Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/10—Chemical features of tobacco products or tobacco substitutes
  • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/10—Chemical features of tobacco products or tobacco substitutes
  • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
  • A24B15/14—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco made of tobacco and a binding agent not derived from tobacco
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/18—Treatment of tobacco products or tobacco substitutes
  • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
  • A24B15/30—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
  • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
  • A24D1/00—Cigars; Cigarettes
  • A24D1/02—Cigars; Cigarettes with special covers
  • A24D1/027—Cigars; Cigarettes with special covers with ventilating means, e.g. perforations

Definitions

• the present invention relates to aerosol-generating compositions and to articles comprising such compositions, for example for use in an aerosol provision system.
• the invention also relates to aerosol provision systems, and to methods for forming aerosol-generating articles.
• 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 composition comprising a first aerosol-generating material comprising botanical material and second aerosol-generating material comprising a thin film, the thin film comprising a binder, an aerosol-former material, and a botanical extract, wherein the thin film comprises less than about 10 wt% water.
• the thin film is substantially free from botanical material.
• the botanical material is tobacco.
• the tobacco is in the form of one or more of: cut rag, lamina and reconstituted tobacco.
• the thin film comprises a tobacco extract.
• the thin film has a nicotine content of from about 2% to about 4% by weight of the thin film.
• the composition comprises from about 10 to about 15 wt% water.
• the composition comprises no more than about 12 wt% water.
• the second aerosol-generating material is included as a sheet positioned to surround at least part of a plug or section comprising the first aerosol-generating material.
• the second aerosol-generating material is included as a cut or shredded sheet which is blended with the first aerosol-generating material.
• 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 article comprises a paper wrapper circumscribing the aerosol-generating composition, wherein the second aerosol-generating material is a sheet positioned between the first aerosol-generating material and the wrapper.
• the article comprises a cooling segment comprising a longitudinally extending air channel for cooling the flow of air therethrough.
• 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 comprises:
• the ventilation area is configured such that when the mouth end section is placed between a user's lips and an aerosol generated by the aerosol generating composition is drawn into the user's mouth through the mouth end section, air is drawn into the mouth end section through the ventilation area.
• the ventilation area comprises a porous wrapper wrapped around the mouth end section.
• the ventilation area comprises at least one hole.
• the ventilation area comprises a plurality of holes equally spaced around the circumference of the mouth end section.
• a system for heating an aerosol-generating composition to volatilise at least one component of the aerosol generating material comprising:
• 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 method for forming an article for use in an aerosol provision system comprising the steps:
• the article formed by the methos is an article according to the second aspect.
• ventilation is provided by providing a porous wrapper around at least a section of the mouth end section.
• the ventilation is provided by forming at least one ventilation hole in the mouth end section.
• the present invention relates generally to an aerosol-generating composition for use in an aerosol-generating article which is configured to heat (but not burn) the composition to generate an aerosol for inhalation.
• the aerosol-generating composition comprises a first aerosol-generating material comprising botanical material and a second aerosol-generating material comprising a thin film, the thin film comprising a binder, and aerosol-former material and a botanical extract.
• the thin film comprises less than 10 wt% water, or no more than about 9 wt%, about 8 wt%, about 7 wt%, about 6 wt% or about 5 wt% water.
• the low water content of the thin film is important as water will tend to be rapidly driven off when the thin film is heated upon use, resulting in the initial generation of steam, which is the cause of the phenomenon referred to as hot puff. It is undesirable for the user to inhale such a puff of steam. Not only is it hot and could cause injury, but it is also generally devoid of flavours or actives and so provides the user with an unsatisfying first puff.
• 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 thin film may also represent a source of aerosol-former material that can be difficult to incorporate into botanical material in large enough amounts to provide the desired aerosol body and visible aerosol whilst still having properties that make the botanical material suitable for incorporation into an aerosol-generating article.
• the thin film may provide flavours and/or active substances in a concentrated form. This means that the amount of such thin film included in the aerosol-generating composition may be reduced compared to the amounts of thin films that are included in conventional aerosol-generating compositions.
• the aerosol generating composition may include as little as 5 wt% of the second aerosol-generating material, whilst still contributing to the generation of a flavourful and impactful aerosol.
• a reduction in the amount of the thin film present in the aerosol-generating composition affords additional flexibility in terms of how this material is incorporated in the aerosol-generating composition and in the design of articles incorporating the aerosol-generating composition. This allows articles to be designed that permit controlled heating of the thin film and controlled generation of an aerosol from the aerosol-generating composition.
