ES2953545T3 - Aerosol generation - Google Patents

Abstract

Disclosed herein is an aerosol-generating substrate comprising an aerosol-generating material, wherein the aerosol-generating material comprises an amorphous solid. The amorphous solid comprises an aerosol generating agent, wherein at least 65% by weight of the aerosol generating agent is aerosolized by heating the aerosol generating material to 370 ° C for a period of ten seconds under an air flow of 1.95 l/min. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Aerosol generation

Technical field

The present invention relates to the generation of aerosols.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of items release an inhalable aerosol or vapor by releasing compounds from a substrate material by heating it without burning it. These may be called non-combustible smoking articles or aerosol-generating assemblies.

An example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain a tobacco material. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be called heat-not-burn devices, tobacco heating devices, or tobacco heating products. Several different arrangements are known for volatilizing at least one component of the solid aerosolizable material.

As another example, there are hybrid e-cigarette/heating tobacco products devices, also known as hybrid electronic tobacco devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further contains a solid aerosolizable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapor or aerosol to produce the inhaled medium.

Documents WO2016/184977 A1, WO 2016/184978 A1 and WO 2015/071682 A1 all disclose an aerosol generating material comprising an aerosol generating agent.

Summary

In its most general form, the invention provides an aerosol generating substrate comprising an aerosol generating material, wherein the aerosol generating material comprises an amorphous solid, the amorphous solid comprising an aerosol generating agent, wherein at least 65% by weight of the aerosol generating agent is aerosolized upon heating the aerosol generating material to 370°C for a period of ten seconds under an air flow of 1.95 L/min; and wherein the aerosol generating substrate further comprises a vehicle upon which the amorphous solid is provided.

In some embodiments, the aerosol generating material comprises an amorphous solid, wherein the amorphous solid comprises:

• 1-60% by weight of a gelling agent; I

• 5-80% by weight of an aerosol generating agent; I

• 10-60% by weight of an active substance;

• and optionally, a flavoring;

where these weights are calculated on a dry weight basis.

In particular embodiments, the amorphous solid comprises:

• 1-60% by weight of a gelling agent; I

• 5-80% by weight of an aerosol generating agent; I

• 10-60% by weight of a tobacco extract;

• and optionally, a flavoring;

where these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating substrate comprises about 0.1-80% by weight of flavorant, calculated on a dry weight basis. In particular embodiments, the aerosol generating substrate comprises approximately 0.5-60% by weight of flavorant, calculated on a dry weight basis.

The invention also provides an aerosol generating article comprising said aerosol generating substrate. The invention also provides an aerosol generating assembly comprising said aerosol generating substrate or aerosol generating article, and a heater that is configured to heat, but not burn the aerosol generating substrate.

Other aspects of the invention described herein may provide the use of the aerosol generating substrate, the aerosol generating article or the aerosol generating assembly, in the generation of an inhalable aerosol.

Other features and advantages of the invention will become apparent from the following description, given by way of example only, and with reference to the accompanying figures.

Brief description of the figures

Figure 1 shows a sectional view of an example of an aerosol generating article.

Figure 2 shows a perspective view of the article of Figure 1.

Figure 3 shows a sectional elevation of an example of an aerosol generating article.

Figure 4 shows a perspective view of the article of Figure 3.

Figure 5 shows a perspective view of an example of an aerosol generating assembly.

Figure 6 shows a sectional view of an example of an aerosol generating assembly.

Figure 7 shows a perspective view of an example of an aerosol generating assembly.

Detailed description

The aerosol-generating material described herein comprises an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous), or as a "dry gel". Amorphous solid is a solid material that can retain some fluid, such as liquid, inside. In some cases, the aerosol generating material comprises from 50% by weight, 60% by weight or 70% by weight amorphous solid to about 90% by weight, 95% by weight or 100% by weight amorphous solid. In some cases, the aerosol generating material consists of an amorphous solid.

As noted above, the invention provides an aerosol generating substrate comprising an aerosol generating material, wherein the aerosol generating material comprises an amorphous solid, the amorphous solid comprising an aerosol generating agent, wherein at least the 65% by weight of the aerosol generating agent is aerosolized by heating the aerosol generating material to 370 ° C for a period of ten seconds under an air flow of 1.95 L / min; and wherein the aerosol generating substrate further comprises a vehicle upon which the amorphous solid is provided.

In some cases, at least 68% by weight, 70% by weight, 72% by weight, 75% by weight or 78% by weight of the aerosol generating agent is aerosolized by heating the aerosol generating material at 370 °C for a period of ten seconds at an air flow rate of 1.95 l/min.

The inventors have established that the transfer of an aerosol generating agent from an amorphous solid is more effective than from other aerosolizable materials such as tobacco.

This means that aerosol-generating materials comprising amorphous solids can deliver the required aerosol volume after a shorter heating period. In other words, such materials can be heated intensely for short periods, reducing energy consumption and increasing efficiency, while providing the necessary amount of aerosol per puff. Due to the high rate of transfer of the aerosol-generating material from the amorphous solid to the inhaled aerosol, it is possible to heat such materials only during inhalation. Optionally, different sections of said material can be heated to provide aerosol for different puffs.

In some cases, the amorphous solid comprises an active substance. For example, in some cases, the amorphous solid comprises a tobacco and/or nicotine extract. In some cases, the amorphous solid may comprise from about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 70% by weight, 50% by weight, 45% by weight or 40% by weight (calculated on a dry weight basis) of active substance. In some cases, the amorphous solid may comprise from about 1 wt.%, 5 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt. weight, 50% by weight, 45% by weight or 40% by weight (calculated on a dry weight basis) of a tobacco and/or nicotine extract.

In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 55% by weight, 50% by weight, 45% by weight or 40% by weight (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 5-60% by weight, 10-55% by weight or 25-55% by weight of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solid comprises 1% by weight, 1.5% by weight, 2% by weight or 2.5% by weight up to about 6% by weight, 5% by weight , 4.5% by weight or 4% by weight (calculated on a dry weight) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that resulting from the tobacco extract.

In some embodiments, the amorphous solid does not comprise tobacco material, but does comprise nicotine. In some of these cases, the amorphous solid may comprise from about 1% by weight, 2% by weight, 3% by weight or 4% by weight to about 20% by weight, 15% by weight, 10% by weight or 5 Weight % (calculated on a dry weight basis) nicotine. For example, the amorphous solid may comprise 1 to 20% by weight or 2 to 5% by weight of nicotine.

