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

Definitions

• the present invention relates to aerosol-generating articles, 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.
• 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.
• 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.
• an aerosol-generating article for use in an aerosol provision system, the article comprising an aerosol-generating composition having a moisture content of no greater than about 15 wt%, the aerosol-generating composition comprising a thin film comprising a botanical extract; wherein the article has no more than about 50% ventilation based on the volume of aerosol generated by the aerosol-generating composition passing through the article when the article is heated by an aerosol delivery device.
• the article has no more than about 40%, no more than about 30%, or no more than about 20% ventilation.
• the thin film comprises a tobacco extract.
• the aerosol-generating composition comprises from about 10 to about 25 wt% of an aerosol-former material.
• the article has a water content of no greater than about 12%.
• the thin film has a water content of no greater than about 5%.
• the thin film is included as a sheet positioned to surround at least part of a plug or section comprising the botanical material.
• the thin film is included as a cut or shredded sheet which is blended with the botanical material.
• the article comprises a first section comprising the botanical material and a second section comprising a rolled sheet of the thin film.
• the article comprises a paper wrapper circumscribing the aerosol-generating composition, wherein the thin film is a sheet positioned between the botanical material and the wrapper.
• the article comprises:
• the ventilation area comprises a porous wrapper wrapped around the mouthpiece.
• the ventilation area comprises a plurality of holes equally spaced around the circumference of the mouthpiece.
• the mouthpiece comprises one or more of a tubular cooling element, a filter plug and a hollow mouth end tube section.
• the heating device is configured to externally heat the aerosol-generating composition, and/or inductively heat the aerosol-generating composition, and/or resistively heat the aerosol-generating composition.
• a third aspect of the invention there is provided a method for preparing an article according to the second aspect, comprising the steps:
• the ventilation is provided by forming at least one ventilation hole in the mouthpiece.
• hot puff 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. This is unpleasant and various approaches have been proposed to reduce or prevent hot puff.
• Ventilation can be an important feature of an aerosol-generating article for reducing the hot puff phenomenon. Ventilation allows ambient air to be drawn into the aerosol-generating article, which mixes with the aerosol generated by heating the aerosol-generating material. The ambient air cools the aerosol, and may cause condensation of some of the gaseous elements, thus reducing hot puff. However, another effect of ventilation is that it dilutes the aerosol, and therefore reduces the perceived impact of the aerosol to the user, affecting delivery of the active and/or flavour.
• the present invention relates generally to an aerosol-generating article comprising an aerosol-generating composition, the article being is configured to heat (but not burn) the aerosol-generating composition to generate an aerosol for inhalation.
• the aerosol-generating article comprises an aerosol-generating composition having a moisture content of no greater than about 15 wt%.
• the article includes ventilation and, specifically has no more than about 50% ventilation based on the volume of aerosol generated by the aerosol-generating composition passing through the article when the article is heated by an aerosol delivery device.
• the combination of the relatively low water content of the aerosol-generating composition and the relatively low level of ventilation means that the aerosol-generating articles provide an impactful aerosol without the risk of the user experiencing hot puff.
• the aerosol-generating composition comprising a thin film comprising a botanical extract provides a number of beneficial properties to the aerosol-generating composition.
• the flavours and/or actives provided by the thin film material which may, for example, comprise a botanical extract 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 is also important to providing an aerosol-generating composition with a controlled water content, remaining at or below about 15 wt%.
• the thin film may also represent a source of aerosol-former material that can be difficult to incorporate into an aerosol-generating composition in large enough amounts to provide the desired aerosol body and visible aerosol.
• Ventilation also helps to slow down the flow of aerosol drawn through the mouthpiece and thereby enables the aerosol to cool sufficiently before it reaches the user.
• a reduction in ventilation has benefits as ventilation dilutes the aerosol generated by heating the aerosol-generating composition, thereby reducing the flavour and the active delivery and therefore diminishing the user experience.
• the ventilation ratio may as high as about 75% based on the volume of the aerosol generated by the aerosol-generating composition and drawn through the article. Indeed, it is challenging to prevent hot puff in a conventional tobacco heating aerosol-generating article with a ventilation ratio as low as about 60%.
