WO2023187410A1 - Substrat comprenant un matériau de génération d'aérosol sur un support et ses utilisations - Google Patents

Substrat comprenant un matériau de génération d'aérosol sur un support et ses utilisations Download PDF

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Publication number
WO2023187410A1
WO2023187410A1 PCT/GB2023/050862 GB2023050862W WO2023187410A1 WO 2023187410 A1 WO2023187410 A1 WO 2023187410A1 GB 2023050862 W GB2023050862 W GB 2023050862W WO 2023187410 A1 WO2023187410 A1 WO 2023187410A1
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WO
WIPO (PCT)
Prior art keywords
aerosol
substrate
generating material
generating
support
Prior art date
Application number
PCT/GB2023/050862
Other languages
English (en)
Inventor
Klaus MATHIE
Barry DIMMICK
Walid Abi Aoun
Original Assignee
Nicoventures Trading Limited
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Publication date
Application filed by Nicoventures Trading Limited filed Critical Nicoventures Trading Limited
Publication of WO2023187410A1 publication Critical patent/WO2023187410A1/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
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
    • A24B15/14—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco made of tobacco and a binding agent not derived from tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/281—Treatment of tobacco products or tobacco substitutes by chemical substances the action of the chemical substances being delayed
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/18—Treatment of tobacco products or tobacco substitutes
    • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
    • A24B15/30—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances
    • A24B15/302—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances by natural substances obtained from animals or plants
    • A24B15/303—Plant extracts other than tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
    • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
    • A24C5/01—Making cigarettes for simulated smoking devices

Definitions

  • a substrate comprising an aerosol-generating material on a support and uses thereof
  • the invention relates to substrates comprising an aerosol-generating material on a support, methods of manufacturing the substrates and uses thereof.
  • Aerosol-generating materials for use in a combustible or a non-combustible aerosol provision system may include a variety of different active substances and/ or flavours.
  • a substrate comprising a support at least partially coated with an aerosol-generating material formed by diying a precursor material whilst in contact with the support, the precursor material comprising an extract from a flavour- and/or active-containing plant material.
  • the support comprises one or more selected from the group consisting of: paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, activated carbon, glass, a sintered material, a composite material, a plant-derived material, a fabric or fleece, a fibrous tow, a metal, or a metal alloy.
  • the support comprises a heating material.
  • the aerosol-generating material covers at least a portion of a surface of the support.
  • a plurality of discrete portions of the aerosol-generating material are provided on the support.
  • the substrate does not include a binder applied to adhere the aerosol-generating material to the support.
  • the aerosol-generating material further comprises an aerosol- former material.
  • the precursor material comprises from about to to about 95% by weight extract from a flavour- or active-containing plant material. In some embodiments, the precursor material comprises from about 1 to about 36 wt% aerosol-former material.
  • the precursor material comprises from o to about 40% by weight of an excipient.
  • the aerosol-generating material comprises from about 45 to about 99% by weight dried extract from the flavour- or active-containing plant material. In some embodiments, the aerosol-generating material comprises from about 1 to about 34% by weight aerosol-former material.
  • the aerosol-generating material comprises from o to about 25% by weight of an excipient.
  • the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa and hemp.
  • the extract from a flavour- or active-containing plant material is an aqueous extract.
  • the extract from a flavour- or active-containing plant material is an aqueous tobacco extract.
  • the aerosol-generating material comprises from about 40 to about 99% by weight tobacco solids.
  • the aerosol-generating material has a water content of no more than about 5% (calculated on a wet weight basis).
  • the substrate comprises a moisture impermeable coating surrounding the aerosol-generating material.
  • the substrate comprises a sorbent material. In some embodiments, the substrate is for use in an aerosol provision system.
  • an article comprising a substrate comprising a support at least partially coated with a dried extract from a flavour- and/or active-containing plant material.
  • the article comprises or consists of a substrate according to the first aspect.
  • a non- combustible aerosol-provision system comprising a substrate according to the first aspect, or an article according to the second aspect.
  • a method for providing a substrate comprising: contacting a support with a precursor material comprising an extract from a flavour- and/ or active-containing plant material; and drying the precursor material to form a coating of an aerosol generating material on the support.
  • the precursor material is dried by freeze-diying, infrared heating, steam heating, microwave heating or air-drying.
  • a moisture-impermeable coating is applied to the aerosolgenerating material.
  • a sorbent is added to the coating of aerosol-generating material.
  • Figure i is a schematic illustration of a substrate as described herein.
  • Figure 2 is a schematic illustration of another substrate as described herein.
  • Figure 3 is a side-on cross sectional view of a first embodiment of a consumable comprising a substrate as described herein;
  • Figure 4 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from the composition of the consumable shown in Figure 3.
  • An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way.
  • Conventional aerosol-generating materials which comprise tobacco material or a tobacco extract may be used in combustible and non-combustible aerosol-generating devices, including hybrid devices and tobacco heating products, to provide the user with an aerosol with an authentic tobacco taste and texture.
  • One issue encountered with such materials is that the content of the flavour, other volatile compound(s) and nicotine decreases with storage of the aerosol-generating material, dropping off particularly towards the end of the life of the material. This is because the more volatile components, including nicotine and many flavours and aromas, are readily released from the material.
  • Aerosol-generating materials that are produced using conventional methods and procedures commonly need to be used within one to three days of production. There is therefore a need to improve the shelf life of the aerosol generating material.
  • a further issue associated with conventional aerosol-generating materials comprising tobacco material or a tobacco extract is that the concentration of the desired components such as nicotine and flavours is relatively low. This limits the concentration of these desired components in the aerosol generated. Additionally, this means that a relatively large amount of the aerosol-generating material is needed and, accordingly, high amounts of energy are required to heat the aerosol-generating material in order to release the desired components.
  • the present invention relates to compositions comprising a dried or dehydrated aerosol generating material formed from an extract from a flavour- and/or active-containing plant material.
  • the extract is a liquid solution or suspension and it may be dried or dehydrated using a process such as spray-diying or freeze- drying.
  • the dried or dehydrated aerosol generating material may be formed from a precursor material comprising the extract from a flavour- and/or active-containing plant material and an aerosol-former material.
  • the aerosol-generating material comprising the dried extract from a flavour- and/or active-containing plant material comprises a high concentration of the flavour and/or active, with little or no material that does not contribute to the aerosol generated from the dried aerosol-generating material. As such, small amounts of the aerosolgenerating material are sufficient to generate aerosol with desired active and flavour content. Further, the aerosol may be generated with the input of relatively low levels of energy.
  • aerosol-generating material being used as a solid substrate is that the low water content reduces issues associated with “hot puff’, which are known in the art.
  • the dried aerosol-generating material has a moisture content of from o to about 10%, or from o to about 5% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.
  • the moisture content of the dried aerosolgenerating material is less than about 3 wt%, for example from about o to about 3 wt%, or from about 0.5 to about 2.5 wt %.
  • Karl Fischer titration is a classic method of chemical analysis for reliably determining the amount of water in a sample, and even just trace amounts. The method can be readily carried out using an automated Karl Fischer titrator. Similarly, the use of GC- TCD is also a well-established method for reliably determining the water content in a sample. Unless stated otherwise, references to moisture content herein are references to the moisture content as measured by Karl Fischer titration.
  • the dried aerosol-generating material may be hygroscopic and so measures may need to be taken to ensure that the aerosol-generating material does not absorb moisture during processing, incorporation into a final product and storage in that final product prior to use.
  • the aerosol-generating material is provided on a support.
  • the combination of the aerosol-generating material and the support is referred to herein as a substrate.
  • the substrate may be used in an aerosol-provision system to generate an aerosol.
  • the support carries the aerosol-generating material and presents it in a manner suitable for use in an aerosol-provision system. This is a particularly beneficial way to provide the aerosol-generating material as this material is highly concentrated so that only veiy small amounts are required compared to the conventional aerosol-generating materials.