In some cases, the total content of active substance and/or flavor may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight. weight or 30% by weight. In some cases, the total content of active substance and/or flavor may be less than about 80% by weight, 70% by weight, 60% by weight, 50% by weight or 40% by weight (all calculated on a dry weight basis).

In some cases, the total content of tobacco extract, nicotine and flavor may be at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25%. by weight or 30% by weight. In some cases, the total content of tobacco material, nicotine and flavor may be less than 80% by weight, 70% by weight, 60% by weight, 50% by weight or 40% by weight (all calculated on a basis of dry weight).

In some cases, the amorphous solid comprises 5-80% by weight of aerosol generating agent. In some cases, the amorphous solid comprises:

• 1-60% by weight of a gelling agent; I

• 5-80% by weight of an aerosol generating agent; I

• 0.1-60% by weight of an active substance and/or a flavoring;

where these weights are calculated on a dry weight basis (DWB).

In some cases, the amorphous solid comprises 5-80% by weight of aerosol generating agent. In some cases, the amorphous solid comprises:

• 1-60% by weight of a gelling agent; I

• 5-80% by weight of an aerosol generating agent; I

• 10-60% by weight of tobacco and/or nicotine extract and/or flavoring;

where these weights are calculated on a dry weight basis (DWB).

The inventors have found that amorphous solids having this composition can be efficiently heated to generate an inhalable aerosol.

Furthermore, the inventors have discovered that the transfer of active ingredients from such an amorphous solid is more efficient than from other aerosolizable materials such as tobacco. In some cases, at least 70% by weight, 72% by weight, 75% by weight, 78% by weight or 80% by weight of an active ingredient is aerosolized by heating the aerosol-generating material to 370 °C for a period of ten seconds with an air flow of 1.95 l/min. In some cases, at least 70% by weight, 72% by weight, 75% by weight, 78% by weight or 80% by weight of all active ingredients are aerosolized by heating the aerosol-generating material at 370 °C for a period of ten seconds with an air flow of 1.95 l/min.

As used herein, "active ingredients", which may alternatively be referred to as "volatile" or "volatile components", refers to components of the amorphous solid that have a physiological or sensory effect on the human body. Specifically, the active ingredients may comprise nicotine or its derivatives, aromas and flavors with high vapor pressure. In some cases, the amorphous solid comprises nicotine. In some cases, the amorphous solid comprises a flavoring. In some cases, the flavoring comprises or consists of menthol.

The amorphous solid may, in some cases, be a hydrogel and comprises less than about 20 wt%, 15 wt%, 12 wt%, or 10 wt% water calculated on a wet weight (WWB) basis. In some cases, the amorphous solid may comprise at least about 1% by weight, 2% by weight, or 5% by weight water (WWB). In some cases, the amorphous solid comprises from about 1% by weight to about 15% by weight of water, or from about 5% by weight to about 15% by weight calculated on a wet weight basis. Suitably, the water content of the amorphous solid may be from about 5% by weight, 7% by weight or 9% by weight to about 15% by weight, 13% by weight or 11% by weight (WWB), more suitably about 10% by weight.

In some cases, the amorphous solid may comprise from 1 to 60% by weight of a gelling agent, where these Weights are calculated on a dry weight basis. Conveniently, the amorphous solid may comprise from about 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, 30% by weight or 27% by weight of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50% by weight, 5-40% by weight, 10-30% by weight or 15-27% by weight of a gelling agent.

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica compounds or silicones, clays, polyvinyl alcohol and combinations thereof. . For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate , kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium cross-linked alginate and/or a calcium cross-linked pectin.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10 to 30% by weight of the amorphous solid (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

The amorphous solid may comprise from about 5 wt.%, 10 wt.%, 20 wt.%, 25 wt.%, 27 wt.% or 30 wt.% to about 60 wt. by weight, 45% by weight, 40% by weight or 35% by weight of an aerosol generating agent (DWB). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise 10 to 60% by weight, 20 to 50% by weight, 25 to 40% by weight or 30 to 35% by weight of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol. The inventors have established that, if the plasticizer content is too high, the amorphous solid may absorb water (as the aerosol generating agent is hygroscopic) resulting in a material that does not create an adequate consumer experience in use. The inventors have established that if the plasticizer content is too low, the amorphous solid can become brittle and break easily. The plasticizer content specified here provides an amorphous solid flexibility that allows the amorphous solid sheet to be wound into a coil, which is useful in the manufacture of aerosol-generating articles.

The amorphous solid may comprise from about 10% by weight, 20% by weight, 30% by weight, 40% by weight or 45% by weight to about 50% by weight, 55% by weight or 60% by weight of extract of tobacco (DWB). For example, the amorphous solid may comprise 20-60% by weight, 40-55% by weight or 45-50% by weight of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises from about 1% by weight, 1.5% by weight or 2% by weight to about 6% by weight, 5% by weight, 4% by weight or 3% by weight nicotine (DWB). In some cases, there may be no nicotine in the amorphous solid other than that resulting from the tobacco extract.

In some cases, the tobacco extract may be an aqueous extract, obtained by extraction with water. The tobacco extract may be an extract of any suitable tobacco, such as single grades or blends, cut rags or whole leaves, including Virginia and/or Burley and/or Oriental. It can also be an extract of "fines" or powder from tobacco particles, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The extract can be obtained from ground tobacco or from reconstituted tobacco material.

In some cases, the amorphous solid may comprise a flavor. Conveniently, the amorphous solid may comprise up to about 60% by weight, 50% by weight, 40% by weight, 30% by weight, 20% by weight, 10% by weight or 5% by weight of a flavor. In some cases, the amorphous solid may comprise at least about 0.1% by weight, 0.5% by weight, 1% by weight, 2% by weight, 5% by weight, 10% by weight, 20% by weight or 30% by weight of a flavor (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60% by weight, 1-60% by weight, 5-60% by weight, 10-60% by weight, 20-50% by weight or 30-40% by weight of a flavor. In some cases, the flavor (if present) comprises, consists essentially of, or consists of menthol. In some cases, the amorphous solid does not comprise a flavor.

In some embodiments, the amorphous solid comprises less than 60% by weight of a filler, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight.

In other embodiments, the amorphous solid comprises less than 20% by weight, suitably less than 10% by weight or less than 5% by weight of a filler. In some cases, the amorphous solid comprises less than 1% by weight of a filler and, in some cases, no filler.

