EP4599699A1

EP4599699A1 - Aerosol generating compositions, articles and systems comprising the same

Info

Publication number: EP4599699A1
Application number: EP24157103.3A
Authority: EP
Inventors: Muhammad Fahim ASHRAF; Walid Abi Aoun
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-02-12
Filing date: 2024-02-12
Publication date: 2025-08-13
Also published as: WO2025172276A1

Abstract

The present invention relates to aerosol-generating compositions and particularly to compositions comprising from about 50 wt% to about 95 wt% of a first aerosol-generating material comprising botanical material and from about 5 wt% to about 50 wt% of a second aerosol-generating material comprising a thin film. The invention also relates to articles comprising such compositions, for example for use in an aerosol provision system. The invention further relates to aerosol provision systems, and to methods for forming aerosol-generating articles.

Description

Technical Field

The present invention relates to aerosol-generating compositions and to articles comprising such compositions, for example for use in an aerosol provision system. The invention also relates to aerosol provision systems, and to methods for forming aerosol-generating articles.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of combustible articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles or aerosol generating articles.
One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolisable material. This solid aerosolisable material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosolisable material are known.

Summary

In accordance with a first aspect of the invention, there is provided an aerosol-generating composition comprising from about 50 wt% to about 95 wt% of a first aerosol-generating material comprising botanical material and from about 5 wt% to about 50 wt% of a second aerosol-generating material comprising a thin film.
In some embodiments, the thin film comprises a binder, an aerosol-former material, and a botanical extract.
In some embodiments, the thin film is substantially free from botanical material.
In some embodiments, the botanical material is tobacco.
In some embodiments, the tobacco is in the form of one or more of: cut rag, lamina and reconstituted tobacco.
In some embodiments, the thin film comprises a tobacco extract.
In some embodiments, the thin film has a nicotine content of from about 1.5% to about 7% by weight of the thin film.
In some embodiments, the thin film has a nicotine content of from about 2% to about 4% by weight of the thin film.
In some embodiments, the aerosol-generating composition comprises from about 70 to about 90% of the first aerosol-generating material and from about 10 wt% to about 30 wt% of a second aerosol-generating material.
In some embodiments, the aerosol-generating composition comprises from about 10 to about 25 wt% of an aerosol-former material.
In some embodiments, the aerosol-generating composition has a water content of no greater than about 12%.
In some embodiments, the thin film has a water content of no greater than about 5%.
According to a second aspect of the invention, there is provided an aerosol-generating article for use in an aerosol provision system, comprising an aerosol-generating segment comprising the aerosol-generating composition according to the first aspect.
In some embodiments, the second aerosol-generating material is included as a sheet positioned to surround at least part of a plug or section comprising the first aerosol-generating material.
In some embodiments, the second aerosol-generating material is included as a cut or shredded sheet which is blended with the first aerosol-generating material.
In some embodiments, the article comprises a first section of the first aerosol-generating material and a second section comprising a rolled sheet of the second aerosol-generating material.
In some embodiments, the article comprises a paper wrapper circumscribing the aerosol-generating composition, wherein the second aerosol-generating material is a sheet positioned between the first aerosol-generating material and the wrapper.
In some embodiments, the article comprises a cooling segment comprising a longitudinally extending air channel for cooling the flow of air therethrough.
According to a third aspect of the invention, there is provided a system for heating an aerosol-generating composition to volatilise at least one component of the aerosol generating material, the system comprising:

an article according to the second aspect, and
an aerosol delivery device for heating the aerosol-generating segment to volatilise at least one component of the aerosol-generating composition.

In some embodiments, the heating device is configured to externally heat the aerosol-generating segment, and/or inductively heat the aerosol-generating segment, and/or resistively heat the aerosol-generating segment.
According to a fourth aspect of the invention, there is provided a method for forming an article according to the second aspect, comprising the steps:

providing an aerosol generating composition according to the first aspect and a wrapping material;
circumscribing the aerosol generating composition with the wrapping material to form an aerosol generating segment; and attaching any further segments.

Brief Description of the Drawings

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

Figure 1 is a side-on cross-sectional view of an article for use in an aerosol provision system, according to one embodiment;
Figure 2 is a side-on cross-sectional view of an article according to another embodiment;
Figure 3 is a side-on cross-sectional view of an article according to an alternative embodiment;
Figure 4 is a side-on cross-sectional view of an article according to a further embodiment;
Figure 5 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from an article according to the present disclosure.

Detailed Description

The present invention relates generally to an aerosol-generating composition for use in an aerosol-generating article which is configured to heat (but not burn) the composition to generate an aerosol for inhalation.
The aerosol-generating composition comprises a first aerosol-generating material comprising botanical material and a second aerosol-generating material comprising a thin film. Specifically, the first aerosol-generating material comprising botanical material is present in an amount of from about 95 wt% to about 50 wt%, and the second aerosol-generating material is present in an amount of from about 5 wt% to about 50 wt%.
The first and second aerosol-generating materials are both to be heated during use to generate one or more aerosols. The combination of the two materials provides a number of beneficial properties to the aerosol-generating composition. For example, the botanical material may provide a source of authentic and natural botanical flavours and active substances. These may be complemented by the flavours and/or actives provided by the thin film material which may, for example, comprise a botanical extract which may provide a concentrated source of such substances. The thin film also provides volatile components, including those of the botanical extract, in a stabilised form.
The thin film may also represent a source of aerosol-former material that can be difficult to incorporate into botanical material in large enough amounts to provide the desired aerosol body and visible aerosol whilst still having properties that make the botanical material suitable for incorporation into an aerosol-generating article.
In embodiments of the invention, the thin film may provide flavours and/or active substances in a concentrated form. This means that the amount of such thin film included in the aerosol-generating composition may be reduced compared to the amounts of thin films that are included in conventional aerosol-generating compositions. For example, the aerosol generating composition may include as little as 5 wt% of the second aerosol-generating material, whilst still contributing to the generation of a flavourful and impactful aerosol.
A reduction in the amount of the thin film present in the aerosol-generating composition affords additional flexibility in terms of how this material is incorporated in the aerosol-generating composition and in the design of articles incorporating the aerosol-generating composition. This allows articles to be designed that permit controlled heating of the thin film and controlled generation of an aerosol from the aerosol-generating composition.
The inclusion of a relatively small amount of thin film may also mean a reduction in the total mass of the aerosol-generating composition and of the aerosol-generating article, with consequent lower costs and potentially lower energy requirements.
There may also be a further benefit in that the sensory quality of the initial puffs, such as the first 1 or 2 puffs, may be improved, leading to a better user experience and increased user satisfaction.
A significant challenge associated with aerosol provision systems is the phenomenon known as "hot puff". This is reference to the steam that is given off when the aerosol-generating material is first heated. As the temperature rises, water evaporates, forming steam which the user can inhale. The greater the water content of the aerosol-generating material, the greater the amount of steam generated on heating and the increased hot puff. Aerosol generating materials with high aerosol-former material content can often have a relatively high moisture content and contribute to hot puff. Reducing the amount of this aerosol-generating material or reducing the water content of this material may significantly reduce the problem of hot puff experienced by users.