  • a substrate comprising: an aerosol-generating material comprising a dried precursor material comprising an extract from a flavour- and/or activecontaining plant material and support.
  • the substrate is formed by applying the precursor composition to a support and drying the precursor composition to provide a dried aerosol-generating material coated on the support.
  • the in situ diying provides sufficient adhesion between the dried aerosolgenerating material and the support that the aerosol-generating material can be attached in this way to supports having either rough and smooth surfaces.
  • no separate binder or glue is required to bind or adhere the aerosol-generating material to the support.
  • the support or a layer of the support may be formed of any material suitable for receiving and holding the aerosol generating material.
  • the support provides a surface upon which the composition is applied.
  • the support may provide a sleeve or cover that surrounds and supports the composition.
  • the support may, for example, be or comprise one or more materials selected from the following: paper; card; paperboard; cardboard; reconstituted material such as reconstituted paper or reconstituted plant material; a plastics material, such as polylactic acid; a ceramic material; activated carbon; glass; a sintered material, such as sintered glass, metal(s), ceramics or plastics; a composite material; a plant-derived material; a fabric or fleece; a fibrous tow such as cellulose acetate tow; a metal, or a metal alloy.
  • the support comprises a material with an inherently rough surface.
  • the support or part thereof may be formed from a paper material, such as tipping paper, porous plug wrap, cigarette paper or tea bag paper.
  • the paper may be a porous paper.
  • the paper preferably has a weight of from about 20 gsm to about too gsm.
  • the support comprises a fabric, fleece or a fibrous material, such as a tow. Such support materials may inherently have a porous structure, with spaces between fibres.
  • the support is a woven or non-woven fabric or fleece comprising a plurality of fibres.
  • the fleece or fabric is manufactured by a dry-laid process, an air-laid process, a wet-laid process, a spun melt process, a melt blown process or the like to entangle fibres or filaments into a web in a manner that does not involve weaving or knitting.
  • the fabrics may comprise fibres formed from materials including cellulose fibres, viscose fibres, regenerated cellulose fibres, wood fibres, cotton fibres, wool fibres, or other fleece forming polymers, such as polyglycolic acid fibres, polylactic acid fibres, polyhydroxyalkanoate fibres, polycaprolactone fibres, polybutylene succinate fibres, polybutylene succinate adipate fibres, and combinations thereof.
  • the fibres are thermostable and/ or biodegradable.
  • the support is a porous material, such as an open-cell reticulated foam or sintered structure.
  • the porous material comprises a ceramic material, activated carbon material, zeolites, silica, wood, cork or other naturally occurring materials with a porous surface.
  • the support is a (dried) tobacco material, such as, tobacco leaf, lamina or stem material, or a reconstituted tobacco material.
  • the precursor of the aerosol-generating material may be applied directly onto any of these the rough or porous support materials and then dried to form the aerosolgenerating material.
  • the support is an air-laid material, such as air-laid paper.
  • air-laid paper This has a highly porous surface structure and in some embodiments, the precursor material is applied to the surface of the air-laid paper. For example, this highly absorbent support may be soaked in the precursor material. In other embodiments, the precursor material may be added during the manufacture of the air-laid paper, the manufacturing process otherwise being a dry process.
  • the support is a porous material, such as an open-cell reticulated foam or sintered structure.
  • the porous material comprises a ceramic material, activated carbon material, zeolites, silica, wood, cork or other naturally occurring materials with a porous surface.
  • the precursor material may be absorbed by the porous material and then dried.
  • the support has a smooth or non-porous surface. The in situ drying of the precursor of the aerosol-generating material means that, following drying, the dried aerosol-generating material is bonded to the surface.
  • the support consists of or comprises a heating material that comprises one or more materials selected from the group consisting of: an electrically- conductive material, a magnetic material, and a magnetic electrically-conductive material.
  • the heating material may comprise a metal or a metal alloy.
  • the heating material may comprise one or more materials selected from the group consisting of: aluminium, gold, iron, nickel, cobalt, conductive carbon, graphite, plain-carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.
  • the heating material may be heated by induction heating.
  • Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field.
  • the heating material may be heated by resistive heating.
  • the heating material is connected to a power supply.
  • the heating may be microwave heating or infrared heating.
  • the heating material has a rough or porous surface, for example, it may be in the form of a mesh or a perforated sheet. In other embodiments, the heating material may have a smooth surface, for example, it may be in the form of a flat strip or ribbon, or a rod or cylinder.
  • the substrates according to the present disclosure comprise an aerosol-generating material comprising one or more active substances and/or flavours, and, optionally, one or more aerosol-former materials.
  • the aerosol-generating material is formed by drying a precursor material comprising an extract from a flavour- and/or active-containing plant material. This drying step is carried out with the precursor material in contact with a support, to provide a substrate comprising the dried aerosol-generating material on a support.
  • the diying process is selected to retain the desired components of the precursor material and, therefore, the aerosol-generating material may comprise one or more active substances and/or flavours.
  • the precursor material further comprises one or more aerosol- former material. Additionally or alternatively, one or more aerosol-former materials may be added to the dried precursor material to provide an aerosol-generating material with the desired aerosol-former material content.
  • the aerosol-generating material may comprise one or more active substances and/or flavours, and, optionally, one or more aerosol -former materials.
  • the precursor material and/or the dried aerosol-generating material may also optionally include one or more other functional materials.
  • the invention enjoys the advantage of an aerosol-generating material that is formulated to have an increased shelf life and so it may be easily transported and stored. Without wishing to be bound by any particular theory, it is hypothesised that the low water content of the dried aerosol-generating material reduces evaporation over time of other solvents, and reduces degradation of nicotine and/or other volatile compounds. A low water content also inhibits microbial growth.
  • compositions comprising the dried aerosol-generating materials described herein are stable at a range of temperatures and humidities and have an increased shelf-life, and are therefore easy to store and transport.
  • the compositions may be stored at temperatures in the range of o-35°C.
  • the compositions may be stored at a relative humidity of up to about 50%, prior to use.
  • the aerosol-generating materials also have the advantage of having a high concentration of the desired components. This means that relatively small amounts of the aerosol-generating material are required and less energy is required to heat and release the desired components. Significantly, the aerosols generated from these materials also provide an authentic tobacco taste of reasonable strength.
  • the aerosol-generating materials may be used as a solid aerosol-generating substrate in Hybrid systems or Tobacco Heating Products (THPs).
  • THPs Tobacco Heating Products
  • the extract from a flavour- or active-substance containing plant material is an extract derived by contacting the plant material with a suitable solvent, such as an aqueous solvent or an alcohol such as ethanol.
  • a suitable solvent such as an aqueous solvent or an alcohol such as ethanol.
  • the liquid portion comprising the solvent and any dissolved plant components may then be separated or partially separated from the remaining solid plant material to provide the extract to be included in the precursor composition and dried.
  • the extract from a flavour- or active-substance containing plant material is an extract derived from tobacco material.
  • the tobacco extract or material may be from or may be any type of tobacco and any part of the tobacco plant, including tobacco lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco extracts or materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here.
  • the tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means.
  • DIET dry-ice expanded tobacco
  • the tobacco material may be reconstituted tobacco material.
  • the tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof.
  • the tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.
  • the tobacco material may be provided in the form of cut rag tobacco.
  • the cut rag tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm) for example.
  • the cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco.
  • the precursor material which is dried to form the aerosol-generating material may comprise at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, or at least about 40 wt% tobacco solids (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 60 wt%, up to about 55 wt%, up to about 50 wt%, up to about 45 wt%, or up to about 40 wt% tobacco solids (calculated on a wet weight basis).
  • the precursor material comprises from about 20 wt% to about 40 wt% tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises at least about to wt%, about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, or at least about 90 wt% extract from a tobacco or other flavour- or active-substance containing plant material (calculated on a wet weight basis).