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate and suitable inorganic adsorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives. In particular cases, the amorphous solid does not contain calcium carbonate like chalk.

In particular embodiments that include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material. This may be particularly advantageous in examples where the amorphous solid is provided as a sheet, such as when an amorphous solid sheet circumscribes a rod of aerosolizable material.

In some embodiments, the amorphous solid does not comprise tobacco fibers. In particular embodiments, the amorphous solid does not comprise fibrous material.

In some embodiments, the aerosol-generating material does not comprise tobacco fibers. In particular embodiments, the aerosol generating material does not comprise fibrous material.

In some embodiments, the aerosol-generating substrate does not comprise tobacco fibers. In particular embodiments, the aerosol generating substrate does not comprise fibrous material.

In some embodiments, the aerosol-generating article does not comprise tobacco fibers. In particular embodiments, the aerosol generating article does not comprise fibrous material.

In some cases, the amorphous solid may consist essentially of a gelling agent, an aerosol generating agent, an active substance, water and, optionally, a flavor. In some cases, the amorphous solid may consist essentially of glycerol, alginates and/or pectins, an active substance and water.

In some cases, the amorphous solid may consist essentially of a gelling agent, an aerosol generating agent, a tobacco extract, water and, optionally, a flavor. In some cases, the amorphous solid may consist essentially of glycerol, alginates and/or pectins, a tobacco extract and water.

The aerosol generating substrate comprises a carrier on which the amorphous solid is provided. This vehicle may facilitate manufacturing and/or handling, for example, (a) by providing a surface on which a suspension can be applied (and from which the suspension does not subsequently need to be separated), (b) by providing a surface not sticky surface for the aerosol generating material, (c) providing some rigidity to the substrate.

In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, grease-resistant paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a reconstituted tobacco leaf. In some cases, the carrier may be formed from materials selected from sheet metal, paper, cardboard, wood, or combinations thereof. In some cases, the support itself may be a laminated structure comprising layers of materials selected from the lists above. In some cases, the support is impregnated with a flavoring or more tobacco extract.

In some cases, the vehicle may be substantially or completely impermeable to gas and/or aerosol. This prevents the passage of aerosol or gas through the vehicle in use, thus 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, for example, on the surface of a heater provided in an aerosol generating assembly. Thus, consumption efficiency and hygiene can improve in some cases.

In some cases, the carrier in the aerosol generating article may comprise or consist of a porous layer that rests on the amorphous solid. For example, the porous layer may be a paper layer. In some particular cases, the amorphous solid is placed in direct contact with the porous layer; The porous layer rests on the amorphous one and forms a strong bond. The amorphous solid is formed by drying a gel and, without being limited by theory, it is believed that the suspension from which the gel is formed partially impregnates the porous layer (e.g. paper) so that when the gel sets and forms cross-links, the porous layer is partially attached to the gel. This provides a strong bond between the gel and the porous layer (and between the dried gel and the porous layer).

Additionally, surface roughness can contribute to the bond strength between the amorphous material and the support. The inventors have found that the roughness of the paper (for the surface resting on the support) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over a range of air pressure 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 specific pressure is filtered between a smooth glass surface and a paper sample, and the time (in seconds ) for a fixed volume of air seeping between these surfaces is "Bekk smoothness".)

Conversely, the surface of the support facing away from the amorphous solid can be arranged in contact with the heater, and a smoother surface can provide more efficient heat transfer. Therefore, in some cases, the carrier is arranged so that it has a rougher side that abuts the amorphous material and a smoother side that faces away from the amorphous material.

In a particular case, the support may be a sheet with a paper support; The paper layer abuts the amorphous solid layer and this abutment provides the properties discussed in the previous paragraphs. The foil reinforcement is substantially impermeable, providing control of the aerosol flow path. A metal foil reinforcement can also serve to conduct heat to the amorphous solid.

In another case, the foil layer of the paper-backed foil abuts the amorphous solid. The sheet is substantially impermeable, thus preventing the water provided in the amorphous solid from being absorbed by the paper, which could weaken its structural integrity.

In some cases, the vehicle is formed from or comprises a sheet of metal, such as aluminum sheet. A metallic support can allow better conduction of thermal energy to the amorphous solid. Additionally, or alternatively, a metal foil can function as a susceptor in an induction heating system. In particular embodiments, the support comprises a layer of metal foil and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, such as about 1 μm to about 10 μm, suitably about 5 μm.

In some cases, the support may be magnetic. This functionality can be used to attach the carrier to the assembly in use, or can be used to generate particular amorphous solid shapes. In some cases, the aerosol generating substrate may comprise one or more magnets that may be used to attach the substrate to an induction heater in use.

In some cases, the aerosol generating material may comprise heating means embedded in the amorphous solid, such as resistive or inductive heating elements.

In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Conveniently, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may comprise more than one layer, and the thickness described here refers to the aggregate thickness of those layers.

The inventors have established that if the amorphous solid is too thick, the heating efficiency is compromised. This negatively affects the energy consumption in use. On the contrary, if the amorphous solid is too thin, it is difficult to manufacture and handle; A very thin material is more difficult to melt and may be brittle, compromising the formation of aerosols during use.

The inventors have established that the thicknesses of amorphous solids stipulated here optimize the properties of the material in view of these competing considerations. The thickness stipulated here is an average thickness for the material. In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

The aerosol generating material comprising the amorphous solid may have any suitable areal density, such as 30 g/m2 to 120 g/m2. In some embodiments, the aerosol-generating material may have an areal density of about 30 to 70 g/m2, or about 40 to 60 g/m2. In some embodiments, the amorphous solid may have an areal density of about 80 to 120 g/m2, or about 70 to 110 g/m2, or particularly about 90 to 110 g/m2. Such areal densities may be particularly suitable when the aerosol-generating material is included in an aerosol-generating assembly/article in sheet form, or as a shredded sheet (described below).

The amorphous solid can be formed as a sheet. It can be incorporated into the article in sheet form. In some cases, the aerosol-generating material may be included as a flat sheet, as a bundled or gathered sheet, as a folded sheet, or as a rolled (i.e., tube-shaped) sheet. In some of these cases, the amorphous solid of these embodiments may be included in an aerosol-generating assembly/article such as a sheet, such as a sheet circumscribing a stick of aerosolizable material (e.g., tobacco). In some other cases, the aerosol-generating material may be formed into a sheet and then ground and incorporated into the article. In some cases, the crushed leaf may be mixed with cut rag tobacco and incorporated into the article. In such cases, the aerosol-generating material may have a mass per unit area of 80-120 g/m2 (so that it has a density comparable to that of chopped rag tobacco, and thus does not separate the components of the mixture). .