Thin film

As referred to herein, the thin film is a sheet material that may be heated to form an aerosol. The thin film may alternatively be referred to as a "dried gel". The thin film is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the thin film is optionally cast or extruded to form the sheet.
The thin film may comprise a binder, such as a gelling agent, and an aerosol-former material. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the thin film may or may not be soluble in the solvent.
The thin film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of from about 0.05 mm, about 0.1 mm or about 0.15 mm to about 0.5 mm or about 0.3 mm.
The thin film may comprise more than one layer or film, and the thickness described herein may refer to the aggregate thickness of those layers or films.
The thin film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of thin film.
The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former material and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the thin film.
The slurry may be heated to remove at least about 60 wt%, about 70 wt%, about 80 wt%, about 85 wt% or about 90 wt% of the solvent.
The thin film may be a "monolithic solid". The thin film may be substantially non-fibrous. In some embodiments, the thin film may be a dried gel. The thin film is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the second aerosol-generating material may, for example, comprise from about 50 wt%, about 60 wt% or about 70 wt% of the thin film, to about 90 wt%, about 95 wt% or about 100 wt% of the thin film.
In some embodiments, the thin film is substantially free from (solid) botanical material. In particular, in some embodiments, the thin film is substantially tobacco free. In some embodiments, the thin film comprises a liquid botanical extract.
The thin film may comprise a number of components, including a binder that binds the components together to form a cohesive whole. The binder may be a gelling agent.
In some embodiments, the thin film may comprise from about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 10 wt%, about 15 wt% or about 20 wt%, to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 25 wt%, about 20 wt%, about 15 wt%, or about 10 wt% of one or more binders (DWB). For example, the thin film may comprise from about 1 to about 40 wt%, from about 2 to about 20 wt% or from about 4 to about 15 wt% of binder (DWB).
Suitably, the thin film may comprise from about 1 wt% to about 60 wt% gelling agent, for example from about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 10 wt%, about 15 wt% or about 20 wt%, to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 25 wt%, about 20 wt%, about 15 wt%, about 10 wt% of a gelling agent (all calculated on a dry weight basis). For example, the second aerosol-generating material may comprise from about 1 to about 30 wt%, from about 2 to about 20 wt% or from about 4 to about 15 wt% of the gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid.
In some embodiments, the gelling agent comprises (or is) one or more compounds selected from polysaccharide gelling agents, such as alginate, pectin, starch or a derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan, agar and agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica or silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin; and polyvinyl alcohol.
In some embodiments the gelling agent comprises (or is) one or more polysaccharide gelling agents.
In some embodiments, the polysaccharide gelling agent is selected from alginate, pectin, starch or a derivative thereof, or cellulose or a derivative thereof. In some embodiments the polysaccharide gelling agent is selected from alginate and a cellulose derivative.
In some embodiments, the gelling agent is a polysaccharide gelling agent, optionally wherein the polysaccharide gelling agent is selected from alginate and a cellulose derivative.
In some embodiments, the alginate is sodium alginate.
In some embodiments, the polysaccharide gelling agent is a cellulose derivative. Without wishing to be bound by theory, the inventors believe that such gelling agents do not react with calcium ions to form crosslinks.
In some embodiments, the polysaccharide gelling agent is alginate.
In some embodiments the gelling agent is not crosslinked. The absence of crosslinks in the gelling agent facilitates quicker delivery of the botanical constituent, derivative or extract (and any optional additional active substances and/or flavours) from the second aerosol-generating material.
Examples of cellulosic gelling agents (also referred to herein as cellulose derivatives) include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments the cellulose or derivative thereof is selected from hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose derivative is CMC.
For example, in some embodiments, the gelling agent comprises (or is) one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, guar gum, acacia gum, alginate and/or pectin.
In some cases, the gelling agent comprises (or is) alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the thin film. In some cases, the aerosol-generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises (or is) alginate, optionally wherein the alginate is present in the aerosol-generating material in an amount of from about 1 to about 10 wt%, for example from about 3 to about 6 wt%, of the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, alginate is the only gelling agent present in the thin film.
In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
In particular embodiments, the gelling agent is carboxymethylcellulose, optionally wherein the carboxymethylcellulose (CMC) is present in an amount of from about 15 to about 50 wt%, for example from about 20 to about 40 wt% or about 30 wt%. In some embodiments, CMC is the only gelling agent present in the thin film.
In some embodiments, the weight ratio of the total amount of gelling agent to the total amount of botanical extract is from about 1:1 to about 1:20, such as from about 1:5 to about 1:15 or from about 1:10 to about 1:12.
To enhance the aerosol-generation, the thin film may preferably comprise an aerosol-former material. The aerosol-former material may comprise one or more constituents capable of forming an aerosol.
The thin film may comprise from about 5 wt%, about 10 wt%, about 15%, about 20 wt%, about 25 wt%, about 27 wt% or about 30 wt% to about 60 wt%, about 55 wt%, about 50 wt%, about 45 wt%, about 40 wt%, or about 35 wt% of an aerosol-former material (DWB). For example, the thin film may comprise from about 10 wt% to about 60 wt%, from about 20 wt% to about 50 wt%, from about 25 wt% to about 40 wt% or from about 30 wt% to about 35 wt% of an aerosol-former material.
Suitably, the thin film may comprise from about 0.1 wt%, about 0.5 wt%, about 1 wt%, about 3 wt%, about 5 wt%, about 7 wt% or about 10 wt% to about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt% or about 25 wt% of an aerosol-former material (all calculated on a dry weight basis). For example, the thin film may comprise from about 0.5 wt% to about 40 wt%, from about 3 wt% to about 35 wt% or from about 10 wt% to about 25 wt% of an aerosol-former material.
In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
In some cases, the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of, or consists of, glycerol.
In some embodiments, the aerosol-former material comprises a mixture of glycerol and propylene glycol in a weight ratio of glycerol to propylene glycol of from about 3:1 to about 1:3, from about 2:1 to about 1:2, from about 1.5:1 to about 1:1.5, from about 55:45 to about 45:55, or about 45:55.
The aerosol-former material may act as a plasticiser. It has been established that if the content of the aerosol-former material is too high, the thin film may absorb water (as the aerosol-former material is hygroscopic) resulting in a material that does not create an appropriate consumption experience in use. It has also been established that if the aerosol-former material content is too low, the thin film may be brittle and easily broken (as the aerosol-former material may act as a plasticiser). The aerosol-former material content specified herein provides a thin film with flexibility which allows the thin film to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles.
The thin film may comprise from about 10 wt%, about 20 wt%, about 30 wt%, about 40 wt% or about 45 wt% to about 60 wt%, about 55 wt% or about 50 wt% of botanical extract (DWB). For example, the thin film may comprise from about 20 to about 60 wt%, from about 40 to about 55 wt% or from about 45 to about 50 wt% of botanical extract (DWB).
