WO2023118228A1 - Procédé de fabrication d'un produit comprenant une matière de génération d'aérosol - Google Patents

Procédé de fabrication d'un produit comprenant une matière de génération d'aérosol Download PDF

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Publication number
WO2023118228A1
WO2023118228A1 PCT/EP2022/087119 EP2022087119W WO2023118228A1 WO 2023118228 A1 WO2023118228 A1 WO 2023118228A1 EP 2022087119 W EP2022087119 W EP 2022087119W WO 2023118228 A1 WO2023118228 A1 WO 2023118228A1
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WO
WIPO (PCT)
Prior art keywords
support
generating material
aerosol generating
aerosol
product
Prior art date
Application number
PCT/EP2022/087119
Other languages
English (en)
Inventor
Joanna SOFFE
Robert Press
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 WO2023118228A1 publication Critical patent/WO2023118228A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B3/00—Preparing tobacco in the factory
    • A24B3/14—Forming reconstituted tobacco products, e.g. wrapper materials, sheets, imitation leaves, rods, cakes; Forms of such products
    • 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
    • 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
    • A24F40/46—Shape or structure of electric heating means
    • A24F40/465—Shape or structure of electric heating means specially adapted for induction heating

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 manufacture of a support portion comprising aerosol generating material, and a support in which the method comprises providing a supportive surface, applying a layer of aerosol generating material slurry to the supportive surface, providing a support, applying the support to the layer of aerosol generating material slurry, allowing or causing the aerosol generating material slurry to at least partially set, separating the at least partially set aerosol generating material and support into a plurality of support portions, and separating the at least partially set aerosol generating material and support or the support portions from the supportive surface.
  • a support portion manufactured according to the method of the first aspect of the present disclosure.
  • a method of manufacture of a product for use in the manufacture of a consumable for use with a non-combustible aerosol provision device comprises a product support and at least one support portion.
  • the method comprises providing a product support, providing at least one support portion according to the second aspect of the present disclosure or made using the method of the first aspect of the present disclosure, and the at least one support portion is applied to the product support.
  • a consumable for use with a non-combustible aerosol provision system in which the consumable is a portion of a product according to the fourth aspect of the present disclosure or made according to the method of the third aspect of the present disclosure which has been shaped and dimensioned to a desired configuration.
  • an aerosol provision device for use with a consumable according to the fifth 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 support.
  • an aerosol provision system comprising an aerosol provision device and a consumable according to the method of the fifth aspect of the present disclosure.
  • an eighth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the fifth aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.
  • Figure 1 shows a schematic perspective view of a first embodiment of a support portion according to an embodiment of the present disclosure
  • Figure 2 shows a schematic embodiment of a method of manufacture of the support portion of Figure 1 ;
  • Figure 3 shows a schematic detail from the method of Figure 2;
  • Figure 4 shows a schematic representative part of an embodiment of the support during the method of Figure 2;
  • Figure 5 shows a schematic perspective view of a second embodiment of a support portion according to an embodiment of the present disclosure
  • Figure 6 shows a schematic representative part of an embodiment of the support during the manufacture of the support portion of Figure 5;
  • Figure 7 shows a schematic sectional view of the support of Figure 6 along section line A - A’;
  • Figure 8 shows a schematic perspective view of a first embodiment of a product manufactured according to the present disclosure and using the support portions of Figure 1 ;
  • Figure 9 shows a schematic embodiment of a method of manufacture of the product of Figure 8;
  • Figure 10 shows a schematic perspective view of a first embodiment of a consumable according to the present disclosure manufactured using the product of Figure 8;
  • Figure 11 shows a schematic perspective view of a second embodiment of a product manufactured according to the present disclosure and using the support portions of Figure 5;
  • Figure 12 shows a schematic sectional view of the product of Figure 11 along section line B - B’;
  • Figure 13 shows a schematic exploded view of the product of Figure 11 ;
  • Figure 14 shows a schematic embodiment of a method of manufacture of the product of Figure 11 ;
  • Figure 15 shows a schematic perspective view of an embodiment of a consumable according to the present disclosure manufactured using the product of Figure 11;
  • Figure 16 shows a schematic sectional view of the consumable of Figure 15 along section line C - C’.