• the ventilation ratio designates the ratio of ambient air drawn in through the ventilation area and combined with the vapour and/or aerosol being drawn through the aerosol-generating article.
• a ventilation ratio of 75% means that the aerosol exiting the aerosol-generating article comprises 75% by volume of ambient air and 25% by volume of the vapour and/or aerosol generated by heating the aerosol-generating composition.
• the ventilation ratio is measured using ISO 9512:2019.
• aerosol-generating articles having no more than about 50% ventilation based on the volume of aerosol generated by the aerosol-generating composition passing through the article when the article is heated by an aerosol delivery device.
• the ventilation is no more than about 49%, no more than about 48%, no more than about 47%, no more than about 46%, no more than about 45%, no more than about 44%, no more than about 43%, no more than about 42%, no more than about 41%, or no more than about 40%.
• the amount of ventilation is selected to ensure that there is no hot puff, whilst providing an aerosol of the desired temperature for user comfort and an aerosol with the desired flavour and/or active delivery. According to the present invention, the amount of ventilation may be reduced because the aerosol-generating composition has a relatively low moisture content, which reduces the risk of hot puff.
• the ventilation is provided by ventilation holes or apertures, for example, formed as laser perforations.
• the ventilation holes may pass though the tipping paper, plug wrap and into the material of the article, such as into a plug or section of the aerosol-generating composition or into the mouthpiece or part thereof.
• the ventilation holes may be arranged as one or more rows around the circumference of the aerosol-generating article.
• One or more of the holes may have the form of a slot.
• the ventilation may be provided by an area surrounded by porous wrapper wrapped around the article, and preferably around the mouthpiece section of the article.
• the porous wrapper allows air to enter the mouthpiece of the article to cool the mouthpiece.
• the porous wrapper may be configured to be partially blocked by a user's lips during use to control the amount of air entering the mouthpiece section through the ventilation area.
• the ventilation is positioned downstream of the aerosol-generating material and is spaced from the mouth end of the aerosol-generating article sufficiently to ensure that it is not blocked when the user contacts the article with their lips during use.
• the ventilation may be positioned from about 17 to about 20 mm from the mouth end of the article.
• the ventilation area may be configured such that when the mouthpiece section is placed between a user's lips and an aerosol generated by the aerosol-generating material is drawn into the user's mouth through mouthpiece section, air is drawn into the mouthpiece section through the ventilation area to cool the mouthpiece section.
• 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.
• 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.
• a substance to be delivered and/or filler may also be present.
• a solvent such as water, is also present and one or more other components of the thin film may or may not be soluble in the solvent.
• the thin film may have a thickness of from 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 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.
• a binder such as a gelling agent
• a solvent such as water
• aerosol-former material such as water
• one or more other components such as one or more substances to be delivered
• the slurry may be heated to remove at least about 60 wt%, 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.
• 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.
• the aerosol-generating composition 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.
• the thin film is substantially free from (solid) botanical material.
• the thin film is substantially tobacco free.
• 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.
• 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).
• 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).
• 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).
• the thin film 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 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.
• polysaccharide gelling agents such as alginate, pectin, starch or a derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan, agar and agarose
• gelatin such as xanthan gum, guar gum and acacia gum
• silica or silicone compounds such as PDMS and sodium silicate
• clays such as kaolin
• polyvinyl alcohol polyvinyl alcohol
• 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 alginate is sodium alginate.
• 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 thin film material.
• cellulosic gelling agents 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).
• 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 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.
• 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 comprises alginate and at least one further gelling agent, such as pectin.
• 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 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.
• 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 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 comprises or consists of a tobacco extract.
• 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 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 to about 60 wt%, from about 20 to about 50 wt% or from about 30 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 to about 60 wt%, from about 20 to about 50 wt% or from about 30 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 from 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 to about 6 wt%, or from about 4 to about 5 wt% nicotine by weight of the thin film (DWB).
• 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 aerosol-generating composition 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 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 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 thin film may have any suitable area density, such as from about 30 g/m 2 to about 120 g/m 2 . In some embodiments, the thin film 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 . In some embodiments, 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 thin film 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 thin film 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 thin film may be formed as a sheet and then shredded and incorporated into the article.