  • precursor material may comprise up to about 99 wt%, up to about 90 wt%, up to about 80 wt%, up to about 70 wt% or up to about 60 wt% extract from tobacco or other flavour- or activesubstance containing plant material (calculated on a wet weight basis).
  • the precursor material comprises around 50 wt% tobacco extract (calculated on a wet weight basis).
  • the aerosol-generating material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% tobacco material or tobacco extract, or flavour- or active-substance containing plant material extract (calculated on a diy weight basis).
  • the aerosol-generating material may comprise about 60 to about 80 wt% tobacco extract (calculated on a diy weight basis).
  • the dried aerosol-generating material may comprise from about 2 wt% to about 10 wt% of nicotine, or from about 3 to about 6 wt% of nicotine (calculated on a dry weight basis).
  • the precursor material comprises around 50 v/v% tobacco extract. Where the precursor material comprises around 50 v/v% tobacco extract and the tobacco extract has a tobacco solid content of between about 55 and about 60 v/v%, the overall tobacco solid content of the precursor material is from about 27.5 to about 30 v/v%. In some embodiments, the tobacco extract has a solids content of between about 40 and about 65 wt%, between about 45 and about 65 wt%, or between about 40 and about 60 wt% (calculated on a wet weight basis). In some embodiments, the water content of the tobacco extract is between about 35 wt% and about 65 wt%, or between about 35 and about 55 wt% (calculated on a wet weight basis). In some embodiments, the nicotine content of the tobacco extract is between about 1 wt% and about 5 wt%
  • the dried aerosol-generating material may comprise at least about 45 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, at least about 90 wt%, or at least about 95 wt% tobacco solids (calculated on a dry weight basis). Additionally or alternatively, the aerosol-generating material may comprise up to about 99 wt%, up to about 98 wt%, up to about 95 wt%, up to about 90 wt% or up to about 80 wt%. In some embodiments, the dried aerosolgenerating material may comprise about 60 to about 80 wt% tobacco solids (calculated on a dry weight basis).
  • the tobacco extract is an aqueous tobacco extract.
  • the tobacco extract may be concentrated and subsequently diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract is not concentrated and may be used directly in the precursor material.
  • the precursor material may be in the form of a sluriy, a suspension, a gel, a liquid or a solid, but in some embodiments which may be preferred, it is in the form of a suspension or liquid. In some embodiments, particles of solid material may be removed from the extract and/or from the precursor material by filtration and/or centrifugation.
  • any particles in the precursor composition may be desirable for any particles in the precursor composition to have an average particle size of no greater than about 3 mm, of no greater than 1 mm, of no greater than about 0.5 mm, or to have an average particle size of no greater than about 0.3 mm, when measured by sieving or by observing the size of the particles by SEM.
  • the water content of the precursor material may be at least about 20 wt%, at least about 30 wt%, at least about 40 wt%, at least about 50 wt%, at least about 60 wt%, at least about 70 wt%, at least about 80 wt%, or at least about 90 wt% on a wet weight basis.
  • the water content of the precursor material may be up to about 95 wt%, up to about 90 wt%, up to about 85 wt%, up to about 80 wt%, up to about 75 wt%, up to about 70 wt%, up to about 65 wt%, up to about 60 wt%, up to about 55 wt% or up to about 50 wt% on a wet weight basis.
  • the water content of the precursor material is between about 40 and about 50 wt % on a wet weight basis (50% and 60 v/v%). When the precursor material has a lower water content, the spray/freeze-diying process is quicker, as there is less water to remove.
  • the dried aerosol-generating material and/or the precursor material comprises one or more active substance. This may be derived from the extract or it may be added. In some embodiments, the extract from a flavour- or activesubstance containing plant material comprises an active substance.
  • the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.
  • the active substance may for example be selected from nutraceuticals, nootropics and psychoactives.
  • the active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
  • the active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
  • the active substance comprises nicotine.
  • the active substance comprises caffeine, melatonin or vitamin B12.
  • the precursor material may comprise an extract from other botanical source(s) along with or instead of the tobacco extract.
  • the extract 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 extract may comprise or be derived from botanicals 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, maijoram, 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, Mentha longifolia,
  • the extract comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof selected from eucalyptus, star anise, cocoa and hemp.
  • the extract comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof selected from rooibos and fennel.
  • the aerosol-generating material and/or the precursor material comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).
  • the aerosol-generating material and/ or the precursor material may comprise one or more cannabinoid compounds selected from the group consisting of cannab
  • the aerosol-generating material and/or the precursor material may comprise cannabidiol (CBD).
  • CBD cannabidiol
  • the aerosol-generating material and/or the precursor material may comprise nicotine and cannabidiol (CBD).
  • the aerosol-generating material and/ or the precursor material may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).
  • the aerosol-generating material further comprises an aerosol-former material. In some embodiments, this aerosol-former material is included in the precursor material.
  • the aerosol-former material may comprise one or more constituents capable of forming an aerosol.
  • the aerosol-former maybe, for instance, a polyol aerosol generator or a non-polyol aerosol generator. It may be a solid or liquid at room temperature, but preferably is a liquid at room temperature.
  • the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Eiythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauiyl acetate, lauric acid, myristic acid, and propylene carbonate.
  • the aerosol former 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-former material comprises one or more compounds selected from eiythritol, propylene glycol, glycerol, vegetable glycerine (VG), triacetin, sorbitol and xylitol.
  • the aerosol-former material comprises, consists essentially of or consists of glycerol.
  • Glycerol provides a visible aerosol when the aerosol-generation device is used. It is common that consumers like the aerosol generating device to provide a visible aerosol, as this enables the consumer to visualise the product and what they are consuming. This makes glycerol a desirable choice for aerosol former material.
  • Propylene glycol has the benefit that it is a better flavour carrier than glycerol.
  • the precursor material comprises at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, or at least about 20 wt% aerosol-former material (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 40 wt%, up to about 35, up to about 30 wt%, up to about 25 wt%, up to about 20 wt%, or up to about 10 wt% aerosol-former material (calculated on a wet weight basis).
  • the precursor material may comprise at most 36 wt% of glycerol.
  • the inventors have demonstrated that dry weight inclusion levels up to 36 wt% (calculated on a dry weight basis) of aerosol-former material are possible.
  • the amount of glycerol in the precursor material, and therefore the dried aerosol material is important because it is both an aerosol-forming material and also a plasticizer. If the concentration of glycerol it too high, it may be detrimental to a critical temperature of the product during the freeze-drying process and may result in collapse of the product if the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide the consumer with an adequate and pleasing aerosol.
  • the dried aerosol-generating material may comprise at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, or at least about 40 wt% aerosol-former material (calculated on a dry weight basis).
  • the dried aerosol-generating material may comprise from about 1 to about 34 wt%, or from about 17 to about 34 wt% aerosol-former material (calculated on a dry weight basis). In some embodiments in which the aerosol-former material is glycerol, the dried aerosol-generating material may comprise from about 13 to about 34 wt% glycerol (calculated on a diy weight basis). In embodiments in which Burley tobacco is used, the aerosol-generating material may comprise from about 17 to about 36 wt% of glycerol. The amount of glycerol in the aerosol material is important because it is both an aerosol-forming material and a plasticizer.
  • the aerosol-generating material and/ or the precursor material further comprises one or more excipients.
  • the excipient stabilises and preserves the precursor material and the inventors have found the inclusion of an excipient especially important for stability when the precursor material comprised glycerol as the aerosolforming material.
  • the excipient may also act as a bulking agent or a filler material.
  • the inclusion of an excipient may also improve the handleability of the dried aerosol-generating material, helping it to retain its granular form by helping to reduce moisture uptake and the resulting increase in tackiness of the material.