  • 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 non- combustible aerosol provision device and a consumable for use with the non- combustible 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 manufacture of a support portion comprising aerosol generating material, and a support in which the method comprises providing a supportive surface, applying a layer of aerosol generating material slurry to the supportive surface, providing a support, applying the support to the layer of aerosol generating material slurry, allowing or causing the aerosol generating material slurry to at least partially set, separating the at least partially set aerosol generating material and support into a plurality of support portions, and separating the at least partially set aerosol generating material and support or the support portions from the supportive surface.
  • the support comprises a plurality of support elements.
  • the aerosol generating material slurry layer can be a continuous sheet on the supportive surface. In other embodiments the aerosol generating material slurry layer can be more accurately deposited so that the amount of the aerosol generating material used is minimised.
  • a further benefit of the method of the present disclosure is that the application of the support to the aerosol generating material slurry has the effect that the natural stickiness of the aerosol generating material slurry ensures that the support is fixed to the aerosol generating material once the aerosol generating material slurry sets.
  • each support portion comprises a portion of the support or at least one support element and aerosolgenerating material.
  • the supportive surface is supported on a rigid surface whilst the aerosol generating material slurry is applied to the supportive surface.
  • This provides a temporary rigidity to the supportive surface and assists in both the accurate application of the support to the aerosol generating material slurry, and avoiding any distortions in the supportive surface being reflected in the configuration of the aerosol generating material slurry when it sets.
  • the supportive surface is under tension in at least one direction whilst the aerosol generating material slurry is applied to the supportive surface.
  • the tension is in at least one direction in the plane of the supportive surface.
  • the application of the support to the aerosol generating material slurry to comprises the application of the support over a portion of or substantially all of the layer of aerosol generating material slurry.
  • the aerosol generating material slurry is applied to the support in a layer of substantially even thickness.
  • the method comprises moving the supportive surface together with the aerosol generating material slurry thereon relative to a blade spaced a predetermined distance from a rigid surface on which the supportive surface is supported.
  • the supportive surface and aerosol generating material slurry thereon passes between the blade and the rigid surface, and the relative movement results in the supportive surface and aerosol generating material slurry having a predetermined thickness. This is a result of the blade scraping excess aerosol generating material slurry from overly thick parts of the aerosol generating material slurry.
  • the blade redistributes any aerosol generating material slurry that is too thick onto thinner parts of the aerosol generating material slurry or to the edge of the aerosol generating material slurry.
  • the method comprises measuring the thickness of the aerosol generating material slurry or the at least partially set aerosol generating material slurry.
  • the measurement of the thickness occurs before or after allowing or causing the aerosol generating material slurry to at least partially set.
  • allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the support and aerosol generating material slurry thereon to an environment in which the rate of setting of the aerosol generating material slurry can be at least controlled. Controlling the environment in which the aerosol generating material slurry sets helps in achieving a set aerosol generating material which is consistent in nature and provides a consistent user experience when the aerosol generating material is aerosolised.
  • allowing or causing the aerosol generating material slurry to at least partially set comprises exposing the aerosol generating material slurry to one or more of electromagnetic radiation, a source of radiant heat, a heated atmosphere, a partial or absolute vacuum, and indirect heating.
  • the electromagnetic radiation is one or more of infrared, microwaves or a radio frequency.
  • the indirectly heating comprises indirectly heating the aerosol generating material slurry by heating the support.
  • the support in turn, heats the aerosol generating material slurry.
  • the layer of aerosol generating material slurry is at least partially set in less than one of 10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds, 60 seconds, 90 seconds, 120 seconds, 180 seconds, 5 minutes, 10 minutes, 15 minutes, 20 minutes, or 30 minutes.
  • the support elements are of a predetermined configuration.
