount of up to about 20wt% of the slurry.
  • the setting the gel (c) may comprise supplying a setting agent to the slurry.
  • 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 form a calcium alginate gel.
  • the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof.
  • the setting agent comprises or consists of calcium formate and/or calcium lactate.
  • the setting agent comprises or consists of calcium formate.
  • the inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.
  • the total amount of the setting agent, such as a calcium source may be 0.5-5wt% (calculated on a dry weight basis).
  • the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%.
  • the inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material.
  • the inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.
  • the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis.
  • the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%.
  • the aerosol generating material will not generally contain any tobacco.
  • supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.
  • Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa).
  • Alginic acid is a copolymer of p-D-mannuronic (M) and a- L-guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide.
  • M p-D-mannuronic
  • G L-guluronic acid
  • the alginate crosslinks to form a gel On addition of calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source.
  • 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.
  • G guluronic acid
  • the drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry.
  • the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%.
  • the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm.
  • the slurry solvent consists essentially of or consists of water.
  • the slurry comprises from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
  • the dry weight content of the slurry may match the dry weight content of the aerosol generating material.
  • the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the disclosure.
  • the aerosol generating material may comprises a flavour.
  • the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour.
  • the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis).
  • the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35- 55wt% or 30-45wt% of a flavour.
  • the flavour comprises, consists essentially of or consists of menthol.
  • the aerosol generating material may comprise a filler.
  • the aerosol generating material comprises less than 60wt% of a filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.
  • the aerosol generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the aerosol generating material comprises less than 1wt% of a filler, and in some cases, comprises no filler.
  • the aerosol generating material comprises at least 1 wt% of the filler, for example, at least 5 wt%, at least 10wt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of the filler. In some embodiments, the aerosol generating material comprises 5-25wt% of the filler.
  • the filler if present, may comprise one or more inorganic filler 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 filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).
  • the aerosol generating material comprises no calcium carbonate such as chalk.
  • the filler is fibrous.
  • the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).
  • including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.
  • the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.
  • the aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
  • the aerosol generating material additionally comprises an active substance.
  • the aerosol generating material additionally comprises a tobacco material and/or nicotine.
  • the aerosol generating material comprises powdered tobacco and/or nicotine and/or a tobacco extract.
  • the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine.
  • the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance.
  • the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material.
  • the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material.
  • the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine.
  • the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
  • the aerosol generating material comprises an active substance such as tobacco extract.
  • the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract.
  • the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract.
  • the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract.
  • the tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 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 aerosol generating material other than that which results from the tobacco extract.
  • the aerosol generating material comprises no tobacco material but does comprise nicotine.
  • the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine.
  • the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.
  • the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%.
  • the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
  • the total content of tobacco material, nicotine and flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
  • the aerosol-generating composition may comprise one or more active substances.
  • the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material.
  • the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material.
  • the active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition in order to achieve a physiological and/or olfactory response.
  • Tobacco material may be present in the aerosol-generating composition in an amount of from about 50 to 95wt%, or about 60 to 90wt%, or about 70 to 90wt%, or about 75 to 85wt%.
  • the tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.
  • the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.
  • Lamina tobacco typically provides superior sensory characteristics.
  • the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.
  • the tobacco material comprises cut tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.
  • 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.
  • the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
  • the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture.
  • the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%.
  • the emulsifying agent may comprise acacia gum.
  • the aerosol generating 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 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1wt%, 2wt% or at least about 5wt% of water (WWB).
  • the aerosol generating material may have any suitable water content, such as from 1wt % to 15wt%.
  • the water content of the aerosol generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.
  • the water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).
  • the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally an active substance.
  • the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally a tobacco material and/or a nicotine source.
  • the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.
  • the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.
  • the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:
  • the aerosol generating material comprises 1-80 wt% of a flavour (dry weight basis).
  • the aerosol generating material comprising:
  • the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising: 1-60 wt% of a gelling agent;
  • the aerosol generating material comprises:
  • the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance.
  • the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour.
  • the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.
  • the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).
  • gelling agent preferably comprising alginate
  • tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%
  • aerosol generating agent preferably comprising glycerol
  • the aerosol generating material comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).
  • the “thickness” of the aerosol generating material describes the shortest distance between a first surface and a second surface.
  • the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet.
  • the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1 ,5mm or 0.05mm to about 1.0mm.