In some embodiments, the botanical extract is a liquid or solid that has been isolated from a botanical material. For example, the extract may be prepared by processing techniques such as expression (such as juicing or pressing) or solvent extraction. Optionally, the extract is concentrated and/or purified, for example by distillation. In some embodiments, the botanical material is macerated, frequently without heating, to soften and degrade the material prior to extraction.
In some cases, the botanical extract is an aqueous extract, obtained by extraction with water. Additionally or alternatively, other solvents may be used, including supercritical fluids.
In some embodiments, the botanical extract included in the thin film is an extract of one or more of any of the botanical materials discussed herein.
In some embodiments, the botanical extract comprises or consists of a tobacco extract.
In some cases, the tobacco extract may be an aqueous extract, obtained by extraction with water. The tobacco extract may be an extract from any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be an extract from tobacco particle 'fines' or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The extract may be obtained from a ground tobacco or a reconstituted tobacco material.
In some embodiments, the botanical extract used to form the thin film has a high content of the non-aqueous component. This will include the soluble botanical components, as well as any non-water solvent or co-solvent. This may also be referred to as a high solids content of the extract, although, for the avoidance of doubt, this is not reference to the presence of solid botanical material.
A conventional aqueous tobacco extract will have a solids (non-aqueous) content of up to about 50%. In contrast, the botanical extracts used in some embodiments of the present invention to form a thin film may have a solids (non-aqueous) content of at least about 65%, at least about 70%, at least about 75% or at least about 78%. This means that the extract is more concentrated than conventional extracts and may provide a thin film with a strong and impactful flavour and active content when heated to form a vapour or aerosol. The high solids content in the botanical extract may, in some embodiments, be achieved by using an alcohol such as ethanol as a co-solvent with water.
In some embodiments, the thin film comprises from about 1 wt%, about 1.5 wt% or about 2 wt% to about 6 wt%, about 5 wt%, about 4 wt% or about 3 wt% of nicotine (DWB). In some cases, there may be no nicotine in the thin film other than that which results from the tobacco extract.
In some embodiments, the thin film comprises an additional or added flavour and/or active substance, in addition to the flavour and/or active substance present in the botanical extract. Suitably, the thin film may comprise up to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 20 wt%, about 10 wt% or about 5 wt% of such an additional flavour and/or active substance. In some cases, the thin film may comprise at least about 0.5 wt%, about 1 wt%, about 2 wt%, about 5 wt%, about 10 wt%, about 20 wt% or about 30 wt% of an additional flavour and/or active substance (all calculated on a dry weight basis). For example, the thin film may comprise from about 10 wt% to about 60 wt%, from about 20 wt% to about 50 wt% or from about 30 wt% to about 40 wt% of an additional flavour and/or active substance.
Suitably, the thin film may comprise up to about 60 wt%, about 50 wt%, about 40 wt%, about 30 wt%, about 20 wt%, about 10 wt% or about 5 wt% of an additional or added flavour. In some cases, the thin film may comprise at least about 0.5 wt%, about 1 wt%, about 2 wt%, about 5 wt%, about 10 wt%, about 20 wt% or about 30 wt% of an additional flavour (all calculated on a dry weight basis). For example, the thin film may comprise from about 10 wt% to about 60 wt%, from about 20 wt% to about 50 wt% or from about 30 wt% to about 40 wt% of an additional flavour. In some cases, the additional flavour (if present) comprises, consists essentially of, or consists of, menthol.
In some cases, the thin film does not comprise an added flavour and/or active substance. In some cases, the thin film does not comprise an additional flavour. In some cases, the thin film does not comprise a further active substance.
In some cases, the total content of botanical extract and additional flavour and/or active substance may be no more than about 80 wt%, about 70 wt%, about 60 wt%, about 50 wt% or about 40 wt% (all calculated on a dry weight basis).
In some embodiments, the thin film comprises nicotine. In some embodiments, this nicotine may be derived from the botanical extract included in the thin film. In other embodiments, such as those where the botanical extract is not a tobacco extract, the nicotine is an additional active substance included in the thin film. In some embodiments, the thin film has a nicotine content of from about 1.5 wt% to about 7 wt% of the thin film (DWB).
In some cases, the thin film may comprise at least about 1.5 wt%, about 2 wt%, about 2.5 wt%, about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt% or about 5 wt% of nicotine (DWB). The thin film may comprise no more than about 7 wt%, about 6.5 wt%, about 6 wt%, about 5.5 wt%, about 5 wt%, about 4.5 wt%, about 4 wt%, about 3.5 wt% or about 3 wt% of nicotine (DWB). For example, the thin film may comprise from about 2 wt% to about 6 wt%, or from about 4 wt% to about 5 wt% nicotine by weight of the thin film (DWB).
In some embodiments, the thin film comprises a filler. The filler may be present to adjust the physical and/or chemical properties of the material. For example, in some embodiments, the filler may increase the tensile strength of the thin film and render it more suitable for large scale manufacture of aerosol-generating articles. On the other hand, inclusion of a filler may add to the cost, weight and density of the thin film. Adding to the mass of the thin film potentially adds to the energy and time required to heat the film to generate the desired aerosol.
In some embodiments, the thin film comprises no more than about 60 wt% of a filler, such as from about 1 wt% to about 60 wt%, or from about 5 wt% to about 50 wt%, or from about 5 wt% to about 30 wt%, or from about 10 wt% to about 20 wt%.
In other embodiments, the thin film comprises no more than about 20 wt%, suitably no more than about 10 wt% or no more than about 5 wt% of a filler. In some cases, the thin film comprises no more than about 1 wt% of a filler, and in some cases, comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp; tobacco pulp; hemp fibre; starch and starch derivatives, such as maltodextrin; chitosan; and cellulose and cellulose derivatives, such as microcrystalline cellulose and nanocrystalline cellulose. In particular cases, the thin film comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. In some embodiments, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including fibrous filler in a thin film may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the thin film is provided as a sheet, such as when a thin film sheet circumscribes a rod of aerosolisable material.
In some embodiments, the thin film does not comprise tobacco fibres. In particular embodiments, the thin film does not comprise fibrous material.
In some embodiments the gelling agent is cellulose, such as CMC, and/or guar gum, and is used together with wood pulp as a filler.
The thin film may, in some cases, comprise water. In some instances, the thin film is a hydrogel. In some embodiments, the thin film comprises no more than about 20 wt%, about 15 wt%, about 12 wt%, about 10 wt%, about 9 wt% or about 8 wt% water. In some cases, the thin film may comprise at least about 1 wt%, about 2 wt% or about 5 wt% water. The thin film may comprise about 10 wt% water. In some cases, the thin film comprises from about 5 wt% to about 10 wt% water, or from about 5 wt% to about 9 wt%. Suitably, the water content of the thin film may be about 5 wt%.
In some cases, the thin film may consist essentially of, or consist of, one or more binders, an aerosol-former material, a botanical extract, water, and one or more fillers. In some cases, the thin film may consist essentially of, or consist of, glycerol, guar gum and/or cellulose, a botanical extract and a filler such as wood pulp.
In some embodiments, the thin film comprises:

1-10 wt% guar gum;
10-30 wt% glycerol;
10-60 wt% of a botanical extract;
1-15 wt% wood pulp; and
20-40 wt% ground cellulose;

It has been found that thin films having these compositions can be efficiently heated to generate an inhalable aerosol.
In some cases, the second aerosol-generating material may additionally comprise a carrier on which the thin film is provided. This carrier may ease manufacture and/or handling through, for example, (a) providing a surface onto which a slurry may be cast (and which the slurry does not need to be separated from later), (b) providing a non-tacky surface for the aerosol-generating material, (c) providing some rigidity to the aerosol-generating material.
In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the carrier may comprise or consist of a botanical material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the carrier itself be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the carrier may also function as a flavour carrier. For example, the carrier may be impregnated with a flavourant or with botanical extract.
In some cases, the carrier may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the carrier in use, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use on, for example, the surface of a heater provided in an aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.
In some cases, the carrier in the aerosol generating article may comprise or consist of a porous layer that abuts the thin film. For example, the porous layer may be a paper layer. In some particular cases, the thin film is disposed in direct contact with the porous layer; the porous layer abuts the thin film and forms a strong bond. The thin film is formed by drying a slurry or gel and, without being limited by theory, it is thought that the slurry or gel partially impregnates the porous layer (e.g., paper) so that when the slurry or gel sets and forms cross-links, the porous layer is partially bound into the thin film. This provides a strong binding between the thin film and the porous layer.
Additionally, surface roughness may contribute to the strength of bond between the thin film and the carrier. The paper roughness (for the surface abutting the carrier) may suitably be in the range of from about 50 to about 1000 Bekk seconds, suitably from about 50 to about 150 Bekk seconds, suitably about 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness".)
Conversely, the surface of the carrier facing away from the thin film may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is disposed so as to have a rougher side abutting the thin film and a smoother side facing away from the thin film.
In one particular case, the carrier may be a paper-backed foil; the paper layer abuts the thin film layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the thin film.
In another case, the foil layer of the paper-backed foil abuts the thin film. The foil is substantially impermeable, thereby preventing water provided in the thin film from being absorbed into the paper which could weaken its structural integrity.
In some cases, the carrier is formed from or comprises metal foil, such as aluminium foil. A metallic carrier may allow for better conduction of thermal energy to the thin film. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of no more than about 20 µm, such as from about 1 µm to about 10 µm, suitably about 5 µm.
In some cases, the carrier may be magnetic. This functionality may be used to fasten the carrier to the assembly in use, or may be used to generate particular thin film shapes. In some cases, the aerosol-generating material may comprise one or more magnets which can be used to fasten the material to an induction heater in use.
In some cases, the aerosol-generating material may comprise heating means embedded in the thin film, such as resistive or inductive heating elements.
In some cases, the thin film may have a thickness of from about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of from about 0.05 mm, about 0.1 mm or about 0.15 mm to about 0.5 mm or about 0.3 mm. A material having a thickness of about 0.2 mm may be particularly suitable. The thin film may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
If the thin film is too thick, then heating efficiency may be compromised. This adversely affects the power consumption in use. Conversely, if the thin film is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.
The thin film thicknesses stipulated herein optimises the material properties in view of these competing considerations. The thickness stipulated herein is a mean thickness for the material. In some cases, the thin film thickness may vary by no more than about 25%, about 20%, about 15%, about 10%, about 5% or about 1%.
The second aerosol-generating material comprising the thin film may have any suitable area density, such as from about 30 g/m² to about 120 g/m². In some embodiments, second aerosol-generating material may have an area density of from about 30 to about 70 g/m², or from about 40 to about 60 g/m². In some embodiments, the thin film may have an area density of from about 80 to about 120 g/m², or from about 70 to about 110 g/m², or particularly from about 90 to about 110 g/m². Such area densities may be particularly suitable where the second aerosol-generating material is included in an aerosol generating article/assembly in sheet form, or as a shredded sheet (described further hereinbelow).
The thin film may be formed as a sheet. It may be incorporated into the article in sheet form. In some cases, the second aerosol-generating material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e., in the form of a tube or as a rolled plug).
In some embodiments, the thin film may be included in an aerosol generating article/assembly as a sheet, such as a sheet circumscribing a rod of the first aerosol-generating material. In some other cases, the second aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with the first aerosol-generating material and incorporated into the article. In such cases, the second aerosol-generating material may have a mass per unit area that is selected to be comparable to the density of the first aerosol-generating material, so the mixture components do not separate. For example, the second aerosol-generating material may have a mass per unit area of from about 80 g/m² to about 120 g/m² so that it has a density comparable to cut rag tobacco.
In some examples, the thin film in sheet form may have a tensile strength of from about 200 N/m to about 900 N/m. In some examples, such as where the thin film does not comprise a filler, the thin film may have a tensile strength of from about 200 N/m to about 400 N/m, or from about 200 N/m to about 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the thin film comprises a filler, the thin film may have a tensile strength of from about 600 N/m to about 900 N/m, or from about 700 N/m to about 900 N/m, or about 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material is included in an aerosol generating article/assembly as a wrapper or as a rolled sheet, suitably in the form of a tube.