  • the configuration of the support elements is determined by the quantity of aerosol generating material overlaid by each support element.
  • the quantity is measured by the area of aerosol generating material, the volume of aerosol generating material, or the mass of aerosol generating material. This is advantageous because it provides a user with a consistent experience when the consumable is used.
  • the combined support and aerosol generating material may be placed into storage.
  • the support and aerosol generating material may be configured as a roll or a concertina of support and aerosol generating material for storage.
  • a barrier paper may be placed over the aerosol generating material prior to the reconfiguration so as to prevent the aerosol generating material from sticking to adjacent layers of support or aerosol generating material.
  • separating the at least partially set aerosol generating material and support into a plurality of support portions is performed using a kiss cutting technique.
  • the partially set aerosol generating material and support can be cut into support portions using alternative cutting techniques.
  • the support is a flexible sheet material.
  • the support is one of a plastics film, a plastics sheet, a metallic film, a metallic foil, or an aluminium foil.
  • the support comprises a susceptor.
  • the support is a laminate material.
  • the support portions are placed into storage and I or transported between their place of manufacture and a different place of intended use once they have been formed.
  • the support portions are moved from the apparatus or production line on which they are produced to production apparatus or a production line for the products into which the support portions are to be incorporated.
  • the separation of the manufacture of the support portions and the manufacture of the products into which the support portions are to be incorporated is advantageous because the rate of manufacture of the support portions and the rate of manufacture of the products into which the support portions are intended to be incorporated can be significantly different.
  • One reason for such different manufacturing rates is that in making the support portions it is necessary for the aerosol generating material slurry applied to the support to set.
  • Setting of aerosol generating material slurry can be accelerated by exposure of the slurry to conditions that will accelerate and assist in the setting of the slurry, but the setting will still require a period of time to occur. That period of time may well be greater than would be available if the application and setting of the aerosol generating material slurry were to be part of the same manufacturing process of the product into which the support portions are to be incorporated. This is particularly so if it is desired to minimise the risk of uneven setting of the aerosol generating material slurry. The minimisation of uneven setting has been found to be assisted by slow rate of setting of the aerosol generating material slurry.
  • a support portion manufactured according to the method of the first aspect of the present disclosure.
  • a method of manufacture of a product for use with a non-combustible aerosol provision device comprises a product support and at least one support portion.
  • the method comprises providing a product support, providing at least one support portion according to the second aspect of the present disclosure made according to the method of the first aspect of the present disclosure, and the at least one support portion is applied to the product support.
  • providing the support portions comprises making the support portions using the method according to the method of the first aspect of the present disclosure.
  • the application of the at least one support portion to the product support comprises application of an adhesive to one or both of the product support and the at least one support portion.
  • the adhesive comprises aerosol generating material slurry. Aerosol generating material slurry acts as an adhesive before it sets and is thus an advantageous material to use as the adhesive. In particular because of the control over and acceptability of the constituent ingredients of an aerosol generating material.
  • the method further comprises providing a second product support, and applying the second product support to the surface of the product support to which the at least one support portion has been applied and the surface of the at least one support portion not in contact with the product support.
  • the method comprises forming a product that is a laminate material with at least some of the product being a laminate comprising a layer of product support, support, aerosol generating material film, and second product support. In that laminate the support and aerosol generating material film are located between the product support and second product support.
  • the application of the at least one support portion to the product support, and the application of the second product support to the surface of the product support to which the at least one support portion has been applied and the surface of the at least one support portion not in contact with the product support occurs subsequently or at approximately the same time.
  • the product support, support portions, and second product supports are all fed into a location where they are fixed to each other.
  • the application of the second product support to the surface of the product support to which the at least one support portions has been applied and the surface of the at least one support portions not in contact with the product support comprises application of an adhesive to one or more of the product support, the at least one support portions, and the second product support.
  • the adhesive comprises aerosol generating material slurry.