  • the thickness may be in the range of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.
  • the aerosol generating material may have a thickness of about 0.015mm to about 1.0mm.
  • the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm.
  • a material having a thickness of 0.2mm is particularly suitable.
  • the aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
  • the thickness stipulated herein is a mean thickness for the material.
  • the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.
  • the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article.
  • the aerosol generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m.
  • tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is included in an aerosol generating article/assembly as a rolled sheet, suitably in the form of a tube.
  • the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 2600 N/m. In some examples, the aerosol generating material may have a tensile strength of from 600 N/m to 2000 N/m, or from 700 N/m to 1500 N/m, or around 1000 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosolgenerating material comprising the aerosol generating material is formed and incorporated into an aerosol-generating consumable as a sheet.
  • the aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m 2 to 350 g/m 2 .
  • the sheet may have a mass per unit area of 50-250 g/m 2 , or from about 70 to 210 g/m 2 , or from about 90 to 190 g/m 2 , or suitably about 100 g/m 2 (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate).
  • the sheet may have a mass per unit area of about 30 to 70 g/m 2 , 40 to 60 g/m 2 , or 25-60 g/m 2 and may be used to wrap an aerosolisable material such as tobacco.
  • wt% 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 refers 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.
  • a weight percentage quoted on a wet weight basis refers to all components, including water.
  • the term sheet denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions when the sheet is flat. The sheet may be a strip, for example.
  • the aerosol generating material may comprise a colourant.
  • the addition of a colourant may alter the visual appearance of the aerosol generating material.
  • the presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material and the aerosol-generating material.
  • the aerosol generating material may be colour-matched to other components of the aerosol-generating material or to other components of an article comprising the aerosol generating material.
  • the colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, foodgrade colourants and pharmaceutical-grade colourants may be used.
  • the colourant is caramel, which may confer the aerosol generating material with a brown appearance.
  • the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material).
  • the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating material.
  • the colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).
  • talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol-generating material. This may reduce the level of tackiness or adhesion of the aerosol-generating material.
  • a product 1 includes a support 2.
  • the support 2 is a longitudinally extending sheet of a laminate material which has a first layer 4 of aluminium foil and a second layer 6 of paper.
  • the first layer 4 has a major surface 8 that faces away from the second layer 6.
  • Each group 10 is, as shown in Figure 2, comprised of thirteen discrete portions 12 of aerosol generating material (for clarity not all portions 12 are labelled).
  • the portions 12 of aerosol generating material are all of the same shape and dimensions, and the portions 12 are positioned in a predetermined relationship relative to each other.
  • the groups 10 are all the same as each other and positioned in a predetermined relationship relative to each other.
  • Figures 1 and 2 there are four groups 10 spaced in the direction perpendicular to the longitudinal extent of the support 2 and there are thirteen discreet portions 12 of aerosol generating material in each group 10. These numbers of groups and discreet portions are for illustration only as are the dimensional proportions of the support 2. Within the scope of the present disclosure there are one or more group 10 and one or more discrete portions 12 in each group 10. Likewise different dimensional proportions of the support 2 are within the scope of the present disclosure.
  • FIGS. 3 and 4 show a first embodiment of a discrete portion 212 of aerosol generating material, and a section through that discrete portion 212 aerosol generating material respectively.
  • the discrete portion 212 has been applied to a surface 8 of the support 2 by two printings of aerosol generating material, each printing using a silk screen or rotary screen printing technique.
  • the first and second printings use a first and second stencil respectively.
  • Each stencil is configured to allow the printing of one or more circular discrete portions of the aerosol generating material.
  • the two stencils have the same configuration and are configured so that the second printing is on top of the first printing.
  • the method of production of the discrete portion 212 is generally as follows:
  • the support 2 is positioned in a predetermined position relative to a first silk screen or rotary screen printer.
  • the first silk screen or rotary screen printer is activated and a layer 236 of aerosol generating material is deposited on the surface 8.
  • the layer 236 of aerosol generating material is allowed or caused to at least partially set.
  • the support 2 is positioned in a predetermined position relative to a second silk screen or rotary screen printer.
  • the second silk screen or rotary screen printer is activated and a layer 238 of aerosol generating material is deposited on the layer 236 of aerosol generating material.
  • FIGS. 5 and 6 show a second embodiment of a discrete portion 312 of aerosol generating material, and a section through that discrete portion 312 aerosol generating material respectively.
