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
• • 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
  • A24B15/30—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
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/20—Devices using solid inhalable precursors

Definitions

• the thin film comprises a tobacco extract.
• 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.
• the aerosol-generating composition comprises a first aerosol-generating material comprising botanical material and a second aerosol-generating material comprising a thin film.
• the first aerosol-generating material comprising botanical material is present in an amount of from about 95 wt% to about 50 wt%
• 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.
• 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 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.
• the thin film may have a thickness of about 0.015 mm to about 1 mm.
• 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.
• 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 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.
• the gelling agent comprises a hydrocolloid.
• the gelling agent comprises (or is) one or more polysaccharide gelling agents.
• 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.
• the gelling agent is a polysaccharide gelling agent, optionally wherein the polysaccharide gelling agent is selected from alginate and a cellulose derivative.
• 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.
• the polysaccharide gelling agent is alginate.
• 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.
• 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).
• CMC carboxymethylcellulose
• HPMC hydroxypropyl methylcellulose
• CAP cellulose acetate propionate
• the cellulose derivative is CMC.
• the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, guar gum, acacia gum, alginate and/or pectin.
• 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.
• a setting agent such as a calcium source
• the aerosol-generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
• 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).
• alginate is the only gelling agent present in the thin film.
• 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.
• CMC carboxymethylcellulose
• 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).
• 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.
• the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
• the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of, or consists of, glycerol.
• the 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).
• 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).
• the botanical extract is a liquid or solid that has been isolated from a botanical material.
• the extract may be prepared by processing techniques such as expression (such as juicing or pressing) or solvent extraction.
• the extract is concentrated and/or purified, for example by distillation.
• the botanical material is macerated, frequently without heating, to soften and degrade the material prior to extraction.
• the botanical extract is an aqueous extract, obtained by extraction with water. Additionally or alternatively, other solvents may be used, including supercritical fluids.
• the botanical extract included in the thin film is an extract of one or more of any of the botanical materials discussed herein.
• the botanical extract comprises or consists of a tobacco extract.
• 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.
• 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%.
• 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.
• 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.
• 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.
• 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.
• 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).
• 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.
• 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.
• 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).
• 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.
• the additional flavour (if present) comprises, consists essentially of, or consists of, menthol.
• 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.
• 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).
• the thin film comprises nicotine.
• this nicotine may be derived from the botanical extract included in the thin film.
• the nicotine is an additional active substance included in the thin film.
• the thin film has a nicotine content of from about 1.5 wt% to about 7 wt% of the thin film (DWB).
• 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).
• 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).
• 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.
• 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%.
• 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%.
• 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 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.
• the thin film comprises no calcium carbonate such as chalk.
• the filler is fibrous.
• the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives.
• the fibrous filler is wood pulp.
• 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.
• the thin film does not comprise tobacco fibres. In particular embodiments, the thin film does not comprise fibrous material.
• 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.
• the thin film is a hydrogel.
• 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.
• 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.
• the thin film comprises from about 5 wt% to about 10 wt% water, or from about 5 wt% to about 9 wt%.
• the water content of the thin film may be about 5 wt%.
• 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.
• 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.
• the thin film comprises:
• 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.
• 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.
• the carrier may comprise or consist of a botanical material, such as a sheet of reconstituted tobacco.
• the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof.
• the carrier itself be a laminate structure comprising layers of materials selected from the preceding lists.
• the carrier may also function as a flavour carrier.
• the carrier may be impregnated with a flavourant or with botanical extract.
• 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.
• the carrier in the aerosol generating article may comprise or consist of a porous layer that abuts the thin film.
• the porous layer may be a paper layer.
• 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.
• 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".
• 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.
• 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.
• 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.
• 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.
• 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.
• a metal foil may function as a susceptor in an induction heating system.
• the carrier comprises a metal foil layer and a support layer, such as cardboard.
• the metal foil layer may have a thickness of no more than about 20 ⁇ m, such as from about 1 ⁇ m to about 10 ⁇ m, suitably about 5 ⁇ m.
• 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.
• the aerosol-generating material may comprise one or more magnets which can be used to fasten the material to an induction heater in use.
• the aerosol-generating material may comprise heating means embedded in the thin film, such as resistive or inductive heating elements.
• the thin film may have a thickness of from about 0.015 mm to about 1.0 mm.
• 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.
• 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/m 2 to about 120 g/m 2 .
• second aerosol-generating material may have an area density of from about 30 to about 70 g/m 2 , or from about 40 to about 60 g/m 2 .
• the thin film may have an area density of from about 80 to about 120 g/m 2 , or from about 70 to about 110 g/m 2 , or particularly from about 90 to about 110 g/m 2 .
• 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.