  • the presence of an excipient may also have an effect on the speed of (freeze) drying.
  • Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextrans such as Dextran 10, Dextran 70, Dextran 90, maltodextrin, gelatin, agar, cyclodextrins, and polyethylene glycols such as PEG 2000-6000, and polyvinylpyrrolidone (PVP 10).
  • the aerosol-generating material and/ or the precursor material comprises one or more excipients in an amount of from o to about 40 wt% on a wet weight basis.
  • the precursor material may comprise at least about 1 wt%, at least about 10 wt%, at least about 20 wt%, at least about 30 wt%, and/or up to about 40 wt%, up to about 30%, up to about 20 wt%, or up to about 10 wt% excipient on a wet weight basis.
  • the aerosol-generating material may comprise at least about 0%, at least about 10 wt%, at least about 20 wt%, or at least about 25 wt% excipient (calculated on a diy weight basis). In some embodiments, the aerosol-generating material may comprise up to about 25%, up to about 20 wt%, up to about 15 wt%, or up to about 10 wt% excipient (calculated on a dry weight basis). In an exemplary embodiment, the aerosol-generating material comprises about 36 wt% glycerol, about 45 wt% tobacco extract, and about 19 wt% excipient on a diy weight basis.
  • the aerosol-generating material comprises from about 17 to about 39 wt% glycerol, from about 41 to about 76 wt% tobacco extract, and from o to about 28 wt% excipient on a dry weight basis.
  • the excipient is agar
  • the precursor material may comprise o wt%, about 5 wt%, or about 10 wt% agar. The inventors have found that agar makes the precursor material more viscous and that the freeze-drying process is easier when the precursor material comprises a lower concentration of the agar excipient.
  • the precursor material comprises about 50 wt% tobacco extract, from o to about 36 wt% aerosol forming agent (for example, from o to about 15 v/v%) and from o to about 40 wt% (for example, about 37.5 v/v%) excipient.
  • the tobacco extract may comprise about 55 wt% tobacco solids and the overall tobacco solids content of the precursor material is about 27.5 wt%.
  • the precursor material comprises about 50 wt% tobacco extract, up to about 36 wt% (for example, about 15 v/v%) glycerol and from o to about 40 wt% (for example, about 37.5 v/v%) excipient.
  • the tobacco extract may comprise about 55 wt% tobacco solids and the overall tobacco solids content of the precursor material is about 27.5 wt%.
  • Some sample formulations of dried aerosol-generating materials formed from aqueous tobacco extracts are summarised in Table 1 below, with the amounts provided on a dry weight basis. These are theoretical values (before drying and inherent losses). Typically from about 80 to 89% of the glycerol is retained following the drying. Glycerol may be used as an aerosol -former material, but can be replaced or partially replaced with one or more other aerosol-former material such as those disclosed herein.
  • the excipient used may be a dextran such as Dextran 70. Again, this may be replaced or partially replaced with alternative excipients, such as those disclosed herein. Table i
  • the percentage content of nicotine in the formulation will depend on the type of tobacco used, and the presence of other components, i.e. the aerosol-former and the excipient.
  • the substrate comprises little or no binder.
  • the aerosol-generating material is not adhered to the support using a binder.
  • the amount of binder present is no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, no more than about 1%, or no more than about 0.5% by weight of the aerosol-generating material.
  • the aerosol-generating material is combined with the binder after the aerosol-generating material has been dried.
  • the aerosol-generating material does comprise one or more binders.
  • the one or more binder is selected from the group consisting of: thermoreversible gelling agents, such as gelatin; starches; polysaccharides; polysaccharide derivatives; celluloses; cellulose derivatives, such as carboxymethylcellulose; gums; protein materials; polyol matrix materials; waxes; wax esters; and other polymers.
  • Suitable polysaccharides include, for example, agar, agarose, pectin, furoidan, furcellan, alginates, carrageenans, starches, dextrans, maltodextrins and cyclodextrins.
  • Suitable cellulosic materials include, for example, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), cellulose acetate butyrate (CAB); cellulose acetate phthalate (CAP), cellulose acetate trimellitate (CAT) and cellulose acetate succinate (CAS), and cellulose ethers.
  • Suitable modified starches include, for example, high-amylose starches, hydroxypropylated starches, octenyl succinate modified starches, starch esters, and starch-based polyelectrolyte complexes (SPECs).
  • Suitable gums include, for example, gum arabic (acacia gum), guar gum, gum karaya, gum tragacanth, gum ghatti, quince seed gum, locust bean gum and xanthan gum.
  • Suitable proteins include zein and gelatin.
  • Suitable polyol matrixes may be formed from polyvinyl alcohol.
  • Suitable waxes include, for example, palmitic acid, carnauba wax, beeswax, candelilla wax, and paraffin wax.
  • Suitable wax esters include, for example, cetyl palmitate and triacontanyl palmitate.
  • Suitable polymers include, for example, shellac, lignin, polyvinyl alcohol, polyurethane, polymerised, hydrolysed ethylene vinyl acetate, a polyester, a polycarbonate, a polymethaciylate, a polyglycol, polyethylene, polystyrene, polypropylene, and polyvinyl chloride.
  • Suitable co-polymers include, for example, methaciylic acid copolymers, and acrylic acid copolymers.
  • the aerosol-generating material and/ or the precursor material comprises one or more flavour-modifier, flavour or flavourant. This may be derived from the extract or it may be added.
  • 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 flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, 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 and/ or the precursor material comprises one or more other functional materials, which may comprise one or more of pH regulators, colouring agents, preservatives, fillers, stabilizers, and/or antioxidants.
  • the aerosol-generating material and/or the precursor material contains a filler component.
  • the filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco.
  • the precursor material comprises less than 60 wt% of a filler, such as from 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt% on a wet weight basis.
  • the filler 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, hemp fibre, cellulose and cellulose derivatives.
  • the dried aerosol-generating material is in the form of a gel.
  • a gelling agent may be added to the aerosol-generating material, the precursor material or may be optionally omitted.
  • the gelling agent may comprise 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 aerosol-generating material and/or the precursor material may comprise an acid.
  • the acid may be an organic acid.
  • the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid.
  • the acid may contain at least one carboxyl functional group.
  • the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid.
  • the acid may be an alpha-keto acid.
  • the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.
  • the acid is selected from one of lactic acid, benzoic acid and levulinic acid.
  • the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid.
  • an acid is may be beneficial in embodiments in which the aerosolgenerating material and/or the precursor material comprises nicotine.
  • the presence of an acid may stabilise dissolved species in the slurry from which the aerosol-generating material is formed.
  • the presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing and during storage.
  • the aerosol-generating material comprises a gelling agent comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active substance and an acid.
  • the dried aerosol-generating material may be in solid form. Having been dried in contact with the support, it will be in the form of a layer or coating on the surface of the support. Where the surface is porous, the pores may be coated or filled with the dried aerosol-generating material.
  • the coating may be in the form of a continuous layer of the dried aerosol-generating material.
  • the coating may have a thickness of from about 10 pm to about 3 mm.
  • the process of applying the precursor material to the support and drying it is repeated to deposit a plurality of layers of dried aerosol-generating material on the support.
  • the thickness of the coating of aerosol-generating material on the support may be built up.
  • the coating may be in the form of a plurality of particles of the dried aerosol -generating material, adhered to the support surface. This will particularly be the case where the precursor material is a slurry or suspension.
  • the aerosol-generating material is applied to or deposited on the support in a plurality of spaced areas of the surface of the support, forming discrete portions of aerosol generating material. These portions may each generate aerosol for a single puff or enough aerosol for a series of puffs.
  • the substrate may allow the portions of aerosol-generating material to be independently heated. In other embodiments, the portions may be heated together, but the aerosol-generating material may be formulated or provided in forms to generate different aerosols and/ or may generate aerosols at different times or at different rates.