  • the discrete portion 312 has been applied to a surface 8 of the support 2 by three printings of aerosol generating material, each printing using a silk screen or rotary screen printing technique.
  • the first, second and third printings use a first, second and third stencil respectively.
  • Each stencil is configured to allow the printing of one or more circular discrete portions of the aerosol generating material.
  • the three stencils have similar configurations and are configured so that the second printing is on top of but smaller than the first printing, and the third printing is on top of and larger than (wholly overlies) the first and second printings.
  • the method of production of the discrete portion 312 is generally as follows:
  • the support 2 is positioned in a predetermined position relative to a first silk screen or rotary screen printer.
  • the first silk screen or rotary screen printer is activated and a layer 336 of aerosol generating material is deposited on the surface 8.
  • the layer 336 of aerosol generating material is allowed or caused to at least partially set.
  • the support 2 is positioned in a predetermined position relative to a second silk screen or rotary screen printer.
  • the second silk screen or rotary screen printer is activated and a layer 338 of aerosol generating material is deposited on a portion of the layer 336 of aerosol generating material.
  • the layer 338 is circular and is centred on the centre of the layer 336. In other non-illustrated embodiments the layer 338 may have different shapes and may not be centred on the layer 336.
  • the layer 338 of aerosol generating material is allowed or caused to at least partially set.
  • the support 2 is positioned in a predetermined position relative to a third silk screen or rotary screen printer.
  • the second silk screen or rotary screen printer is activated and a layer 340 of aerosol generating material is deposited over the layers 336 and 338 and a portion of the surface 8.
  • the layer 340 is circular and is centred on the centre of the layers 336 and 338.
  • the layer 340 may have different shapes and may not be centred on the layer 336 and I or 338.
  • the product may be configured for storage.
  • An example of a storage configuration for the product 1 is achieved by rolling the support 2 into a roll about a bobbin with a sheet of protective material placed between the layers of support 2 in the roll.
  • the product 1 may then be stored until it is required for use in the manufacture of a number of consumables 14 for use with an aerosol provision device.
  • the consumable 14 is formed by cutting the support 2 into portions, so that, as shown in Figure 7, each consumable 14 comprises a portion of the support 2 and a group 10.
  • An alternative storage configuration for product 1 is to form the support 2 into a concertina around fold lines that extend perpendicular to the longitudinal extent of the support 2. Again, a sheet of protective material may be placed over the surface 8 of the support 2 prior to forming the support 2 into the concertina.
  • the support 2 is fed off a feeder roll 16. The support 2 then follows a winding or serpentine manufacturing path in the direction indicated by arrows D around a plurality of rollers R until it is wound onto a storage roll 18.
  • the vertically upwards direction is indicated by arrow V and, as may be seen, for the majority of the manufacturing path the support is at an angle to the horizontal.
  • the support is, in the direction of the manufacturing path, or the longitudinal extent of the support is at an angle of more than 60 degrees to horizontal.
  • the rotatory printing apparatus 20A comprises a mesh screen that is formed into a tube.
  • the mesh is first prepared for use, with the pre-use preparation of the mesh (the pre-press process) including use of a stencil to cause the mesh to be able to pass aerosol generating material slurry through the mesh only at the desired positions of the portions 12 of the aerosol generating material.
  • aerosol generating material slurry is introduced into the inside of the tube of mesh.
  • the tube is rotated with the outside of the mesh tube rotating at the same speed as the support 2 travels along the manufacturing path, and a squeegee within the tube squeezes aerosol generating material slurry out of the tube through the mesh at the positions on the mesh that the aerosol generating material may pass through.
  • the aerosol generating material passing through the mesh is applied to the surface 8 of the support 2.
  • the support After the support has passed through the first rotatory printing apparatus 20A, it passes a first source of infrared radiation 22A which directs infrared radiation onto the surface 8 of the support 2 and the discrete portions 12 of aerosol generating material on the surface 8.
  • the infrared radiation increases the speed of setting of the aerosol generating material slurry.
  • the portions 12 of aerosol generating material slurry also at least partially set as they travel from the first rotatory printing apparatus 20A to the first source of infrared radiation 22A and from there to the first measurement means 24A.
  • the first measurement means 24A measures the thickness of the portions 12 of the aerosol generating material to confirm that they are as expected.