In some examples, the sheet-shaped amorphous solid may have a tensile strength of about 200 N/m about 900 N/m. In some examples, such as when the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet and then ground and incorporated into an aerosol-generating article. In some examples, such as when the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m. m. Such tensile strengths may be particularly suitable for embodiments where the aerosol generating material is included in an aerosol generating assembly/article as a rolled sheet, suitably in tube form.

In some cases, at least part of the aerosol-generated material may be included as a rolled sheet, forming a tubular rod of aerosol-generating material. The tubular nature of the aerosol generating material in such cases can be adapted for use in several ways. In some cases, the aerosol generating article is configured for use with an aerosol generating assembly in which a heater is provided within the tube in use. In other cases, the aerosol generating article is configured for use with an aerosol generating assembly in which a heater is provided outside the tube in use. In such cases, it may be that no component of the aerosol generating assembly is disposed in the tube in use; rather, the tube provides a flow path for the aerosol or vapor in use; This can reduce or prevent condensation of the aerosol or vapor on the reusable components of the aerosol generating set, thus improving consumption efficiency and hygiene. In some of these cases, the outer wall of the tube may be substantially or completely impermeable to the gas/aerosol, further controlling the flow path.

Other aspects of the invention include an aerosol generating article comprising an aerosol generating material described herein, and an aerosol generating assembly comprising said substrate or aerosol generating article.

In some cases, the article or assembly may additionally comprise a filter and/or cooling element. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool the gaseous components so that they condense to form an aerosol. It can also act to separate very hot parts of the appliance from the user. The filter, if present, may comprise any suitable filter known in the art, such as a cellulose acetate plug.

The assembly heater is configured to heat and not burn the aerosol generating material. The heater may be, in some cases, a thin film electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to the heat of the product in use. The aerosol generating assembly may comprise a plurality of heaters. The heaters can be powered by a battery.

In some cases, the heater can heat, without burning, aerosolizable materials to between 120°C and 350°C in use. In some cases, the heater can heat, without burning, aerosolizable materials to between 140°C and 250°C in use. In some use cases, substantially all of the amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the solid is disposed between about 0.010 mm and 2.0 mm of the heater, suitably between about 0.02 mm, 0.05 mm or 0.1 mm and 1.0 mm or 0.5 mm. These minimum distances can, in some cases, reflect the thickness of a support that supports the amorphous solid. In some cases, a surface of the amorphous solid may rest directly on the heater.

In some cases, the heater may be embedded in the aerosol generating substrate. In some of these cases, the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit). In other cases of this type, the heater may be a susceptor embedded in the aerosol generating substrate, which is heated by induction.

In some cases, the aerosol generation assembly may be a non-combustion heating device. That is, it may contain a solid material that contains tobacco (and no aerosolizable liquid material). In some cases, the amorphous solid may comprise the tobacco material. A heat-without-burn device is described in WO 2015/062983 A2, which is incorporated by reference in its entirety.

In some cases, the aerosol generating assembly may be a hybrid tobacco electronic device. That is, it may contain a solid aerosolizable material and a liquid aerosolizable material. In some cases, the amorphous solid may comprise nicotine. In some cases, the amorphous solid may comprise a tobacco material. In some cases, the amorphous solid may comprise a tobacco material and a separate nicotine source. Separate aerosolizable materials can be heated by separate heaters, the same heater or, in one case, a downstream aerosolizable material can be heated by a hot aerosol that is generated from the upstream aerosolizable material. A hybrid electronic tobacco device is disclosed in WO 2016/135331 A1.

The aerosol generating assembly or article may additionally comprise ventilation openings. In some In some cases, ventilation openings may be provided in the filter and/or the cooling element. These openings may allow cold air to enter the article during use, which may mix with the heated volatilized components, thereby cooling the aerosol.

Ventilation improves the generation of visible heated volatilized components of the article when heated during use. The heated volatilized components are made visible by the cooling process of the heated volatilized components so that supersaturation of the heated volatilized components occurs. The heated volatilized components then undergo droplet formation, also known as nucleation, and finally the aerosol particle size of the heated volatilized components increases by further condensation of the heated volatilized components and by coagulation of the newly formed droplets to from the heated volatilized components.

In some cases, the ratio of cold air to the sum of heated volatilized components and cold air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% allows the heated volatilized components to become visible by the method described above. The visibility of the heated volatilized components allows the user to identify that the volatilized components have been generated and adds to the sensory experience of smoking.

In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilized components. In some cases, the ventilation ratio may be at least 60% or 65%.

The assembly may comprise an integrated aerosol generating article and a heater, or may comprise a heating device into which the article is inserted during use.

Referring to Figures 1 and 2, a partially cut away sectional view and a perspective view of an example of an aerosol generating article 101 are shown. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 5 to 7, which is described below. In use, item 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of device 51.

The article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol generating material 103 and a filter assembly 105 in the form of a rod. The aerosol generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments it may be included in the form of a crushed leaf. In some embodiments, the aerosol-generating material described herein may be incorporated in sheet form and in crushed form.

The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109, and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth or proximal end, and a second end 115. , also known as the distal end. The aerosol generating material body 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent to the aerosol generating material body 103 between the aerosol generating material body 103 and the filter segment 109, such that the cooling segment 107 is in a supportive relationship with the aerosol generating material 103 and the filter segment 103. In other examples, there may be a separation between the body of the aerosol generating material 103 and the cooling segment 107 and between the body of the aerosol generating material 103 and the filter segment 109. The filter segment 109 is located between the cooling segment 107 and the mouth end segment 111. The end segment of the mouth 111 is located towards the proximal end 113 of the article 101, adjacent to the filter segment 109. In one example, the filter segment 109 is in a supporting relationship with the mouth end segment 111. In one embodiment , the total length of the filter assembly 105 is between 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm.

In one example, the aerosol generating material rod 103 is between 34 mm and 50 mm in length, suitably between 38 mm and 46 mm in length, suitably 42 mm in length.

In one example, the total length of article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

An axial end of the aerosol-generating material body 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) that covers the end axial of the body of the aerosol generating material 103.