Botanical material

The first aerosol-generating material comprises a botanical material.
As used herein, the term "botanical material" includes any material derived from plants including, but not limited to, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. In some embodiments, the term "botanical material" refers to solid plant matter (i.e., part of a plant) and does not encompass a "botanical extract".
Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the botanical is selected from rooibos and fennel.
In some embodiments, the botanical material comprises leaf material.
In some embodiments, the botanical material is tobacco material.
As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.
The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle 'fines' or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibres, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.
The botanical material may, in some cases, comprise water. In some instances, the botanical material is a dried botanical material, that is, the plant material has been treated to remove the water naturally present in the plant. In some embodiments, the botanical material comprises no more than about 20 wt%, about 15 wt%, about 12 wt% or about 10 wt% water. In some cases, the botanical material may comprise at least about 1 wt%, about 2 wt% or about 5 wt% water. The botanical may comprise from about 10 wt% to about 20 wt% water, or from about 10 wt% to about 15 wt%. Suitably, the water content of the thin film may be about 12 wt%.
In some embodiments, the first aerosol-generating material comprises an aerosol-former material. For example, the aerosol-former material may be added to or incorporated into the botanical material.
In some embodiments, the first aerosol-generating material comprises at least about 10 wt%, about 12 wt%, about 15 wt%, about 18 wt%, about 20 wt% or about 22 wt% of aerosol-former material. Additionally or alternatively, the first aerosol-generating material comprises no more than about 25 wt%, about 22 wt%, about 20 wt%, about 18 wt%, about 15 wt% or about 12 wt% of aerosol-former material. In some embodiments, the amount of aerosol-former material in the first aerosol-generating material is from about 15 wt% to about 25 wt%, or from about 20 wt% to about 25 wt% (DWB).

Aerosol-generating composition

The aerosol-generating composition is a combination of two or more different aerosol-generating materials, the first aerosol-generating material comprising botanical material and the second aerosol-generating material comprising a thin film.
The aerosol-generating composition comprises from about 50 wt% to about 95 wt% of a first aerosol-generating material comprising botanical material and from about 5 wt% to about 50 wt% of a second aerosol-generating material comprising a thin film.
In some embodiments, the aerosol-generating composition comprises from about 70 to about 90% of the first aerosol-generating material and from about 10 wt% to about 30 wt% of a second aerosol-generating material.
The two aerosol-generating materials are included in the aerosol-generating composition. The aerosol-generating materials may differ in one or more further ways. For example, in some embodiments, the first and second aerosol-generating materials include different active substances.
The aerosol-generating materials may have different thicknesses and/or may be provided in otherwise different sizes, such as cut to different dimensions or average particle sizes.
The density of the aerosol-generating materials may be different.
In some embodiments, the aerosol-generating materials include different components or the same components in different amounts.
The two or more aerosol-generating materials may be included in the aerosol-generating material in different amounts.
In some embodiments, the different aerosol-generating materials may be mixed to form a largely homogenous blend. In other embodiments, the distribution of the different aerosol-generating materials is controlled to provide a desired distribution within the material, optionally with the materials being unmixed or substantially unmixed. Where the aerosol-generating composition comprises a blend of two or more different aerosol-generating materials this may control the release of the active agents. For example, the blend may provide a consistent release throughout use of the consumable, and may be configured/formulated to provide either a rapid release or a slow release.
The aerosol-generating materials may be arranged within the composition to allow them to be heated together or separately. Separate heating may mean in terms of timing, for example, sequentially, and/or in terms of heating to different temperatures.
As discussed above, the thin film of the first aerosol-generating material may comprise an aerosol-former material. In addition, an aerosol-former material may optionally also be included in the second aerosol-generating material. In some embodiments, the aerosol-generating composition comprises (in total) from about 10 to about 25 wt% of an aerosol-former material (DWB).
In some embodiments, the aerosol-generating composition comprises at least about 10 wt%, about 12 wt%, about 15 wt%, about 18 wt%, about 20 wt% or about 22 wt% of one or more aerosol-former material. Additionally or alternatively, the aerosol-generating composition comprises no more than about 25 wt%, about 22 wt%, about 20 wt%, about 18 wt%, about 15 wt% or about 12 wt% of aerosol-former material. In some embodiments, the amount of aerosol-former material in the aerosol-generating composition is from about 15 wt% to about 25 wt%, or from about 20 wt% to about 25 wt% (DWB).
The aerosol-generating composition may comprise water. In some embodiments, the aerosol-generating composition comprises no more than about 20 wt%, about 15 wt%, about 12 wt% or about 10 wt% water. In some cases, the aerosol-generating composition may comprise at least about 1 wt%, about 2 wt% or about 5 wt% water. In some cases, the aerosol-generating composition comprises from about 5 wt% to about 15 wt% water, or from about 10 wt% to about 12 wt%.