  • a substrate 1 comprising a cylindrical support 2, the outer surface of which has been covered with a precursor material that has subsequently been dried to form a coating of dried aerosol-generating material 3, as discussed herein, bound to the surface of the support.
  • Figure 2 illustrates an embodiment in which the support 1 comprises a flat support 2. A portion of one surface of the support 2 has been covered with a precursor material that has subsequently been dried to form a portion of dried aerosol-generating material 3 bound to the surface of the support 2.
  • the drying methods used to diy the precursor material may be any suitable diying process, including freeze-drying.
  • the drying process used must be compatible with the precursor material and the desired make-up of the aerosol-generating material.
  • it may be desirable for the aerosol-generating material to include active and/or flavour substances derived from the extract in the precursor material it is important to select a drying method that will retain a sufficient amount of these components.
  • the precursor material is freeze-dried using freeze-drying microscopy, for example using a Lyostat freeze-drying microscope.
  • Freeze-drying also known as lyophilisation or cryodesiccation, is a process in which the precursor material is frozen, the temperature lowered and the water is removed via sublimation under reduced pressure conditions. Without wishing to be bound by any specific theory, it is believed that the low processing temperatures and rapid water loss via sublimation avoid changes in the aerosol-generating material’s structure, appearance and characteristics. This process preserves the structure of the precursor material, and reduces the loss and decomposition of volatile flavour compounds.
  • the precursor material is frozen, for example, snap-frozen using liquid nitrogen or the like.
  • This frozen form which may have a desired size or shape, may then be dried, for example by freeze-drying.
  • Other diying processes that could be used in the present invention include, for example, infrared heating, steam heating, microwave heating or simple air-drying.
  • the dried aerosol-generating material has a lower water content than the precursor material.
  • the water content of the aerosol-generating material may be at most about 0.5 wt%, about 1 wt%, about 2%, about 5 wt%, about 10 wt%, or about 20 wt%
  • the water content of the dried aerosol -generating material may be reduced from the precursor material by at least about 50 wt%, about 60 wt%, about 70 wt%, about 80 wt%, about 90 wt%, about 95 wt%, about 98 wt%, or by about too wt%.
  • the dried aerosol-generating material has a water content of less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, less than about 2 wt% or less than about 1 wt% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer measurement.
  • the precursor material comprises Burley tobacco extract and a water content of 60 wt%. After the freeze-drying operation described herein, the dried aerosol generating material has a water content of 3 wt%.
  • a lower water content of the dried aerosol-generating material is associated with longer shelf-life and stability. However, very low water content may be associated be a brittle structure and a smaller particle size, as well as taking longer to process.
  • the material is also very hygroscopic. If the water content of the dried aerosol-generating material is too high on the other hand, the desired increased stability may not be achieved.
  • the dried aerosol-generating material may also not be as easy to handle with higher water content, with the material becoming sticky. Moisture protection
  • the substrate further includes a material to prevent or reduce the absorption of moisture by the dried aerosol-generating material.
  • the hygroscopic aerosol-generating material has a moisture content of no greater than about 10% or no greater than about 5% (calculated on a wet weight basis), as measured by gas chromatography-thermal conductivity detector (GC- TCD) or Karl Fischer titration. This moisture content is stable when the substrate of the present invention further includes a material to prevent or reduce the absorption of moisture, meaning that the moisture content of the aerosol-generating material is within this range not only when it is first prepared, but also after incorporation into an aerosol-generating article and following transport and storage.
  • GC- TCD gas chromatography-thermal conductivity detector
  • the substrates disclosed herein further comprise a moisture impermeable coating surrounding the formed aerosol-generating material. This coating creates a moisture impermeable barrier around the dried-aerosol generating material.
  • the physical and chemical properties of the coating materials are important. In addition to forming a moisture impermeable coating, the coating also needs to remain stable and in place during the period between manufacture and use by the consumer.
  • the moisture impermeable coating it is desirable for the moisture impermeable coating to become permeable when the aerosol-generating material is heated to generate an aerosol. This is necessary to ensure that the aerosol can be released.
  • the coating is rendered permeable by melting or other decomposition of the coating material or at least part of the coating.
  • the decomposition of the coating involves the coating losing its physical integrity so that it no longer forms a barrier around the aerosol-generating material. This may, for example, involve the coating melting, crumbling, disintegrating or otherwise breaking down.
  • the coating materials should therefore be selected so that the moisture impermeable coatings remain intact when exposed to normal environmental temperatures. Therefore, in some embodiments, the coating materials used should be ones that form moisture impermeable coatings that are stable at temperatures below 40 or 5O°C. In some embodiments, it may be desirable to select a coating material that will form a moisture impermeable coating that remains intact during more extreme temperatures that may be encountered during storage and transport, such as those of 60 to 8o°C.
  • the moisture impermeable coating may become permeable when the temperature is raised to about too to no°C, so as to avoid superheating any moisture present in the coated aerosol-generating material.
  • the coating opens rapidly upon heating to form an aerosol. This will reduce the likelihood of the coating interfering with the volatilisation and the release of the resultant gas or vapour.
  • the temperature at which the moisture impermeable coating becomes permeable is at least about 5O°C, at least about 6o°C, at least about 7O°C at least about 8o°C, at least about 9O°C, at least about too°C, at least about no°C, at least about 12O°C at least about 13O°C, at least about 14O°C, at least about 15O°C, at least about t6o°C, at least about 17O°C, at least about t8o°C, at least about 19O°C or at least about 200°C.
  • the temperature at which the moisture impermeable coating becomes permeable is no more than about 28O°C, no more than about 27O°C, no more than about 26o°C, no more than about 25O°C, no more than about 24O°C, no more than about 23O°C, no more than about 220°C, no more than about 2to°C or no more than 200°C, no more than about 19O°C, no more than about t8o°C, no more than about 17O°C, no more than about t6o°C, no more than about 15O°C, no more than about 14O°C, no more than about 13O°C, no more than about 12O°C, no more than about no°C, or no more than about too°C.
  • the moisture impermeable coating comprises one or more materials selected from: a polysaccharide or cellulosic material, or a derivative thereof; a gum; a protein material; a polyol matrix material; a wax; a wax ester; and a polymer.
  • Suitable polysaccharides include, for example, agar, agarose, pectin, furoidan, furcellan, alginates, carrageenans, starches, dextrans, maltodextrins and cyclodextrins.
  • Suitable cellulosic materials include, for example, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose (HEC), cellulose acetate butyrate (CAB); cellulose acetate phthalate (CAP), cellulose acetate trimellitate (CAT) and cellulose acetate succinate (CAS), and cellulose ethers.
  • Suitable modified starches include, for example, high-amylose starches, hydroxypropylated starches, octenyl succinate modified starches, starch esters, and starch-based polyelectrolyte complexes (SPECs).
  • Suitable gums include, for example, gum arabic (acacia gum), guar gum, gum karaya, gum tragacanth, gum ghatti, quince seed gum, locust bean gum and xanthan gum.
  • Suitable proteins include zein and gelatin.
  • Suitable polyol matrixes may be formed from polyvinyl alcohol.
  • Suitable waxes include, for example, palmitic acid, carnauba wax, beeswax, candelilla wax, and paraffin wax.
  • Suitable wax esters include, for example, cetyl palmitate and triacontanyl palmitate.
  • Suitable polymers include, for example, shellac, lignin, polyvinyl alcohol, polyurethane, polymerised, hydrolysed ethylene vinyl acetate, a polyester, a polycarbonate, a polymethaciylate, a polyglycol, polyethylene, polystryrene, polypropylene, and polyvinyl chloride.
  • Suitable co-polymers include, for example, methaciylic acid copolymers, and acrylic acid copolymers
  • the coating material comprises additives that are released upon heating the substrate and which therefore contribute to the generated aerosol.
  • the coating material may comprise an active substance, including one or more of the active substances described elsewhere herein.