• the shredded sheet may be mixed with a further aerosol-generating material, such as a botanical material, and incorporated into the article.
• the thin film material may have a mass per unit area that is selected to be comparable to the density of the further aerosol-generating material, so the mixed materials do not separate.
• the thin film may have a mass per unit area of from about 80 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 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 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 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 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 mouthpiece may 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 ventilation is provided into the cooling element.
• the ventilation is provided into the filter.
• the perforations may extend into the plug of filter material to ensure that the ambient air enters the plug of filter material and adequately mixes with the aerosol travelling through the filter plug.
• 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.
• ventilation is provided into the hollow tubular body, which has been found to be particularly beneficial in assisting with the aerosol generation process.
• the aerosol generating material and the mouthpiece made up of one or more of a cooling element, filter plug and hollow tubular mouth end section, may be axially aligned along a longitudinal axis.
• the one or more sections making up the mouthpiece may be joined by a porous wrapper.
• the porous wrapper may be exposed by the at least one hole or aperture of the ventilation area.
• the aerosol generating material and the mouthpiece may be joined by a wrapper, wherein a portion of the porous wrapper joining the section(s) of the mouthpiece may be exposed by a split in the wrapper.
• the aerosol-generating article and/or the aerosol-generating portion thereof comprises the thin film in the form of a sheet positioned to surround at least part of a plug or section comprising a further aerosol-generating material or a non-aerosol-generating filler material or a void.
• the thin film is included in the form of a cut or shredded sheet which is blended with a further aerosol-generating material or a non-aerosol-generating filler material.
• the aerosol generating portion of the article comprises a first section comprising the thin film and a second section comprising a further aerosol-generating material.
• the first section comprises a rolled sheet of the thin film.
• the article comprises a paper wrapper circumscribing the aerosol-generating composition, wherein the thin film is positioned between the wrapper and a further aerosol-generating material or a non-aerosol generating filler material.
• the thin film is a sheet which is positioned between the wrapper and a plug of other material.
• the thin film is provided on the inner surface of the wrapper.
• 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 about 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.
• Ambient air drawn into the mouthpiece 3 through the ventilation apertures 12 acts to cool and reduce the temperature of the mouthpiece 3.
• the ventilation area is configured such that when the mouthpiece 3 is placed between a user's lips, and an aerosol generated by the aerosol-generating composition 2 is drawn into the user's mouth through the cooling section 13 and mouthpiece 3, air is drawn into the cooling section 13 through the ventilation apertures 12 to cool the mouthpiece 3.
• 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.
• 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.
• 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 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 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 method comprises the steps of:
• the provision of ventilation into the article comprises forming holes or apertures to allow ambient air to be drawn into the article.
• the apertures are formed using a laser.
• the apertures allow air to be drawn into a cooling section, a filter plug and/or a mouth end hollow tube element of the article.
• the provision of ventilation into the article comprises forming a porous section of the side wall of the article by surrounding the article with a porous wrapper.
• the porous wrapper is positioned to allow air to be drawn into a cooling section, a filter plug and/or a mouth end hollow tube element of the article.
• 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.
• the layer is formed by electro spraying the slurry.
• the layer is formed by casting the slurry.
• the slurry is applied to a carrier.
• 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.
• 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.
• Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa).
• Alginic acid is a copolymer of ⁇ -D-mannuronic (M) and ⁇ -L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide.
• M ⁇ -D-mannuronic
• G ⁇ -L-guluronic acid
• the alginate crosslinks to form a gel On addition of calcium cations, the alginate crosslinks to form a gel.
• the inventors have determined that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source.
• the gel-precursor may comprise an alginate salt in which at least about 40%, about 45%, about 50%, about 55%, about 60% or about 70% of the monomer units in the alginate copolymer are ⁇ -L-guluronic acid (G) units.
• 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).
• the dry weight content of the slurry will match the dry weight content of the thin film.
• the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.
• a tobacco extract was obtained by extraction with deionised and purified 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 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.
• ARBOCEL B 600 ground cellulose
• 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.
• the slurry is mixed to ensure that it is a homogenous mixture before it is cast onto a metal plate to a thickness of 2mm and allowed to set to form a gel.
• 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 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).
• 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.
• 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).
• CBD cannabigerol

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