Article

An article for use in an aerosol provision system comprises an aerosol-generating portion comprising the aerosol-generating composition described herein.
In some embodiments, the aerosol generating article may be circumscribed by a wrapping material such as paper.
In some cases, the article may additionally comprise a filter and/or cooling element. In some embodiments, the filter and/or cooling element and the aerosol-generating portion are joined by tipping paper that circumscribes at least a portion of both of these parts of the article.
The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the apparatus from the user. In some embodiments, the cooling segment comprises a longitudinally extending air channel for cooling the flow of air therethrough.
The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug or a paper plug, and optionally including capsule.
In some embodiments, the article comprises a mouth end hollow tubular body. The one or more sections selected from the mouth end tubular body, filter plug and cooling element may be combined by a wrapping material to form a mouthpiece of the article. The mouthpiece may be attached to the aerosol-generating portion, for example by a tipping paper.
In some embodiments, the aerosol-generating article and/or the aerosol-generating portion thereof comprises the second aerosol-generating material in the form of a sheet positioned to surround at least part of a plug or section comprising the first aerosol-generating material.
In some embodiments, the second aerosol-generating material is included in the form of a cut or shredded sheet which is blended with the first aerosol-generating material.
In some embodiments, the aerosol generating portion of the article comprises a first section comprising the first aerosol-generating material and a second section comprising the second aerosol-generating material. In some embodiments, the section comprises a rolled sheet of the second aerosol-generating material.
In some embodiments, the article comprises a paper wrapper circumscribing the aerosol-generating composition, wherein the second aerosol-generating material is positioned between the first aerosol-generating material and the wrapper. In some embodiments, the second aerosol-generating material is a sheet which is positioned between the wrapper and the first aerosol generating material. In some embodiments, the thin film is provided on the inner surface of the wrapper circumscribing the second aerosol-generating material.
Figure 1 is a side-on cross-sectional view of an article 1 for use in an aerosol provision system. In the present case, the article comprises a consumable for a non-combustible aerosol provision system.
The article comprises an aerosol generating portion, in the present case a cylindrical aerosol-generating portion 2, and a mouthpiece 3 downstream from and connected to the aerosol-generating portion 2.
The aerosol-generating portion 2 comprises a rod or segment of aerosol-generating composition 20 wrapped in a rod wrapper 10.
In Figure 1, the rod of aerosol-generating composition 20 comprises a blend of a first aerosol-generating material comprising botanical material and a second aerosol-generating material comprising a thin film. In this embodiment, the two materials are cut or shredded and the two different shredded materials are blended and formed into a rod segment. In this embodiment, the two aerosol-generating materials are fairly evenly distributed within the rod and along the length of the rod.
The article 1 also comprises a mouthpiece 3 which has a mouth end 3b and a distal end 3a that abuts the aerosol-generating portion 2.
The mouthpiece 3 illustrated in Figure 1 is located at the mouth end of the article 1 and comprises three elements, a mouthpiece body 14 downstream of a cooling section 13, and a hollow tubular element 15 downstream of the mouthpiece body 14. In other embodiments, one or two of these different mouthpiece elements may be omitted or duplicated, and/or the elements may be provided in a different sequence. For example, the hollow tubular element 15 may be omitted, and the mouthpiece body 14 may form the mouth end of the article. In some examples where the hollow tubular element 15 is omitted, the length of the mouthpiece body 14 may be increased, or a further body of material may be provided at the mouth end.
In an alternative arrangement that is not illustrated, the mouthpiece comprises a mouthpiece body at the mouth end of the mouthpiece, optionally comprising a plug of cellulose acetate tow or paper, and optionally including capsule. Adjacent to this mouthpiece body is a first tube, optionally formed from paper, which abuts at its other end a further tubular section, optionally comprising cellulose acetate.
In the mouthpiece shown in Figure 1, the cooling section 13, mouthpiece body 14 and hollow tubular element 15 are connected by a combining wrapping material 11.
As shown in Figure 1, tipping paper 9 is wrapped around the full length of the mouthpiece 3 and over part of the aerosol generating portion 2. The tipping paper 9 has an adhesive on its inner surface (not shown) to connect the mouthpiece 3 and rod 2. In the illustrated embodiment, the tipping paper 9 extends 5 mm over the rod of aerosol generating material 2 but it can alternatively extend from about 3 mm to about 15 mm over the rod 2, or from about 4 mm to about 6 mm, to provide a secure attachment between the mouthpiece 3 and rod 2.
In the illustrated embodiment, the article 1 is provided with first and second parallel rows of perforations 12 through the tipping material 9, combining wrapping material 11 and cooling section 13, providing ventilation into the mouthpiece 3 at the cooling section 13. The perforations 12 shown are formed as laser perforations, at positions about 18 mm and about 19 mm respectively from the downstream, mouth-end 3b of the mouthpiece 3. In other examples, the ventilation can be provided into the mouthpiece 3 at other locations.
Figure 2 shows an article 1 with a similar overall construction to the article shown in Figure 1 and described above. Specifically, the mouthpiece and wrappers are the same.
In Figure 2, the rod comprising the aerosol-generating composition is different to that shown in Figure 1. In this embodiment, the aerosol-generating portion comprises a rod or segment comprising the first aerosol-generating material 21. This may be a rod of shredded botanical material. The entire length of this rod or segment is surrounded by a sheet 22 of a second aerosol-generating material comprising a thin film. In this embodiment, the two aerosol-generating materials are provided together but they are not blended and they are present in the aerosol-generating portion is different and distinct or separate forms. In the embodiment illustrated in Figure 2, both of the two aerosol-generating materials are present along the entire length of the aerosol-generating portion 2.
Figure 3 shows an article 1 with a similar overall construction to the article shown in Figure 2 and described above. Specifically, the mouthpiece and wrappers are the same.
In Figure 3, the aerosol-generating portion 2 differs from that shown in Figure 2 in that only part of the length of the rod or segment comprising the first aerosol-generating material 21 is surrounded by a sheet 22 of a second aerosol-generating material comprising a thin film. Once again, the first aerosol-generating material 21 may be shredded botanical material. The Thus, in the embodiment illustrated in Figure 3, only the first aerosol-generating material 21 is present along the entire length of the aerosol-generating portion 2. The second aerosol-generating material 22 is present over only part of the length of the aerosol-generating portion 2. This arrangement means that the second aerosol-generating material 22 may be heated and generate an aerosol at specific times during the overall use of the article.
Figure 4 shows an article 1 with a different construction of aerosol-generating portion 2. Once again, the mouthpiece and wrappers are the same as shown in the foregoing figures and are as described above.
In Figure 4, the aerosol-generating portion 2 comprises two separate segments. The first segment is a rod or plug comprising the first aerosol-generating material 21. This segment abuts the distal end 3a of the mouthpiece 3. The second segment of the aerosol-generating portion 2 is a rod or plug comprising the second aerosol-generating material 22 comprising a thin film. This second segment is formed from a roll of a sheet of the second aerosol-generating material forming a plug. In alternative embodiments, the rod or plug may comprise a folded or gathered sheet of the second aerosol-generating material 22, aligned strips of the second aerosol-generating sheet material, or a plug of cut or shredded second aerosol-generating sheet material.
In the embodiment illustrated in Figure 4, the first aerosol-generating material 21 and second aerosol-generating material 22 are present at different locations along the length of the aerosol-generating portion 2. This will allow them to be separately or independently heated, if desired.
In Figure 4, the two segments of the aerosol-generating portion 2 are separately wrapped by wrappers 10 and 6. The two segments are held together by a tipping paper 7 which is wrapped around the full length of the segment comprising the second aerosol-generating material 22 and over part of the segment comprising the first aerosol generating material 21. The tipping paper 7 has an adhesive on its inner surface (not shown) to connect the segments of the aerosol-generating portion 2. In the illustrated embodiment, the tipping paper 7 extends 5 mm over the segment comprising the first aerosol generating material 21 but it can alternatively extend over the entire length of the aerosol-generating portion 2, or even over the entire length of the article 1.