  • the support 2 next reaches a second rotatory printing apparatus 20B which applies a second layer of aerosol generating material slurry onto the portions 12 of the aerosol generating material applied to the surface 8 of the support by the first rotatory printing apparatus 20A.
  • the support then reaches a second source of infrared radiation 22B and subsequently a second measurement means 24B. Both the second source of infrared radiation 22B and second measurement means 24B function as the first source of infrared radiation 22A and first measurement means 24A.
  • the support 2 next passes through the third, fourth, fifth and sixth rotatory printing apparatus 20C, 20D, 20E, 20F, source of infrared radiation 22C, 22D, 22E, 22F, and measurement means 24C, 24D, 24E, 24F.
  • any of the measurement means 24A to F find that the portions 12 aerosol generating material are thicker than a predetermined thickness then a controller of one of the rotatory printing apparatus 20 further along the manufacturing path can be caused to not have that rotatory printing apparatus 20 apply a layer of aerosol generating material slurry to the overly thick portions 12 of aerosol generating material.
  • a seventh rotatory printing apparatus 20G, seventh source of infrared radiation 22G and seventh measurement means 24G that only applies aerosol generating material slurry to the portions 12 of aerosol generating material if the sixth measurement means 24F measures the portions 12 of aerosol generating material to be of below a predetermined thickness.
  • the support passes through a forced chilling apparatus 26 that causes the temperature of the support and aerosol generating material to be lowered thus stabilising the aerosol generating material and lessening any evaporation from the aerosol generating material.
  • a protective sheet material 30 is laid over the surface 8 of the support 2 and the support 2 rolled onto the storage roll 18.
  • the protective sheet material 30 is fed off a protective sheet material feed roll 28.
  • the protective sheet 28 stops the portions 12 of aerosol generating material sticking to the second layer 6 of the support when the support is in the storage roll 18.
  • the support 2 is slit along its length between each longitudinally extending row of groups 10.
  • the number of rotatory printing apparatus 20, sources of infrared radiation 22 and measurement means 24 is given as an example only. Within the scope of the present disclosure there may be one or more rotatory printing apparatus 20, sources of infrared radiation 22 and measurement means 24.
  • each rotatory printing apparatus 20A to F or G may be replaced with a screen printing apparatus and the movement of the support 2 along the manufacturing path paused whilst the screen printing occurs.
  • a product 101 is comprised of a sheet of support material 102 which as a first surface 108.
  • the support material 102 is a laminate with the same structure as the support 2 described in connection with Figures 1 and 2 above.
  • On the first surface 108 of the support material 102 are a number of groups 10 (for clarity not all of the groups 10 are labelled) of discrete portions 12 of aerosol generating material.
  • the groups 10 are again as described above and as shown in Figure 2.
  • FIG 9 there are twenty four groups 10 disposed on the surface 108 of the support 102 and there are thirteen discreet portions 12 of aerosol generating material in each group 10. These numbers of groups and discreet portions are for illustration only as are the dimensional proportions of the sheet of support material 102. Within the scope of the present disclosure there are one or more group 10 and one or more discrete portions 12 in each group 10. Likewise different dimensional proportions of the sheet of support material 102 are within the scope of the present disclosure.
  • this Figure 10 shows a flow diagram for the manufacture of the product 101.
  • the sheet of support material 102 is first placed in a first screen printing apparatus 120A.
  • the screen printing apparatus 120A comprises a mesh screen.
  • the Mesh is first prepared for use, with the pre-use preparation of the mesh (the pre-press process) including use of a stencil to cause the mesh to be able to pass aerosol generating material slurry through the mesh only at the desired positions of the portions 12 of the aerosol generating material on the sheet of support material 102.
  • a squeegee pushes aerosol generating material slurry through the mesh at the positions on the mesh that the aerosol generating material may pass through.
  • the aerosol generating material passing through the mesh is applied to the surface 108 of the support 102.
  • the sheet of support material 102 After the sheet of support material 102 has been printed by the first silk screen printing apparatus 120A, it is moved to a position adjacent a first source of infrared radiation 122A which directs infrared radiation onto the surface 108 of the sheet of support material 102 and the discrete portions 12 of aerosol generating material on the surface 108.
  • the infrared radiation increases the speed of setting of the aerosol generating material slurry.
  • the portions 12 of aerosol generating material slurry also at least partially set as the sheet of support material 102 is moved from the first silk screen printing apparatus 120A to the first source of infrared radiation 122A and from there to the first measurement means 124A.