• the inclusion of a relatively small amount of thin film may also mean a reduction in the total mass of the aerosol-generating composition and of the aerosol-generating article, with consequent lower costs and potentially lower energy requirements.
• the sensory quality of the initial puffs such as the first 1 or 2 puffs, may be improved, leading to a better user experience and increased user satisfaction.
• 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 second aerosol-generating material may, for example, comprise from about 50 wt%, about 60 wt% or about 70 wt% of the thin film, to about 90 wt%, about 95 wt% or about 100 wt% of the thin film.
• 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 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 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 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 second aerosol-generating 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 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 to about 60 wt%, from about 20 to about 50 wt%, from about 25 to about 40 wt% or from about 30 to about 35 wt% of an aerosol-former material.
• the thin film may comprise from about 0.1 wt%, about 0.5 wt%, about 1 wt%, about 3 wt%, about 5 wt%, about 7 wt% or about 10 wt% to about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt% or about 25 wt% of an aerosol-former material (all calculated on a dry weight basis).
• the thin film may comprise from about 0.5 to about 40 wt%, from about 3 to about 35 wt% or from about 10 to about 25 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 that 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 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 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 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 is a hydrogel.
• the thin film comprises no more than about 9.5 wt%, about 9 wt%, about 8.5 wt%, about 8 wt%, about 7.5 wt%, about 7 wt%, about 6.5 wt%, about 6 wt%, about 5.5 wt%, about 5 wt%, about 4.5 wt%, about 4 wt% or about 3.5 wt% water.
• the thin film may comprise at least about 1 wt%, about 1.5 wt%, about 2 wt%, about 2.5 wt% or about 3 wt% water.
• 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 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 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.
• 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 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 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 different aerosol-generating materials may be provided in different proportions and in different configurations.
• the aerosol-generating composition comprises from about 5 wt% to about 95 wt% of a first aerosol-generating material comprising botanical material and from about 95 wt% to about 5 wt% of a second aerosol-generating material comprising a thin film.
• the aerosol-generating composition comprises from about 5 wt%, about 10 wt%, about 15 wt%, about 20 wt%, about 25 wt%, about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, about 50 wt%, about 55 wt%, about 60 wt%, about 65 wt%, about 70 wt%, about 75 wt%, about 80 wt%, about 85 wt%, about 90 wt% or about 95 wt% of the first aerosol-generating material or of the second aerosol-generating material.
• the aerosol-generating composition comprises no more than about 95 wt%, about 90 wt%, about 85 wt%, about 80 wt%, about 75 wt%, about 70 wt%, about 65 wt%, about 60 wt%, about 55 wt%, about 50 wt%, about 45 wt%, about 40 wt%, about 35 wt%, about 30 wt%, about 25 wt%, about 20 wt%, about 15 wt%, about 10 wt% or about 5 wt% of the first aerosol-generating material or of the second aerosol-generating material.
• 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 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 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 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.
• 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 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 about 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 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 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 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 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 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 o-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide.
• M ⁇ -D-mannuronic
• G o-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 o-L-guluronic acid (G) units.
• G o-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).
• 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.
• 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 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.
• the gel had set, it was dried in an oven at 65°C from approximately 2 hours. Drying resulted in a 90% shrinkage, a thin film having approximately 10 wt% water and a thickness of about 0.2 mm.
• the aim is to provide a thin film with a tensile strength of at least about 7 N/mm.
• the film should also be 70 to 200 GSM.
• the dried cast sheet met these criteria and had a glycerol content of approximately 17 wt% and a nicotine content of approximately 2.5 wt%.
• the 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 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.
• 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
• flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch,
• the flavour may suitably comprise one or more mint-flavours suitably a mint oil from any species of the genus Mentha.
• the flavour may suitably comprise, consist essentially of, or consist of, menthol.
• the flavour comprises menthol, spearmint and/or peppermint.
• the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
• the flavour comprises eugenol.
• the flavour comprises flavour components extracted from cannabis.
• the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
• a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.
• weight percentages by weight described herein are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis.
• a weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol.
• a weight percentage quoted on a wet weight basis refers to all components, including water.

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• 2024
  • 2024-02-12 EP EP24157106.6A patent/EP4599701A1/fr active Pending
• 2025
  • 2025-02-11 WO PCT/EP2025/053584 patent/WO2025172289A1/fr active Pending

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