  • the application of the second product support to the product support includes compressing the second product support against the product support in one or more locations where there is no support portion. Such locations may include, but not be limited to, around the edges of the product support / second product support, and in the regions between support portions that will ultimately be cut when consumables are made using the product. The compression of the product support and second product support against each other may lead to deformation of one or both of the product support and second product support.
  • one or both of the product support and the second product support is a material which undergoes a dimensional change if an aerosol generating material slurry is applied to the material.
  • a material for the product support and I or second product support may be, without limitation, paper.
  • the dimensional change may be an expansion of the material. This can cause wrinkles in the material which is undesirable.
  • one or both of the product support and the second product support is a material which has a physical property that changes if an aerosol generating material slurry is applied to the material. That physical property may be, without limitation, strength, flatness, or colour.
  • the method further comprises introducing one or more perforations through at least one part of the product.
  • Such perforations allow aerosol generated from the aerosol generating material to escape the product when aerosol is generated. This assists the maximum aerosol be extracted from the aerosol generating material.
  • at least one perforation extends wholly through the product.
  • at least one perforation extends only partially through the product. The perforations may be blind in that they have only one open end.
  • a consumable for use with a non-combustible aerosol provision system in which the consumable is a portion of a product according to the fourth aspect of the present disclosure or made according to the method of the third aspect of the present disclosure which has been shaped and dimensioned to a desired configuration.
  • an aerosol provision device for use with a consumable according to the fifth 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 support.
  • an aerosol provision system comprising an aerosol provision device and a consumable according to the fifth aspect of the present disclosure.
  • an eighth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the fifth aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.
  • 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-generating film may have a thickness of about 0.015 mm to about 1 mm.
  • the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.
  • 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 0.1 wt%, 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. In some examples, pectin is comprised in the gelling agent in an amount of from about 3 to 15wt% of the aerosol generating material.
  • 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. It has been 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). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. It has been 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. It has been 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 invention.
  • 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. Surprisingly it has been identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. 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. In particular examples, 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 0.1mm 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 support portion 2 comprises aerosol generating material 4 and a plurality of support elements 6 (for clarity not all of the support elements 6 are labelled).
  • the number and layout of the support elements 6 on the aerosol generating material 4 are illustrative and the present disclosure includes more and less discrete portions and different layouts.
  • a method of manufacturing a plurality of support portions 2 starts with providing a roll 8 of a supportive surface 28.
  • the supportive surface 28 is wound off the roll 8 and moves across surface of a rigid flat bed 10.
  • the surface of the bed 10 supports the supportive surface 28 and as a result the supportive surface 28 is flat.
  • one or more tension means not shown, keep the supportive surface 28 in tension in the direction of travel of the supportive surface 28 (indicated by arrow 12).
  • the supportive surface 28 is a flexible sheet material.
  • Application station 14 includes a means (not shown) for applying a layer of aerosol generating material slurry 4 to the surface 16 of the supportive surface 28.
  • a suitable means for the application layer of the aerosol generating material slurry 4 is, without limitation, a rotary screen printing apparatus (not shown).
  • the means for applying the aerosol generating material slurry 4 to the supportive surface 28 applies the discrete portions 6 of aerosol generating material slurry in a substantially even thickness layer.
  • the application station 14 also includes a blade 18 (shown in Figure 3) beneath which the supportive surface 28 and of aerosol generating material slurry layer 4 may move.
  • the blade 18 will scrape off any aerosol generating material slurry 4A that stands more than a distance D1 from the surface of the bed 10. Prior measurement of the thickness of the supportive surface 28 will allow calculation of the thickness D2 of the aerosol generating material slurry 4.
  • the position of the blade 18 relative to the bed 10 may be adjusted (by means not shown) to achieve a desired thickness D2.
  • the supportive surface 28 will next move on to a second application station 20 where the supports (also referenced as support elements) 6 are applied to the free surface 16 of the aerosol generating material slurry 4.
  • the support elements 6 are applied to the free surface 16 in a predetermined pattern.
  • a representative example of the aerosol generating material slurry 4 and support elements 6 on the supportive surface 28 is shown in Figure 4.