The aerosol generating material body 103 is attached to the filter assembly 105 by an annular nozzle paper (not shown), which is located substantially around the circumference of the filter assembly 105 to surround the filter assembly 105 and extend partially along the body of aerosol generating material 103. In one example, the nozzle paper is made of standard 58 g/m2 nozzle base paper. In one example, the nozzle paper nozzle has a length of between 42 mm and 50 mm, suitably 46 mm.

In one example, the cooling segment 107 is an annular tube and is located around and defines an air space within the cooling segment. The air space provides a chamber for the heated volatilized components generated from the body of the aerosol generating material 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but rigid enough to resist axial compression forces and bending moments that may arise during manufacturing and while the article 101 is in use during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0. 29mm.

The cooling segment 107 provides a physical displacement between the aerosol generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient along the cooling segment 107. In one example, The cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilized component entering a first end of the cooling segment 107 and a heated volatilized component exiting a second end of the cooling segment. 107. In one example, the cooling segment 107 is configured to provide a temperature differential of at least 60 degrees Celsius between a heated volatilized component entering through a first end of the cooling segment 107 and a heated volatilized component exiting through a second end of the cooling segment 107. This temperature differential across the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol generating material 103 when heated by the device 51. If not physical displacement was provided between the filter segment 109 and the body of the aerosol generating material 103 and the heating elements of the device 51, then the temperature sensitive filter segment may 109 be damaged during use, so it would not perform its required functions. with the same effectiveness.

In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm.

The cooling segment 107 is made of paper, which means that it is composed of a material that does not generate compounds of concern, for example, toxic compounds when used in conjunction with the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow internal chamber but maintains mechanical rigidity. Spiral wound paper tubes can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outside diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created from a rigid cap wrapper or nozzle paper. The rigid cap wrapper or tip paper is manufactured to have sufficient rigidity to withstand axial compression forces and bending moments that may arise during manufacturing and while the item 101 is in use during insertion into the device. 51.

Filter segment 109 may be formed of any filter material sufficient to remove one or more volatilized compounds from the heated volatilized components of the aerosol-generating material. In one example, the filter segment 109 is made of a monoacetate material, such as cellulose acetate. Filter segment 109 provides cooling and reduction of irritation of the heated volatilized components without depleting the amount of the heated volatilized components to a level unsatisfactory to the user.

In some embodiments, a capsule (not shown) may be provided in the filter segment 109. It may be disposed substantially in the center of the filter segment 109, both across the diameter of the filter segment 109 and along the length of the filter segment 109. In other cases, it may be offset in one or more dimensions. The capsule may, in some cases, when present, contain a volatile component such as a flavoring or an aerosol generating agent.

The density of the cellulose acetate tow material of filter segment 109 controls the pressure drop across filter segment 109, which in turn controls the tensile strength of article 101. Therefore, material selection of the filter segment 109 is important for controlling the stretch resistance of the article 101. In addition, the filter segment performs a filtration function on the article 101.

In one example, the filter segment 109 is made of a grade 8Y15 filter tow material, which provides a filtration effect on the heated volatilized material, while reducing the size of the condensed aerosol droplets that result from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect by providing more cooling to the heated volatilized components leaving the cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6 mm and 10 mm in length, suitably 8 mm.

The mouth end segment 111 is an annular tube and is located around and defines an air space within the mouth end segment 111. The air space provides a chamber for heated volatilized components flowing from the mouth end segment 111. filter 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but rigid enough to resist axial compression forces and bending moments that may arise during manufacturing and while the article is in use during insertion into device 51. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, suitably 8 mm.

The mouth end segment 111 can be manufactured from a spirally wound paper tube that provides a hollow internal chamber but maintains critical mechanical rigidity. Spiral wound paper tubes can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outside diameter, roundness and straightness.

The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed by a single tube and the filter segment 109 is located within that tube separating the mouth end segment. 111 and the cooling segment 107.

Referring to Figures 3 and 4, a partially cut away section and perspective views of an example of an article 301 are shown. The reference signs shown in Figures 3 and 4 are equivalent to the reference signs shown in figures 1 and 2, but with an increment of 200.

In the example of item 301 shown in Figures 3 and 4, a vent region 317 is provided in item 301 to allow air to flow into the interior of item 301 from the outside of item 301. In one example, The vent region 317 takes the form of one or more vents 317 formed through the outer layer of the item 301. The vents may be located in the cooling segment 307 to assist with cooling of the item 301. In As an example, the vent region 317 comprises one or more rows of holes and, preferably, each row of holes is arranged circumferentially around the article 301 in a cross section that is substantially perpendicular to a longitudinal axis of the article 301.

In an example, there are between one and four rows of vents to provide ventilation to the article 301. Each row of vents can have between 12 and 36 vents 317. The vents 317 can, for example, have between 100 and 500 μm in diameter. In one example, an axial spacing between rows of vents 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.

In one example, the vents 317 are of uniform size. In another example, the vents 317 vary in size. The vent holes may be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before forming the article 301. The holes Vents 317 are positioned to provide effective cooling to item 301.

In one example, the rows of vent holes 317 are located at least 11 mm from the proximal end 313 of the article, suitably between 17 mm and 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is positioned so that the user does not block the ventilation holes 317 when the item 301 is in use.

Providing the rows of vent holes between 17 mm and 20 mm from the proximal end 313 of the item 301 allows the vent holes 317 to be located outside of the device 51, when the item 301 is fully inserted into the device 51, as can be seen in Figures 6 and 7. By locating the vents outside the device, unheated air can enter the item 301 through the vents from the outside of the device 51 to assist with the cooling of the item 301.

The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 51, when the item 301 is fully inserted into the device 51. The length of the cooling segment 307 provides a first function of providing a space physical between the heater arrangement of the device 51 and the heat sensitive filter arrangement 309, and a second function of allowing the ventilation holes 317 to be located in the cooling segment, while also located outside the device 51, when item 301 is completely inserted into device 51. As can be seen in the Figures 6 and 7, the majority of the cooling element 307 is located within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. It is in this portion of the cooling element 307 that is extends outside the device 51 in which the ventilation holes 317 are located.

Referring now to Figures 5 to 7 in more detail, an example of a device 51 arranged to heat aerosol-generating material to volatilize at least one component of said aerosol-generating material, typically to form an aerosol that can be inhaled, is shown. . Device 51 is a heating device that releases compounds by heating, but not burning, the aerosol generating material.