Assembly

The invention also relates to an aerosol generating assembly comprising an aerosol generating article described herein and a heater configured to heat but not burn the aerosol-generating composition (also referred to herein as the aerosolisable material).
The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to product heat in use. The aerosol generating assembly may comprise a plurality of heaters. The heater(s) may be powered by a battery.
In some cases, the heater may heat, without burning, the aerosolisable material to a temperature of from about 120°C to about 350°C in use. In some cases, the heater may heat, without burning, the aerosolisable material to from about 140°C to about 250°C in use. In some cases in use, substantially all of the second aerosol-generating composition is no more than about 4 mm, about 3 mm, about 2 mm or about 1 mm from the heater. In some cases, the second aerosol-generating composition is disposed from about 0.01 mm to about 2 mm from the heater, suitably from about 0.02 mm to about 1.0 mm, suitably from about 0.1 mm to about 0.5 mm. These minimum distances may, in some cases, reflect the thickness of a carrier that supports the thin film. In some cases, a surface of the thin film and/or of the second aerosol-generating composition may directly abut the heater.
In some cases, the heater may be embedded in the aerosol-generating composition. In some such cases, the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol-generating composition, which is heated by induction.
In some cases, the aerosol generating assembly may be a heat-not-burn device. That is, it may contain a solid aerosol-generating composition and no liquid aerosolisable material. In some cases, the aerosol-generating composition may comprise tobacco material. A heat-not-burn device is disclosed in WO 2015/062983 A2 , which is incorporated by reference in its entirety.
In some cases, the aerosol generating assembly may be an electronic tobacco hybrid device. That is, it may contain a solid aerosol-generating composition and a liquid aerosolisable material. In some cases, the solid aerosol-generating composition may comprise nicotine. In some cases, the solid aerosol-generating composition may comprise a tobacco material. In some cases, the solid aerosol-generating composition may comprise a tobacco material and a separate nicotine source. The separate aerosolisable materials may be heated by separate heaters, the same heater or, in one case, a downstream solid aerosol-generating composition may be heated by a hot aerosol which is generated from the upstream aerosolisable material. An electronic hybrid device is disclosed in WO 2016/135331 A1 , which is incorporated by reference in its entirety.
The aerosol generating article or assembly may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised components from the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by further condensation of the heated volatilised components and by coagulation of newly formed droplets from the heated volatilised components.
In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least about 15%. A ventilation ratio of about 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.
In another example, the ventilation ratio is from about 50% to about 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least about 60% or about 65%.
The assembly may comprise an integrated aerosol generating article and heater, or may comprise a heater device into which the article is inserted in use. In either case, the heater is configured to heat but not burn the aerosol-generating composition.
Figure 5 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating composition of an article or consumable 110, as described herein. For example, the article 110 may be any one of the articles 1 shown in Figures 1 to 4.
In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating composition as described herein, for instance an article as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article 110 together form a system.
The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly. The article 110 is illustrated having a rod-shape, like the articles 1 illustrated in Figures 1 to 4.
The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In Figure 5, the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow "B".
The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112. This switch may also actuate the means for opening the container inserted into the device, in readiness for its use.
The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

Method of Manufacture

The invention also provides a method of making an aerosol-generating article as described herein.
Specifically, the method comprises the steps of:

providing an aerosol generating composition as described herein, comprising a first aerosol-generating material and a second aerosol-generating material, and a wrapping material; and
circumscribing the aerosol generating composition with the wrapping material to form an aerosol generating segment. Any additional segment or parts of the article may be attached to the aerosol-generating segment.

The method may comprise making the aerosol generating composition as described herein, and incorporating it into an aerosol generating article.
The method may comprise (a) forming a slurry comprising components of the thin film or precursors thereof, (b) forming a layer of the slurry, (c) optionally setting the slurry to form a gel, and (d) drying to form a thin film.
The step (b) of forming a layer of the slurry may comprise spraying, casting or extruding the slurry, for example. In some cases, the layer is formed by electro spraying the slurry. In some cases, the layer is formed by casting the slurry.
In some cases, the slurry is applied to a carrier.
In some cases, the steps (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electro spraying). In some cases, these steps may occur sequentially.
In some examples, the slurry has a viscosity of from about 10 to about 20 Pa·s at 46.5 °C, such as from about 14 to about 16 Pa·s at 46.5 °C. In some examples, the slurry may have an elastic modulus of from about 5 to about 1200 Pa (also referred to as storage modulus); in some cases, the slurry may have a viscous modulus of from about 5 to about 600 Pa (also referred to as loss modulus).
The step (c) of setting the gel may comprise the addition of a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gelling agent, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
The total amount of the setting agent, such as a calcium source, may be from about 0.5 to about 5 wt% (calculated on a dry weight basis). The addition of too little setting agent may result in a thin film which does not stabilise the thin film components and results in these components dropping out of the thin film. The addition of too much setting agent results in a thin film that is very tacky and/or too brittle, and consequently has poor handleability.
In some cases however, no setting agent is needed because the botanical extract contains sufficient calcium to effect gelation. This may, for example, be true of tobacco extracts.
Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. The inventors have determined that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, about 45%, about 50%, about 55%, about 60% or about 70% of the monomer units in the alginate copolymer are a-L-guluronic acid (G) units.
In some cases, the slurry solvent may consist essentially of, or consist of, water. In some cases, the slurry may comprise from about 50 wt%, about 60 wt%, about 70 wt%, about 80 wt% or about 90 wt% of solvent (WWB).
In cases where the solvent consists of water, the dry weight content of the slurry will match the dry weight content of the thin film. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.