• 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).
• 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.
• the second aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article.
• the shredded sheet may be mixed with the first aerosol-generating material and incorporated into the article.
• 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.
• the second aerosol-generating material may have a mass per unit area of from about 80 g/m 2 to about 120 g/m 2 so that it has a density comparable to cut rag tobacco.
• 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.
• 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.
• 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.
• the first aerosol-generating material comprises a botanical material.
• 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
• 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.
• the botanical is selected from eucalyptus, star anise, cocoa and hemp.
• the botanical is selected from rooibos and fennel.
• the botanical material comprises leaf material.
• the botanical material is tobacco material.
• tobacco material refers to any material comprising tobacco or derivatives thereof.
• 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.
• 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.
• the botanical material comprises no more than about 20 wt%, about 15 wt%, about 12 wt% or about 10 wt% water.
• 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%.
• the water content of the thin film may be about 12 wt%.
• the first aerosol-generating material comprises an aerosol-former material.
• the aerosol-former material may be added to or incorporated into the botanical material.
• 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).
• 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.
• 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.
• 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.
• 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.
• the different aerosol-generating materials may be mixed to form a largely homogenous blend.
• 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.
• the aerosol-generating composition comprises a blend of two or more different aerosol-generating materials this may control the release of the active agents.
• 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.
• the thin film of the first aerosol-generating material may comprise an aerosol-former material.
• an aerosol-former material may optionally also be included in the second aerosol-generating material.
• the aerosol-generating composition comprises (in total) from about 10 to about 25 wt% of an aerosol-former material (DWB).
• 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%.
• An article for use in an aerosol provision system comprises an aerosol-generating portion comprising the aerosol-generating composition described herein.
• the aerosol generating article may be circumscribed by a wrapping material such as paper.
• the article may additionally comprise a filter and/or cooling element.
• 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 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.
• the cooling segment comprises a longitudinally extending air channel for cooling the flow of air therethrough.
• the filter may comprise any suitable filter known in the art such as a cellulose acetate plug or a paper plug, and optionally including capsule.
• 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.
• 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.
• 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.
• 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.
• the section comprises a rolled sheet of the second aerosol-generating material.
• 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.
• the second aerosol-generating material is a sheet which is positioned between the wrapper and the first aerosol generating material.
• 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.
• 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.
• 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.
• the two materials are cut or shredded and the two different shredded materials are blended and formed into a rod segment.
• 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.
• these different mouthpiece elements may be omitted or duplicated, and/or the elements may be provided in a different sequence.
• the hollow tubular element 15 may be omitted, and the mouthpiece body 14 may form the mouth end of the article.
• the length of the mouthpiece body 14 may be increased, or a further body of material may be provided at the mouth end.
• 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.
• the cooling section 13, mouthpiece body 14 and hollow tubular element 15 are connected by a combining wrapping material 11.
• 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.
• 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.
• 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.
• 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.
• the rod comprising the aerosol-generating composition is different to that shown in Figure 1 .
• 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.
• 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.
• 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.
• the first aerosol-generating material 21 may be shredded botanical material.
• 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.
• the mouthpiece and wrappers are the same as shown in the foregoing figures and are as described above.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• the heater may be embedded in the aerosol-generating composition.
• the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit).
• the heater may be a susceptor embedded in the aerosol-generating composition, which is heated by induction.
• 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.
• the solid aerosol-generating composition may comprise nicotine.
• the solid aerosol-generating composition may comprise a tobacco material.
• 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.
• the ratio of the cool air to the sum of the heated volatilised components and the cool air 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.
• 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.
• the article 110 may be any one of the articles 1 shown in Figures 1 to 4 .
• 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.
• 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.
• 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.
• 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.
• a socket/port 114 may be a charging port, such as a USB charging port.
• the invention also provides a method of making an aerosol-generating article as described herein.
• the method comprises the steps of:
• the method may comprise making the aerosol generating composition as described herein, and incorporating it into an aerosol generating article.
• 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.
• 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.
• 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.
• 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.
• G a-L-guluronic acid
• 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).
• 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 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 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.
• 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.
• 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.
• the active substance comprises nicotine.
• the active substance comprises caffeine, melatonin or vitamin B12.
• 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.
• the flavour comprises menthol, spearmint and/or peppermint.
• 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.

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• 2024
  • 2024-02-12 EP EP24157103.3A patent/EP4599699A1/fr active Pending
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  • 2025-02-11 WO PCT/EP2025/053551 patent/WO2025172276A1/fr active Pending

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