A first end 53 is sometimes referred to herein as the mouth or proximal end 53 of the device 51 and a second end 55 is sometimes referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button 57 to allowing the device 51 as a whole to be turned on and off as desired by the user.

The device 51 comprises a housing 59 to locate and protect various internal components of the device 51. In the example shown, the housing 59 comprises a single-body sleeve 11 that spans the perimeter of the device 51, topped with a top panel 17 that generally defining the 'top' of the device 51 and a bottom panel 19 generally defining the 'bottom' of the device 51. In another example, the housing comprises a front panel, a back panel and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

The top panel 17 and/or the bottom panel 19 may be removably attached to the unibody sleeve 11, to allow easy access to the interior of the device 51, or may be "permanently" attached to the unibody sleeve 11. , for example, to discourage a user from accessing the interior of the device 51. In one example, panels 17 and 19 are made of a plastic material, including, for example, fiberglass-filled nylon formed by injection molding , and the one-piece sleeve 11 is made of aluminum, although other materials and other manufacturing processes can be used.

The top panel 17 of the device 51 has an opening 20 at the end of the mouth 53 of the device 51 through which, in use, the article 101, 301, including the aerosol generating material, can be inserted into the device 51 and removed from device 51 by a user.

The housing 59 has located or fixed therein a heater arrangement 23, a control circuit 25 and a power supply 27. In this example, the heater arrangement 23, the control circuit 25 and the power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), with the control circuit 25 generally located between the heater arrangement 23 and the power supply 27, although other locations are possible.

The control circuit 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol generating material in item 101, 301 as discussed below.

The power source 27 may be, for example, a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when necessary and under the control of the control circuit 25 to heat the aerosol generating material in the article (as discussed, to volatilize the aerosol generating material without causing the aerosol generating material to burn).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 can be used without causing the device 51 as a whole to be unduly long. As will be understood, in general, a physically large power supply has a greater capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours or similar) and therefore the duration of 51 device battery may be longer

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101, 301 comprising the aerosol generating material is inserted for heating during use. . Different arrangements are possible for the heating arrangement 23. For example, the heater arrangement 23 may comprise a single heating element or may be formed by a plurality of heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least partially annular or partially tubular around its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which can be laminated and sintered. Other heating arrangements are possible, including, for example, inductive heating, infrared heating elements, which heat by emitting infrared radiation, or resistive heating elements formed, for example, of a resistive electrical winding.

In a particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is sized so that substantially the entire body of aerosol generating material 103, 303 of item 101, 301 is inserted into the heater arrangement 23 when the item 101, 301 is inserted into the device 51.

The or each heating element can be arranged so that selected zones of the aerosol-generating material can be heated independently, for example, in turns (over time, as discussed above) or together (simultaneously) as desired.

The heating arrangement 23 in this example is surrounded at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce the passage of heat from the heater arrangement 23 to the outside of the device 51. This helps to maintain low energy requirements for heater arrangement 23 as it reduces overall heat losses. The insulator 31 also helps keep the exterior of the device 51 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve that provides a low pressure region between the two walls of the sleeve. . That is, the insulator 31 may be, for example, a "vacuum" tube, that is, a tube that has been at least partially evacuated to minimize heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including the use of heat-insulating materials, including, for example, a suitable foam-type material, in addition to or instead of a double-walled sleeve.

The housing 59 may further comprise several internal support structures 37 to support all the internal components as well as the heating arrangement 23.

The device 51 further comprises a collar 33 that extends around and protrudes from the opening 20 into the housing 59 and a generally tubular chamber 35 that is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 It further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along the outer surface of the chamber 35, and each arranged circumferentially around the outer surface of the chamber 35. There is a air space 36 between the hollow chamber 35 and the article 101, 301 when inserted into the device 51 in at least part of the length of the hollow chamber 35. The air space 36 is around the entire circumference of the article 101, 301 over at least part of the cooling segment 307.

The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and projecting towards the opening 20. The ridges 60 occupy space within the opening 20 so that the open space of the opening 20 in the locations of the ridges 60 is less than the open space of the opening 20 at the locations without the ridges 60. The ridges 60 are configured to engage an item 101, 301 inserted into the device to help secure it within the device 51. The Open spaces (not shown in the figures) defined by adjacent pairs of ridges 60 and article 101, 301 form ventilation routes around the exterior of article 101, 301. These ventilation routes allow hot vapors that have escaped from the article 101, 301 exit the device 51 and allow cooling air to flow into the device 51 around the article 101, 301 in the air space 36.

In operation, the article 101, 301 is removably inserted into an insertion point 20 of the device 51, as shown in Figures 5 to 7. With particular reference to Figure 6, in one example, the body of generating material aerosol 103, 303, which is located towards the distal end 115, 315 of article 101, 301, is received completely within the heater arrangement 23 of device 51. The proximal end 113, 313 of article 101, 301 extends from the device 51 and acts as a mouthpiece assembly for a user.

In operation, the heater arrangement 23 will heat the article 101, 301 to volatilize at least one component of the aerosol generating material from the body of the aerosol generating material 103, 303.

The primary flow path for the hot volatilized components of the aerosol generating material body 103, 303 is axially through the article 101, 301, through the chamber within the cooling segment 107, 307, through the filter segment 109, 309, through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatilized components generated from the body of the aerosol-generating material is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilized component travels through the cooling segment 107, 307, it will cool and some volatilized components will condense on the inner surface of the cooling segment 107, 307.

In the examples of item 301 shown in Figures 3 and 4, cold air will be able to enter the cooling segment 307 through the ventilation holes 317 formed in the cooling segment 307. This cold air will mix with the components heated volatilized to provide additional cooling to the heated volatilized components.

Manufacturing the aerosol-generating material may in some cases comprise (a) forming a suspension comprising components of the amorphous solid material, (b) forming a layer of the suspension, (c) fixing the suspension to form a gel, and (d ) dry the gel to form an amorphous solid.

Step (b) of forming a suspension layer may comprise, for example, spraying, casting or extruding the suspension. In some cases, the suspension layer is formed by electrospray of the suspension. In some cases, the slurry layer is formed by straining the slurry.

In some cases, steps (b) and/or (c) and/or (d) may occur, at least partially, simultaneously (e.g., during electrospray). In some cases, these stages may occur sequentially.

Step (b) may comprise forming a layer of the suspension on a support.

In some examples, the suspension has a viscosity of about 10 to about 20 Pas at 46.5°C, such as about 14 to about 16 Pas at 46.5°C.