Example

In one example, a tobacco extract was obtained by extraction with ethanol and deionised water. The extract comprised 3.12 wt% nicotine and had a solids content (including nicotine) of 62.92 wt% (WWB).
The extract was then used to form a mixture of binder, aerosol-former material, filler and deionised and purified water, forming a slurry having the following composition.

Slurry Components wt% (WWB)

Extract 45%

Wood pulp 11%

Guar gum 4%

Glycerol 18%

Ground cellulose 22%
The slurry was made in a Silverson L5M-A Laboratory Mixer which was placed in a 10-litre glass or metal beaker. A premix of glycerol and guar gum was formed and kept.
Step 1: Add wood pulp and water (97% moisture) to the beaker and run the mixer at a speed of 1200 rpm for 2 minutes.
Step 2: Add ground cellulose (ARBOCEL B 600) slowly over a period of 2 minutes into the wood pulp mixture. Increase the speed to 2000 rpm and blend for an additional 2 minutes.
Step 3: Add tobacco extract slowly over 2 minutes into the slurry mix keeping the mixer speed at 2000 rpm and blend for a further 3 minutes.
Step 4: Add the premix of glycerol and guar gum slowly to slurry over 2 minutes at a speed of 3000 rpm and blend for an additional 5 minutes.
Step 5: Adjust the casting knife between 0.10 to 0.13 cm and cast the slurry in sheets on a metal plate. Dry the sheets at a temperature between 70°C and 120°C for 3 hours in an oven.
In an alternative casting process, the slurry is mixed to ensure that it is a homogenous mixture before it is cast onto a metal plate to a thickness of approximately 2 mm and allowed to set to form a gel.
Once the gel had set, it was dried in an oven at 65°C for approximately 2 hours. Drying resulted in approximately 90% shrinkage, the resultant thin film having approximately 10 wt% water and a thickness of 0.2 mm.
The aim is to provide a thin film with a tensile strength of at least about 7 N/mm. The film should also be 70 to 200 GSM. The dried cast sheet met these criteria and had a glycerol content of approximately 17 wt% and a nicotine content of approximately 2.5 wt%.
The thin film is in the form of a sheet and this sheet is used to wrap a plug of first aerosol material comprising cut rag tobacco. The plug of the cut rag tobacco surrounded by the thin film material is then circumscribed by an outer paper wrap. The outer paper wrapper provides the article with an attractive and clean appearance, and adequate stiffness. The wrapper may also help to retain the glycerol within the aerosol-generating composition.

Definitions

The terms 'upstream' and 'downstream' used herein are relative terms defined in relation to the direction of mainstream aerosol drawn though an article or device in use.
The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, 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 cannabis or another botanical (other than tobacco).
In some embodiments, the active substance comprises nicotine.
In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress neurotransmitter release in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).
As used herein, the terms "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, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
The flavour may suitably comprise one or more mint-flavours suitably a mint oil from any species of the genus Mentha. The flavour may suitably comprise, consist essentially of, or consist of, menthol.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint.
In some embodiments, 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.
In some embodiments, 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 eucalyptol, WS-3.
All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.
For the avoidance of doubt, where in this specification the term "comprises" is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms "consists essentially of" or "consists of" in place of "comprises". Reference to a material "comprising" certain features means that those features are included in, contained in, or held within the material.
The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

An aerosol-generating composition comprising from about 50 wt% to about 95 wt% of a first aerosol-generating material comprising botanical material and from about 5 wt% to about 50 wt% of a second aerosol-generating material comprising a thin film.
An aerosol-generating composition as claimed in claim 1, wherein the thin film comprises a binder, an aerosol-former material, and a botanical extract.
An aerosol-generating composition as claimed in claim 1 or claim 2, wherein the thin film is substantially free from botanical material.
An aerosol-generating composition as claimed in any one of claims 1 to 3, wherein the botanical material is tobacco, optionally wherein the tobacco is in the form of one or more of: cut rag, lamina and reconstituted tobacco.
An aerosol-generating composition as claimed in any one of claims 1 to 4, wherein the thin film comprises a tobacco extract.
An aerosol-generating composition as claimed in any one of claims 1 to 5, wherein the thin film has a nicotine content of from about 1.5% to about 7% by weight of the thin film, optionally wherein the thin film has a nicotine content of from about 2% to about 4% by weight of the thin film.
An aerosol-generating composition as claimed in any one of claims 1 to 6, comprising from about 70 to about 90% of the first aerosol-generating material and from about 10 wt% to about 30 wt% of a second aerosol-generating material.
An aerosol-generating composition as claimed in any one of claims 1 to 7, comprising from about 10 to about 25 wt% of an aerosol-former material.
An aerosol-generating composition as claimed in any one of claims 1 to 8, having a water content of no greater than about 12%, optionally wherein the thin film has a water content of no greater than about 5%.
An aerosol-generating article for use in an aerosol provision system, comprising an aerosol-generating segment comprising the aerosol-generating composition as claimed in any one of claims 1 to 9, optionally wherein the second aerosol-generating material is included as a sheet positioned to surround at least part of a plug or section comprising the first aerosol-generating material.
An aerosol-generating article as claimed in claim 10, wherein the second aerosol-generating material is included as a cut or shredded sheet which is blended with the first aerosol-generating material.
An aerosol-generating article as claimed in any one of claims 10 or claim 11, comprising a first section of the first aerosol-generating material and a second section comprising a rolled sheet of the second aerosol-generating material.
An aerosol-generating article as claimed in any one of claims 10 to 12, comprising a paper wrapper circumscribing the aerosol-generating composition, wherein the second aerosol-generating material is a sheet positioned between the first aerosol-generating material and the wrapper, and/or comprising a cooling segment comprising a longitudinally extending air channel for cooling the flow of air therethrough.
A system for heating an aerosol-generating composition to volatilise at least one component of the aerosol generating composition, the system comprising:
an aerosol-generating article as claimed in any one of claims 10 to 13, and

an aerosol delivery device for heating the aerosol-generating segment to volatilise at least one component of the aerosol-generating composition,

optionally wherein the heating device is configured to externally heat the aerosol-generating segment, and/or inductively heat the aerosol-generating segment, and/or resistively heat the aerosol-generating segment.
A method for forming an aerosol-generating article according to any one of claims 10 to 13, comprising the steps:
providing an aerosol generating composition as claimed in any one of claims 1 to 9 and a wrapping material;

circumscribing the aerosol generating composition with the wrapping material to form an aerosol generating segment; and attaching any further segments.