  • the coating material may comprise a flavour, including one or more of the flavours and flavourants described elsewhere herein.
  • the flavour added to the coating is a hydrophobic flavour. This may mean that the flavour further enhances the moisture-impermeability of the coating.
  • the intention of the coating is to prevent or retard the adsorption of moisture by the aerosol-generating material, in some embodiments the moisture impermeable coating completely encapsulates the aerosol-generating material. An incomplete coating may sufficiently retard the absorption of moisture to provide some benefit, but in preferred embodiments, the coating should cover at least 80%, at least 90%, at least 95% or at least 99% of the surface area of the aerosol-generating material.
  • the moisture impermeable coating prevents the dried aerosolgenerating material absorbing any moisture from the surrounding environment.
  • the coating will be thick enough to confer the desired moisture impermeability.
  • the thickness of the coating may, in some embodiments, further influence the temperature at which the coating becomes permeable and allow volatile components generated by heating the dried aerosol-generating material to be released from the substrate.
  • the thickness of the coating may also, in some embodiments, influence the rate at which the coating becomes permeable once exposed to the temperature of decomposition. This may allow the rate of release of the volatile components from the heated aerosol-generating material to be controlled.
  • the moisture impermeable coating has a thickness of from about 1 pm to about too pm. In some embodiments, the thickness of the coating is at least about 1 pm, at least about
  • the thickness of the coating is up to about too pm, up to about 90 pm, up to about 80 pm, up to about 75 pm, up to about 70 pm, up to about 65 pm, up to about 60 pm, up to about 55 pm, up to about 50 pm, up to about 45 pm or up to about 40pm.
  • the thickness of the coating is from about 5 to about 50 pm.
  • the minimum thickness of the coating may be dictated by the thickness required to ensure that the coating is moisture impermeable or sufficiently moisture impermeable to protect the surrounded aerosol-generating material.
  • the maximum thickness of the coating may be dictated by the time required to ensure that the coating is opened to enough of an extent to allow the vapour or aerosol generating by the heating of the aerosol-generating material to be generated and released. For this reason, in some embodiments, thicker coatings may be less preferred.
  • the thickness of the moisture-impermeable coating applied to the aerosol-generating material may be substantially uniform, for example, varying by no more than 20%, 15%, 10% or no more than 5%. In other embodiments, the thickness of the moisture-impermeable coating applied to the aerosol-generating material may vary by as much as 50% or more. In some embodiments, this will result in a coating which does not decompose in a uniform manner. For example, areas where the coating is thinner may tend to decompose faster. This may help to provide a more gradual and sustained release of the aerosol generated by heating the substrate comprising the aerosol-generating material.
  • a substrate comprises a plurality of discrete portions of aerosol generating material, each coated with the same material. Additionally or alternatively, a substrate comprises a plurality of discrete portions of aerosol generating material, each coated with the same thickness of coating.
  • a substrate comprises a plurality of discrete portions of aerosol generating material, including at least two portions coated with different coating materials. Additionally or alternatively, the substrate comprises a plurality of discrete portions of aerosol-generating material, including at least two portions with coatings of different thicknesses.
  • the coatings of different portions of the aerosol- generating material may decompose at different temperatures or at different rates to control the release of volatile components generated by heating the substrate.
  • extended and controlled release of the volatile components may be achieved by the substrate comprising discrete portions of the dried aerosol- generating material that are surrounded by coatings of different thickness.
  • extended and controlled release of the volatile components may be achieved by the substrate comprising discrete portions of the dried aerosolgenerating material are surrounded by coatings of different coating materials.
  • the substrates disclosed herein may include one or more coatings to provide a predictable and consistent release of active and/or flavour components upon heating and over the course of a heating session. This means that the aerosol generating system can reliably provide a consistent aerosol, irrespective of the length of time the substrate has been stored or the conditions under which it has been stored prior to use.
  • the aerosol-generating material has the desired particle size and shape before the moisture-impermeable coating is applied. In some embodiments, the aerosol-generating material has a particle size of from about i mm to about 20 mm (as measured by sieving), and optionally a size from about 1 mm to about 4 mm
  • the coating may be applied to the substrate using any conventional coating process.
  • the coating material may be spraying onto the support cariying the aerosol-generating material. Processes such as dipping or pan -coating may also be used.
  • the coating is applied directly onto the surface of the aerosolgenerating material.
  • the coating is applied to the surface of the aerosol-generating material in the form of a powder.
  • the average particle size of the coating powder is from about too nm to about 50 pm.
  • the average particle size of the coating powder is at least about too nm, at least about 200 nm, at least about 300 nm, at least about 400 nm, at least about 500 nm, at least about 600 nm, at least about 700 nm, at least about 800 nm, at least about 900 nm, at least about 1 pm, at least about 2 pm, at least about 3 pm, at least about 4 pm, at least about 5 pm, at least about 10 pm, , at least about 15 pm, at least about 20 pm, at least about 25 pm, at least about 30 pm, at least about 35 pm, or at least about 40 pm.
  • the average particle size of the coating powder is no more than about 50 pm, no more than about 45 pm, no more than about 40 pm, no more than about 35 pm, no more than about 30 pm, no more than about 25 pm, no more than about 20 jam, no more than about 15 jam, no more than about 10 jam, no more than about 5 jam, no more than about 4 jam, no more than about 3 jam, no more than about 2 jam, or no more than about 1 jam.
  • the coating adheres to the surface of the aerosol-generating material by virtue of inter-particle forces, such as Van der Waals forces.
  • the surface of the aerosol-generating material is tacky and so particles of coating material readily adhere to the surface to form a complete or substantially complete coating. The tackiness of the aerosol-generating material may be adjusted by adjusting the moisture content of the aerosol-generating material at the time when the coating is applied.
  • the moisture impermeable coating is formed as part of the spray-drying or freeze-drying step.
  • the moisture impermeable coating forming material may be included in the precursor material and forms a coating as the precursor material is dried. This may require the aerosol-generating material and coating material to have chemical properties that ensure that the coating material migrates to the surface of the dried material so that it surrounds the dried aerosolgenerating material.
  • the coating material is an apolar and/ or hydrophobic material that may be included in the precursor material to be dried. Once these coated particles are formed by the drying step, they can be agglomerated.
  • the moisture-impermeable coating has the benefit of protecting the aerosol-generating material from moisture and the negative effects this can have in the material and the aerosol generated when it is heated.
  • the coating can also, as mentioned, control the release of the aerosol generated by heating the aerosolgenerating material.
  • the aerosol-generating material may be tacky or sticky. This can make the material difficult to process and handle.
  • the coating applied to the surface of the aerosol-generating material masks this tackiness, rendering the substrate more readily processed and handled. As a result, it may be preferred to add the coating after the aeroslologenerating material has been applied to the support.
  • the coating may also enhance the structural integrity of the aerosol-generating material.
  • the coating gives the aerosol-generating material on the support additional support and strength, reducing the tendency for it to break and form dust that can be detrimental to the products and machineiy used to make them.
  • the substrates described herein include a sorbent material.
  • This sorbent material is intended to absorb or adsorb moisture from the environment, thus reducing the exposure of the aerosol-generating material to moisture, thus reducing the absorption of moisture by the aerosol -generating material prior to its use.
  • the competition between the aerosol-generating material and the sorbent material for moisture means that the amount of moisture absorbed by the aerosol-generating material is reduced.
  • the sorbent material is more hygroscopic than the aerosolgenerating material.
  • the Dynamic Vapour Sorption (DVS) is a gravimetric technique that may be used to measure how quickly a sample of a material absorbs water by varying the vapour concentration surrounding the sample and measuring the change in mass which this produces. DVS may be used to measure of the rate of water uptake of both the sorbent material and the aerosol-generating material.
  • the rate of water uptake of the sorbent material preferably being greater than that of the aerosol-generating material.