Step (c) of setting the gel may comprise the addition of a setting agent to the suspension. For example, the suspension 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 suspension to form a calcium alginate gel. .

The total amount of the setting agent, as a source of calcium, may be 0.5 to 5% by weight (calculated on a dry weight basis). The inventors have discovered that the addition of too little setting agent can result in an amorphous solid that does not stabilize the amorphous solid components and results in these components falling away from the amorphous solid. The inventors have discovered that the addition of too much setting agent results in an amorphous solid that is very sticky and consequently has poor workability.

However, in some cases, a setting agent is not needed; Tobacco extract may contain enough calcium to effect gelation.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of units (blocks) of p-D-mannuronic acid (M) and a-L-guluronic acid (G) linked together with (1,4)-glycosidic bonds to form a polysaccharide. By adding calcium cations, the alginate cross-links to form a gel. The inventors have determined that alginate salts with a high G monomer content more easily form a gel upon addition of the calcium source. Therefore, in some cases, the gel precursor product comprises an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomeric units in the copolymer of alginate are units of a-L-guluronic acid (G).

The suspension itself may also form part of the invention. In some cases, the suspending solvent may consist essentially of water. In some cases, the suspension may comprise about 50% by weight, 60% by weight, 70% by weight, 80% by weight or 90% by weight solvent (WWB).

In cases where the solvent consists of water, the dry weight content of the suspension may coincide with the dry weight content of the amorphous solid. Therefore, the discussion herein related to solid composition is explicitly described in combination with the suspension aspect of the invention.

EXEMPLARY ACHIEVEMENTS

In some embodiments, the amorphous solid comprises menthol.

Particular embodiments comprising an amorphous solid containing menthol may be particularly suitable for inclusion in an aerosol generating assembly/article such as a crushed leaf. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 20% by weight to about 40% by weight , or about 25% by weight to 35% by weight; menthol in an amount of about 35% by weight to about 60% by weight, or about 40% by weight to 55% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of about 10% by weight to about 30% by weight, or from about 15% by weight to about 25% by weight (DWB).

In one embodiment, the amorphous solid comprises approximately 32-33% by weight of an alginate/pectin gelling agent mixture; about 47-48% by weight of menthol flavoring; and approximately 19-20% by weight of glycerol aerosol generating agent (DWB).

As noted above, the amorphous solid of these embodiments may be included in an aerosol generating assembly/article as a ground sheet. Shredded leaf may be provided in the item/set mixed with chopped tobacco. Alternatively, the amorphous solid may be provided as an unground sheet. Conveniently, the ground or unground sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

Particular embodiments of the menthol-containing amorphous solid may be particularly suitable for inclusion in an aerosol-generating assembly/article such as a sheet, such as a sheet circumscribing a stick of aerosolizable material (e.g., tobacco). In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of about 5% by weight to about 40% by weight , or about 10% by weight to 30% by weight; menthol in an amount of about 10% by weight to about 50% by weight, or about 15% by weight to 40% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of about 5% by weight to about 40% by weight, or from about 10% by weight to about 35% by weight; and optionally filled in an amount of up to 60% by weight, for example, in an amount of 5% by weight to 20% by weight, or about 40% by weight to 60% by weight (DWB).

In one of these embodiments, the amorphous solid comprises about 11% by weight of an alginate/pectin gelling agent mixture, about 56% by weight of wood pulp filler, about 18% menthol flavoring, and about 15% by weight of glycerol (DWB).

In another of these embodiments, the amorphous solid comprises about 22% by weight of an alginate/pectin gelling agent mixture, about 12% by weight of wood pulp filler, about 36% menthol flavoring and about 30% by weight of glycerol (DWB).

As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is provided on a support comprising paper. In one embodiment, the sheet is provided on a support comprising a metal sheet, suitably an aluminum metal sheet. In this embodiment, the amorphous solid may abut the metal sheet.

In one embodiment, the sheet forms part of a laminated material with a layer (preferably comprising paper) attached to a top and bottom surface of the sheet. Suitably, the amorphous solid sheet has a thickness of about 0.015 mm to about 1 mm.

In some embodiments, the amorphous solid comprises a flavoring that does not contain menthol. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of about 5 to about 40% by weight, or from about 10% by weight to about 35% by weight , or from about 20% by weight to about 35% by weight; flavoring in an amount of about 0.1% by weight to about 40% by weight, from about 1% by weight to about 30% by weight, or from about 1% by weight to about 20% by weight, or from about 5 % by weight to about 20% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of 15% by weight to 75% by weight, or from about 30% by weight to about 70% by weight, or from about 50% by weight to about 65% by weight; and optionally filler (suitably wood pulp) in an amount of less than about 60% by weight, or about 20% by weight, or about 10% by weight, or about 5% by weight (preferably, the amorphous solid does not include filling) (DWB).

In one of these embodiments, the amorphous solid comprises approximately 27% by weight of alginate gelling agent, approximately 14% by weight of flavorant, and approximately 57% by weight of glycerol aerosol generating agent (DWB).

In another of these embodiments, the amorphous solid comprises approximately 29% by weight of alginate gelling agent, approximately 9% by weight of flavoring and approximately 60% by weight of glycerol (DWB).

The amorphous solid of these embodiments may be included in an aerosol generating assembly/article as a ground leaf, optionally mixed with chopped tobacco. Alternatively, the amorphous solid of these embodiments may be included in an aerosol-generating assembly/article such as a sheet, such as a sheet circumscribing a stick of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating assembly/article as a layer portion disposed on a support.

In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of about 5% by weight to about 40% by weight, or about 10% by weight to 30 % by weight, or about 15 % by weight to about 25 % by weight; tobacco extract in an amount of about 30% by weight to about 60% by weight, or from about 40% by weight to 55% by weight, or from about 45% by weight to about 50% by weight; aerosol generating agent (preferably comprising glycerol) in an amount of about 10% by weight to about 50% by weight, or from about 20% by weight to about 40% by weight, or from about 25% by weight to about 35 % by weight (DWB).

In one embodiment, the amorphous solid comprises about 20% by weight alginate gelling agent, about 48% by weight Virginia tobacco extract, and about 32% by weight glycerol (DWB).

The amorphous solid of these embodiments may have any suitable water content. For example, the amorphous solid may have a water content of about 5% by weight to about 15% by weight, or from about 7% by weight to about 13% by weight, or about 10% by weight.