  • the supportive surface 28 will next move on to a setting station 54 where the Aerosol generating material slurry 4 is exposed to infrared radiation in order to enhance the rate of setting of the aerosol generating material slurry into an at least partially set aerosol generating material.
  • the supportive surface 28 Once the supportive surface 28 leaves the setting station 20 it passes across the bed 10 to a cutting station 22.
  • suitable cutting means cut the aerosol generating material 4 into a plurality of support portions 2.
  • the cutting means cut along cut lines 24 and 26 to form the support portions 2.
  • the aerosol generating material 4 is separated from the supportive surface 28 and stored after the aerosol generating material slurry 4 has set or at least partially set and before the supportive surface 28 reaches the cutting station 22.
  • the support portions 2 may be stored after they have been cut into support portions 2. They may be stored until they are used for the manufacture of a product as discussed below.
  • a support portion 102 comprises aerosol generating material 104 and a support element 106.
  • the support portion 102 is in the form of a support element 106 that extends across substantially the whole of the surface 116 of the aerosol generating material 104.
  • the manufacture of the support portion 102 is very similar to that described in connection with support portion 2 and Figures 2 to 4 above with the following differences.
  • the aerosol generating material 104 is applied to substantially all of the supportive surface 28 in a continuous layer as is shown in Figure 6.
  • a further difference is that the cutting station 22 the portions 102 are cut out of the aerosol generating material 104 by cutting around the support elements 106.
  • the cut lines 126 (not all of which are labelled for clarity) are shown in Figure 7.
  • the support portions 102 or the aerosol generating material 104 after the aerosol generating material slurry 104 has set or at least partially set may be stored before being used, or cut into support portions 102 respectively.
  • the support portions each support a predetermined quantity of aerosol generating material 104 which is overlaid by the support elements 6, 106. As a result, they will each be capable of producing a predetermined quantity of aerosol when the support elements 106 are heated.
  • the predetermined quantity may be defined in terms of the area of aerosol generating material, the volume of aerosol generating material, or the mass of aerosol generating material.
  • a product 30 includes a product support 32 and a plurality of support portions 2.
  • the support portions 2 are adhered to a surface 34 of the product support 32 using an adhesive (not shown).
  • the product support 32 is paper, and the adhesive is aerosol generating material slurry.
  • a roll 36 of product support 32 is provided.
  • the product support 32 is fed off the roll and across the surface of a flat bed 38 in the direction indicated by arrow 40.
  • the bed 38 prevents the product support 32 from moving in the downwards direction as illustrated in Figure 9.
  • the product support 32 moves along the bed 38 to reach an attachment station 42 at which support portions 2 are attached to the product support 32.
  • support portions 2 are supplied to the attachment station 42 from a store (not shown) of support portions 2.
  • an adhesive application means 44 applies adhesive to the support portions 2 by a suitable adhesive application method.
  • the support portions 2 are attached to the product support 32 using the adhesive.
  • the product support 32 and support portions 2 continue to move along the bed 38 whilst the adhesive dries.
  • the product support 32 and support portions 2 are then reconfigured ready for storage.
  • the reconfiguration is folding the product support 32 into a concertina.
  • different storage configurations may be adopted.
  • the product 30 is fed through a separation station (not shown) in which the product 30 is cut into a plurality of consumables 50 (shown in Figure 10).
  • the consumables may then be stored or supplied to users of the consumables 50.
  • a product 130 includes a product support 132, a second product support 146, and a plurality of support portions 102.
  • the support portions 102 are located between the product support 132 and second product support 146 and adhered to at least one of the surface 134 of the product support 132 and the surface 148 of the second product support 146 using an adhesive (not shown).
  • the product support 136 and second product support 146 are both formed from paper.
  • the adhesive is aerosol generating material slurry.
  • a roll 136 of product support 132 is provided.
  • the product support 132 is fed off the roll and across the surface of a flat bed 38 in the direction indicated by arrow 40.
  • the bed 38 prevents the product support 132 from moving in the downwards direction as illustrated in Figure 14.