  • the rate of water uptake of the sorbent material is preferably greater than that of the aerosol-generating material at or above about 20% RH, above about 30% RH, above about 40% RH or above about 50% RH.
  • the sorbent material not only absorbs or adsorbs moisture, but will also prevent the release of this water (as vapour) in a manner that may interfere with the desired aerosol being generated by heating the aerosol-generating material. Therefore, in some embodiments, the sorbent holds onto the captured moisture whilst the aerosol-generating material is heated to form an aerosol. Thus, in some embodiments, the sorbent material holds the absorbed or adsorbed moisture at a temperature of up to about 200°C, about 25O°C, about 3OO°C, up to about 325°C, or up to about 35O°C.
  • the sorbent releases the water at a temperature of from about ioo°C to about 150 °C, so that it releases the water at a temperature below that at which the first puff of aerosol for inhalation by the consumer will be generated.
  • the sorbent material is a desiccant.
  • Suitable sorbent materials may comprise one or more selected from the group consisting of: silica gel, molecular sieves, activated carbon, zeolites, sodium aciylic acid, and simple salts, carbonates and hydroxides, such as alkaline earth metal or alkali metal salts, carbonates and hydrides, for example calcium chloride, sodium chloride, magnesium sulphate, potassium carbonate and sodium hydroxide.
  • These sorbent materials are suitable for inclusion in a composition that is to be heated to generate an aerosol for inhalation by a consumer.
  • the sorbent material is stable at the temperatures to which it is exposed when the composition is heated to generate an aerosol.
  • the sorbent does not decompose, melt or otherwise disintegrate when exposed to elevated temperatures during use of the compositions.
  • the substrate comprises the sorbent material on the surface of the aerosol-generating material.
  • the sorbent material may form a partial or incomplete coating surrounding the portion of aerosol-generating material on the support.
  • the partial or incomplete coating means that the aerosol generated by heating the aerosol-generating material can be released from the substrate and is available for inhalation.
  • the partial coating is in the form or a permeable network. This ensures that the sorbent is present on the surface of the aerosolgenerating material, but that it does not prevent the volatiles generated by heating the aerosol-generating material being released.
  • the substrate comprises sorbent material in the form of particles. These particles may, for example, be included with the aerosol-generating material on the support.
  • the sorbent and the aerosol-generating material are homogenously mixed.
  • the particles of sorbent are only present on the surface of the portion of aerosol-generating material.
  • the sorbent particles may be concentrated in one or more locations to increase their exposure to ambient moisture. This may mean that the moisture is more likely to be absorbed or adsorbed by the sorbent material than by the aerosolgenerating material.
  • the substrate comprises one or more sorbent particles or granules.
  • the sorbent particles have an average size of at least about 50 nm, at least about too nm, at least about 200 nm, at least about 500 nm, at least about 1 pm, at least about 10 pm, at least about 50 pm, at least about too pm, at least about 200 pm, at least about 500 pm, at least about 600 pm, at least about 700 pm, at least about 800 pm, at least about 900 pm, or at least about 1 mm.
  • the sorbent particles have an average size of no more than about 3 mm, no more than about 2.5 mm, no more than about 2 mm, no more than about 1.5 mm, no more than about 1 mm, no more than about 900 pm, no more than about 800 pm, no more than about 700 pm, no more than about 600 pm, or no more than about 500 pm.
  • the composition comprises an agglomerate formed from one or more particles of aerosol-generating material and one or more particles of a sorbent material.
  • the sorbent may be present on or at the surface of the agglomerate, or the sorbent may be more concentrated at the surface.
  • the agglomerates of aerosol-generating material and sorbent material have an average size from about 3 mm to about 20 mm.
  • the amount of sorbent material included in the substrate is at least about 5% based on the total weight of the composition, at least about 10%, at least about 15%, at least about 20%, at least about 25% or at least about 30%.
  • the amount of sorbent material included in the composition is no more than about 50% based on the total weight of the composition, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25% or no more than about 20%.
  • the amount of sorbent included is from about 5 to about 40% by weight of the composition, or from about 10 to 30% by weight of the composition.
  • the amount of the sorbent to be included may be limited by the potential swelling of the sorbent material as it absorbs moisture. This increase in size of the sorbent will increase the volume of the substrate comprising the aerosol-generating material and sorbent material. In extreme circumstances, where large amounts of sorbent are included in the composition and in an environment with a high level of moisture, the expansion of the sorbent may cause issues such as the substrate no longer fitting onto the aerosol-provision device, or the release of the aerosol being compromised. Use of the substrates
  • the substrates comprising the aerosol-generating material and support may be used in combustible or non-combustible aerosol provision systems, or in an aerosol-free delivery system.
  • the substrate is provided in a consumable.
  • the substrate may be used as a consumable.
  • the present invention also relates to a consumable or article, comprising a substrate comprising a support at least partially coated with an aerosol-generating material.
  • the aerosol-generating material may be formed by diying a precursor material whilst in contact with the support.
  • the precursor material may comprise an extract from a flavour- and/or active-containing plant material.
  • a consumable is an article comprising aerosol-generating material, part or all of which is intended to be consumed during use by a user.
  • the aerosol-generating material or at least some of the aerosol-generating material, is provided as part of a substrate as disclosed herein, comprising the aerosol-generating material and a support.
  • a consumable may comprise one or more other components, such as an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent.
  • a consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.
  • the heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.
  • at least some of these components of a consumable may also be components of the substrate described herein.
  • the consumable may be any shape or size that is appropriate to the smoking device.
  • the consumable is a rod shape. In other embodiments, it may take the form of a flat strip, a rod, or a flexible sleeve.
  • the substrate comprising an aerosol-generating material and a support is provided in an aerosol-generating device such as a tobacco-heating product (THP) or hybrid e-cigarette product.
  • an aerosol-generating device such as a tobacco-heating product (THP) or hybrid e-cigarette product.
  • the substrate may be directly heated without burning to provide an inhalable aerosol.
  • heating the substrate will first cause the coating to decompose, to breach the barrier it forms around the aerosol-generating material. Then, the aerosolised components of the aerosol-generating material, for example the glycerol, nicotine and/or tobacco flavour will be released.
  • the substrate comprising an aerosol-generating material and a support may be incorporated into the consumable in the absence of any other carrier or other material that would need to be heated.
  • the total mass of the dried aerosol generating material included for use in a delivery system is up to about 200 mg, up to about 190 mg, up to about 180 mg, up to about 170 mg, up to about 160 mg, up to about 150 mg, up to about 140 mg, up to about 130 mg, up to about 120 mg, up to about no mg, up to about too mg, up to about 90 mg, up to about 80 mg, up to about 70 mg, up to about 60 mg, or up to about 50 mg.
  • the total mass of the dried aerosol generating material included may be at least about 5 mg, at least about 10 mg, at least about 15 mg, at least about 20 mg, at least about 25 mg, at least about 30 mg, at least about 35 mg, at least about 40 mg, at least about 45 mg, or at least about 50 mg.
  • the total mass of the dried aerosol-generating material is sufficient to provide aerosol, for example, for up to about to puffs to be generated in a single session or over a series of multiple sessions.
  • the total mass of the dried aerosol-generating material provided is from about to to too mg, or from about 25 to about 50 mg.
  • the delivery systems described herein can be combustible aerosol provision systems, non-combustible aerosol provision systems or an aerosol-free delivery systems.
  • the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not
  • a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.
  • the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.
  • the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
  • 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 aerosol-generating material is not a requirement.
  • END electronic nicotine delivery system
  • the non-combustible aerosol provision system is an aerosol- generating material heating system, also known as a heat-not-burn system.
  • a heat-not-burn 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 and may be an aerosol-generating material provided on a support.