  • the first measurement means 124A measures the thickness of the portions 12 of the aerosol generating material to confirm that they are as expected.
  • the sheet of support material 102 is next moved to a second silk screen printing apparatus 120B which applies a second layer of aerosol generating material slurry onto the portions 12 of the aerosol generating material applied to the surface 108 of the sheet of support material 102 by the first silk screen printing apparatus 120A.
  • the sheet of support material 102 is then moved to a second source of infrared radiation 122B and subsequently a second measurement means 124B. Both the second source of infrared radiation 122B and second measurement means 124B function as the first source of infrared radiation 122A and first measurement means 124A.
  • a controller 132 determines if the thickness of the portions 12 of aerosol generating material exceeds a predetermined minimum thickness. If the answer to that determination is Yes, then the sheet of support material 102 is moved to a storage position 134. If the answer to that determination is No, the sheet of support material 102 is placed on the second silk screen printing apparatus 120B for the application of further aerosol generating material slurry to the portions 12 of aerosol generating material, drying and re-measurement. The determination as to the thickness is then made again.

Landscapes

  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

Est divulgué un procédé de fabrication d'un produit (1), le produit comprenant des parties discrètes (12) de matériau de génération d'aérosol et un support (2). Le procédé consiste à fournir un support (2), appliquer une suspension de matériau de génération d'aérosol au support (2) et la suspension de matériau de génération d'aérosol est appliquée au support (2) à l'aide d'une technique d'impression en sérigraphie sur rotative ou en sérigraphie.
PCT/EP2022/087111 2021-12-20 2022-12-20 Procédé de fabrication d'un consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol WO2023118223A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB202118580 2021-12-20
GB2118580.6 2021-12-20

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Publication Number Publication Date
WO2023118223A1 true WO2023118223A1 (fr) 2023-06-29

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2007078A (en) * 1977-09-16 1979-05-16 Gallaher Ltd Smoking rod wrapper
US4286605A (en) * 1978-07-27 1981-09-01 Imperial Group Limited Treating sheet material for making cigar wrappers
US5369723A (en) * 1992-09-11 1994-11-29 Philip Morris Incorporated Tobacco flavor unit for electrical smoking article comprising fibrous mat
US6053176A (en) * 1999-02-23 2000-04-25 Philip Morris Incorporated Heater and method for efficiently generating an aerosol from an indexing substrate
US9307789B2 (en) * 2011-12-01 2016-04-12 Tannpapier Gmbh Mouthpiece lining paper for a smoking article
EP3232824B1 (fr) * 2014-12-16 2018-09-26 Philip Morris Products S.a.s. Appareil pour la production d'une bande de coulée de matière de tabac homogénéisé
US10575549B2 (en) * 2014-12-16 2020-03-03 Philip Morris Products S.A. Casting apparatus for the production of a cast web of homogenized tobacco material
WO2021144676A1 (fr) * 2020-01-16 2021-07-22 Garbuio S.P.A. Procédé de fabrication de substances végétales et/ou alcaloïdes reconstituées et installation pour la mise en œuvre de ce procédé

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2007078A (en) * 1977-09-16 1979-05-16 Gallaher Ltd Smoking rod wrapper
US4286605A (en) * 1978-07-27 1981-09-01 Imperial Group Limited Treating sheet material for making cigar wrappers
US5369723A (en) * 1992-09-11 1994-11-29 Philip Morris Incorporated Tobacco flavor unit for electrical smoking article comprising fibrous mat
US6053176A (en) * 1999-02-23 2000-04-25 Philip Morris Incorporated Heater and method for efficiently generating an aerosol from an indexing substrate
US9307789B2 (en) * 2011-12-01 2016-04-12 Tannpapier Gmbh Mouthpiece lining paper for a smoking article
EP3232824B1 (fr) * 2014-12-16 2018-09-26 Philip Morris Products S.a.s. Appareil pour la production d'une bande de coulée de matière de tabac homogénéisé
US10575549B2 (en) * 2014-12-16 2020-03-03 Philip Morris Products S.A. Casting apparatus for the production of a cast web of homogenized tobacco material
WO2021144676A1 (fr) * 2020-01-16 2021-07-22 Garbuio S.P.A. Procédé de fabrication de substances végétales et/ou alcaloïdes reconstituées et installation pour la mise en œuvre de ce procédé

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