  • the product support 132 moves along the bed 38 to reach an attachment station 42 at which support portions 102 are attached to the product support 32.
  • support portions 102 are supplied to the attachment station 42 from a store (not shown) of support portions 102.
  • an adhesive application means 44 applies adhesive to the support portions 102 by a suitable adhesive application method.
  • the support portions 102 are attached to the product support 132 using the adhesive.
  • the support portions 102 are attached to the product support 132 in the pattern shown in Figure 13.
  • the product support 132 and support portions 102 continue to move along the bed 38 to a second attachment station 152.
  • a second product support 146 which is fed from a roll 150 of second product support 146, is laid over the product support 132 and support portions 102 and attached to at least one of the product support 132 and support portions 102.
  • the attachment of the second product support 146 to at least one of the product support 132 and support portions 102 is via an adhesive (not shown).
  • the adhesive is applied to a surface 148 of the second product support 146 by a second adhesive application means 144.
  • the second adhesive application means 144 applies adhesive to the surface 148 by a suitable adhesive application method.
  • the second attachment station 152 includes a compression element (not shown) that is configured to at least compress the surface 148 of the second product support 146 against the surface 134 of the product support adjacent to the edges of the product support 132 and second product support 146.
  • the compression is both adjacent to the edges of the product support 132 and second product support 146, and in the regions of the product 130 through which the product 130 will be cut when the product 130 is separated into consumables.
  • the product support 132, support portions 102, and second product support 146 have passed the second attachment station they are then reconfigured ready for storage.
  • the reconfiguration is folding the product support 132 / second product support 146 into a concertina.
  • different storage configurations may be adopted.
  • the product 130 is fed through a separation station (not shown) in which the product 130 is cut into a plurality of consumables 150 (shown in Figures 15 and 16) along the dotted lines shown in Figure 13.
  • the consumables may then be stored or supplied to users of the consumables 150.

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  • Medicinal Preparation (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une partie de support (2, 102) comprenant une matière de génération d'aérosol (4, 104), et un support (6, 106). Le procédé consiste à fournir une surface de support (28), appliquer une couche de suspension de matière de génération d'aérosol (4, 104) sur la surface de support (28), fournir un support (6, 106), appliquer le support (6, 106) sur la couche de suspension de matière de génération d'aérosol (4, 104), permettre à la suspension de matière de génération d'aérosol (4, 104) de durcir au moins partiellement ou l'amener à durcir au moins partiellement, la séparer de la matière de génération d'aérosol au moins partiellement durcie (4, 104) et du support (6) en une pluralité de parties de support (2, 102), et la séparer de la matière de génération d'aérosol au moins partiellement durcie (4, 104) et du support (6, 106) ou des parties de support (2, 102) à partir de la surface de support (28).
PCT/EP2022/087119 2021-12-20 2022-12-20 Procédé de fabrication d'un produit comprenant une matière de génération d'aérosol WO2023118228A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2118577.2 2021-12-20
GB202118577 2021-12-20

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WO2023118228A1 true WO2023118228A1 (fr) 2023-06-29

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021105462A1 (fr) * 2019-11-29 2021-06-03 Nicoventures Trading Limited Système électronique de fourniture d'aérosol
GB2591074A (en) * 2019-11-29 2021-07-21 Nicoventures Trading Ltd Non-combustible aerosol provision device and a method of heating an aerosol-generating material
WO2023012297A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol
WO2023012299A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol
WO2023012301A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021105462A1 (fr) * 2019-11-29 2021-06-03 Nicoventures Trading Limited Système électronique de fourniture d'aérosol
GB2591074A (en) * 2019-11-29 2021-07-21 Nicoventures Trading Ltd Non-combustible aerosol provision device and a method of heating an aerosol-generating material
WO2023012297A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol
WO2023012299A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol
WO2023012301A1 (fr) * 2021-08-04 2023-02-09 Nicoventures Trading Limited Consommable destiné à être utilisé avec un dispositif de fourniture d'aérosol

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