  • 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 a substrate comprising an aerosol-generating material and a support 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 noncombustible 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 a substrate comprising an aerosol -generating material and a support 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 a substrate comprising an aerosol-generating material and a support, 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.
  • Figure 3 is a side-on cross sectional view of a consumable or article 10 for use in an aerosol delivery system.
  • the article 10 comprises a mouthpiece segment 11, and an aerosol generating segment 12.
  • the aerosol generating segment 12 is in the form of a cylindrical rod and comprises a substrate 14 comprising an aerosol-generating material on a support.
  • the substrate 14 can be any of the substrates comprising an aerosol-generating material and a support discussed herein, such as the embodiment illustrated in Figure 1.
  • the aerosol-generating segment 12 can be provided in other forms.
  • the mouthpiece segment it in the illustrated embodiment includes a body of material 15 such as a plug of fibrous or filamentaiy tow.
  • a cooling section 13 comprising a hollow tube 16 formed from a suitable material such as cellulose acetate, paper or a heat absorbing material.
  • the consumable 10 further comprises a wrapper 17, such as a paper wrapper, circumscribing the mouthpiece segment 11, the cooling section 13 and the aerosol generating segment 12.
  • a wrapper 17 such as a paper wrapper
  • Figure 4 shows an example of a non-combustible aerosol provision device too for generating aerosol from an aerosol -generating medium/ material such as the composition of a consumable no, as described herein.
  • the device too may be used to heat a replaceable article no comprising the aerosol-generating medium, for instance an article 10 as illustrated in Figure 3 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device too.
  • the device too and replaceable article no together form a system.
  • the device too comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device too.
  • the device too has an opening 104 in one end, through which the article no may be inserted for heating by a heating assembly. In use, the article no may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.
  • the device too of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article no is in place.
  • the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow “B”.
  • the device too may also include a user-operable control element 112, such as a button or switch, which operates the device too when pressed.
  • a user may turn on the device too by operating the switch 112.
  • the device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a batteiy of the device too.
  • the socket 114 may be a charging port, such as a USB charging port.
  • the substance to be delivered may be the aerosol-generating material of a substrate as described herein, and optionally another aerosol-generating material that may or may not be heated.
  • the substrate and other aerosol-generating material may comprise one or more active constituents, one or more flavours, one or more aerosol -former materials, and/or one or more other functional materials.
  • the invention enjoys the advantage of longer shelflife than other tobacco extracts.
  • the nicotine content of the precursor and aerosol-generating material after the freeze drying process has been calculated, providing an indication of the amount of nicotine retained following the processing.
  • the nicotine recovery of the dried aerosol generating material is at least about 76 wt% on a dry weight basis.
  • the nicotine recoveiy of the dried aerosol generating material compared to the original tobacco extract may be at least about 60%, at least about 70%, at least about 75%, at least about 80%, or at least about 90% on a diy weight basis.
  • the glycerol content of the precursor and dried aerosol-generating material after the freeze diying process has been calculated, providing an indication of the amount of glycerol retained following the processing.
  • the glycerol recovery of the dried aerosol generating material is at least about 85%.
  • the glycerol recovery of the dried aerosol generating material compared to the precursor material may be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90% at least about 95% on a dry weight basis.
  • Example 1 In addition, once surrounded by the moisture impermeable coating, the content of volatile components such as nicotine and flavours, and the content of the aerosolforming material in the aerosol-generating material will be maintained until the composition is heated to generate an aerosol. This will be even without packaging or other protection from exposure to moisture.
  • Example 1
  • the precursor material comprised essentially of aqueous tobacco extract, and glycerol.
  • the aqueous tobacco extract was diluted further with glycerol up to about 24 wt% (calculated on a dry weight basis).
  • the Burley aqueous tobacco extract had a tobacco solid content of about 40 wt%, and a water content of about 60 wt%.
  • the precursor material was dried via freeze drying.
  • the precursor material comprised essentially of aqueous tobacco extract, glycerol and Dextran 70.
  • the glycerol content was about o to about 15 v/v%, or up to about 36 wt% calculated on a diy weight basis.
  • the precursor material was dried via freeze drying.
  • Example 3 The precursor material of Example 1 or Example 2 is applied to the surface of a support comprising a sheet of a fleece fabric.
  • the fleece fabric is then freeze dried to provide a substrate comprising the fleece fabric and a coating of dried aerosol-generating material.
  • Example 4
  • Example 1 or Example 2 The precursor material of Example 1 or Example 2 is applied to the surface of a support comprising a susceptor comprising a rigid strip of aluminium by dipping the susceptor in bath of the precursor material. The coated susceptor is then rapidly dried to leave a thin layer of the dried aerosol-generating material on its surface.
  • Example 1 or Example 2 The precursor material of Example 1 or Example 2 is applied to the surface of a support comprising a susceptor comprising a rigid strip of aluminium.
  • the precursor material is flash-frozen on the surface of the susceptor by exposure to liquid nitrogen. This process is repeated to build up the layers of the precursor material on the surface of the susceptor.
  • the coated susceptor is then rapidly dried to leave a thin layer of the dried aerosol-generating material on its surface.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Agronomy & Crop Science (AREA)
  • Botany (AREA)
  • Manufacture Of Tobacco Products (AREA)

Abstract

L'invention concerne des substrats comprenant un support au moins partiellement revêtu d'un matériau de génération d'aérosol formé par séchage d'un matériau précurseur tout en étant en contact avec le support, le matériau précurseur comprenant un extrait issu d'un matériau végétal contenant un arôme et/ou un actif et éventuellement un matériau de formation d'aérosol. Les substrats peuvent être utilisés pour générer un aérosol. Par exemple, les substrats peuvent être utilisés dans des systèmes de fourniture d'aérosol combustibles ou non combustibles. L'invention concerne également des systèmes de fourniture d'aérosol comprenant les substrats, et des procédés de fourniture d'un substrat.
PCT/GB2023/050862 2022-04-01 2023-03-31 Substrat comprenant un matériau de génération d'aérosol sur un support et ses utilisations WO2023187410A1 (fr)

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GBGB2204838.3A GB202204838D0 (en) 2022-04-01 2022-04-01 A substrate comprising an aerosol-generating material on a support and uses thereof
GB2204838.3 2022-04-01

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017178394A1 (fr) * 2016-04-11 2017-10-19 Philip Morris Products S.A. Article générant un aérosol
WO2018122070A1 (fr) * 2016-12-30 2018-07-05 Philip Morris Products S.A. Feuille contenant de la nicotine
WO2020028468A1 (fr) * 2018-07-31 2020-02-06 Nicoventures Trading Limited Substrat de génération d'aérosol
US20210195938A1 (en) * 2019-12-27 2021-07-01 Nicoventures Trading Limited Substrate with multiple aerosol forming materials for aerosol delivery device
US20210204593A1 (en) * 2020-01-02 2021-07-08 R.J. Reynolds Tobacco Company Smoking article with downstream flavor addition
WO2021224604A1 (fr) * 2020-05-05 2021-11-11 Nicoventures Trading Limited Matière génératrice d'aérosol

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017178394A1 (fr) * 2016-04-11 2017-10-19 Philip Morris Products S.A. Article générant un aérosol
WO2018122070A1 (fr) * 2016-12-30 2018-07-05 Philip Morris Products S.A. Feuille contenant de la nicotine
WO2020028468A1 (fr) * 2018-07-31 2020-02-06 Nicoventures Trading Limited Substrat de génération d'aérosol
US20210195938A1 (en) * 2019-12-27 2021-07-01 Nicoventures Trading Limited Substrate with multiple aerosol forming materials for aerosol delivery device
US20210204593A1 (en) * 2020-01-02 2021-07-08 R.J. Reynolds Tobacco Company Smoking article with downstream flavor addition
WO2021224604A1 (fr) * 2020-05-05 2021-11-11 Nicoventures Trading Limited Matière génératrice d'aérosol

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