The amorphous solid of these embodiments may be included in an aerosol generating assembly/article as a ground leaf, optionally mixed with chopped tobacco. Alternatively, the amorphous solid of these embodiments may be included in an aerosol-generating assembly/article such as a sheet, such as a sheet circumscribing a stick of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solid of these embodiments may be included in an aerosol generating assembly/article as a layer portion disposed on a support. Conveniently, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm, or from about 50 μm to about 100 μm, or from about 60 μm to about 90 μm, suitably about 77 μm.

The suspension to form this amorphous solid may also form part of the invention. In some cases, the suspension may have an elastic modulus of about 5 to 1200 Pa (also called storage modulus); In some cases, the suspension may have a viscous modulus of about 5 to 600 Pa (also called loss modulus).

DEFINITIONS

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 can be selected, for example, from nutraceuticals, nootropics, psychoactives. The active substance can be of natural origin or obtained synthetically. The active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids or constituents, derivatives or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or other botanical.

In some embodiments, the active substance comprises nicotine.

In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As indicated herein, the active substance may comprise one or more cannabis constituents, derivatives or extracts, such as one or more cannabinoids or terpenes.

Cannabinoids are a class of natural or synthetic chemical compounds that act on cannabinoid receptors (i.e., CB1 and CB2) on cells that repress the release of neurotransmitters in the brain. Cannabinoids can be natural (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, but are not limited to: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin ( CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabitriol ( CBO), tetrahydrocannabmolic acid (THCA) and tetrahydrocannabivarinic acid (THCV A).

As indicated herein, the active substance may comprise or be derived from one or more botanical ingredients or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells or the like. Alternatively, the material may comprise an active compound that exists naturally in a botanical, obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, powder, crushed particles, granules, granules, fragments, strips, sheets or the like. Examples of botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, mint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazelnut, hibiscus, bay leaf, licorice, matcha , matte, skin orange, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron , lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak, turmeric, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, cassis, valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, basil, chives, carvi, verbena, tarragon, geranium, blackberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. Mint can be chosen from the following varieties of mint : Mentha arvensis, Mentha cv, Mentha niliaca, Mint, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Menta suaveolens.

In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the botanical is selected from rooibos and fennel.

As used herein, the terms "flavor" and "flavoring" refer to materials that, where local regulations permit, may be used to create a desired flavor, aroma, or other somatosensory sensation in a product for adult consumers. They may include natural flavor materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese whitebark magnolia leaf, chamomile, fenugreek, clove , maple, matcha, menthol, Japanese mint, anise seed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, blackberry, citrus fruits, Drambuie, bourbon, scotch, gin, tequila, rum, spearmint, mint, lavender, aloe vera , cardamom, celery, husk, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, pepper, ginger, coriander, coffee, hemp, a peppermint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, coriander, myrtle, cassis, valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, limonene, thymol, camphene), enhancers taste, bitterness receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose , sorbitol or mannitol) and other additives such as charcoal, chlorophyll, minerals, botanicals or breath freshening agents. They can be imitation, synthetic or natural ingredients or mixtures thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder or gas.

The flavor may suitably comprise one or more mint flavours, suitably a mint oil of any species of the genus Mentha. The flavor may suitably comprise, consist essentially of, or consist of menthol.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint.

In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberries.

In some embodiments, the flavor comprises eugenol.

In some embodiments, the flavor comprises flavor components extracted from tobacco.

In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some embodiments, the flavor may comprise a sensation, which is intended to achieve a somatosensory sensation that is generally chemically induced and perceived by stimulation of the fifth cranial crest (trigeminal crest), in addition to or instead of the aroma crests or of taste, and these may include agents that provide a warming, cooling, tingling and numbing effect. A suitable thermal effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

As used herein, the term "aerosol generating agent" refers to an agent that promotes the generation of an aerosol. An aerosol-generating agent may promote the generation of an aerosol by promoting an initial vaporization and/or condensation of a gas to an inhalable solid and/or liquid aerosol.

Suitable aerosol generating agents include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol and glycols such as propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and esters of acid aliphatic carboxylic such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol generating agent may suitably have a composition that does not dissolve menthol. The aerosol generating agent may suitably comprise, consist essentially of, or consist of glycerol.

As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fiber, chopped 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 rags or whole leaf, including Virginia and/or Burley and/or Oriental. They can also be 'fine' particles or tobacco 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 fibers and may be formed by casting, a Fourdrinier-based papermaking type approach with subsequent addition of tobacco extract, or by extrusion.

All weight percentages described herein (indicated as % by weight) are calculated on a dry weight basis unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight expressed as dry weight refers to the entire extract, suspension or material, except water, and may include components that themselves are liquid at room temperature and pressure, such as glycerol. In contrast, a weight percentage expressed in wet weight refers to all components, including water.

For the avoidance of doubt, where the term "comprises" is used in this specification to define the invention or features of the invention, embodiments are also described in which the invention or feature may be defined using the terms "consists essentially of." or "consists of" instead of "comprises." Reference to a material "comprising" certain characteristics means that those characteristics are included, contained or retained within the material.

The above embodiments should be understood as illustrative examples of the invention. It should be understood that any feature described in connection with any embodiment may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be used without departing from the scope of the invention, which is defined in the appended claims.

Claims (13)

1. An aerosol generating substrate comprising an aerosol generating material, wherein the aerosol generating material comprises an amorphous solid, the amorphous solid comprising an aerosol generating agent, wherein at least 65% by weight of the agent aerosol generator is aerosolized by heating the aerosol generating material to 370 °C for a period of ten seconds with an air flow of 1.95 l/min; and wherein the aerosol generating substrate further comprises a vehicle upon which the amorphous solid is provided. 2. An aerosol generating substrate according to claim 1, wherein at least 70% by weight of the aerosol generating agent is aerosolized by heating the aerosol generating material to 370 ° C for a period of ten seconds under a flow of air 1.95 l/min. 3. An aerosol generating substrate according to any of the preceding claims, wherein the amorphous solid comprises 5 to 80% by weight of aerosol generating agent, calculated on a dry weight basis. 4. An aerosol generating substrate according to any of the preceding claims, wherein the aerosol generating agent is selected from erythritol, sorbitol, glycerol, glycols, monohydric alcohols, high boiling hydrocarbons, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate. 5. An aerosol generating substrate according to claim 4, wherein the aerosol generating agent comprises glycerol. 6. An aerosol generating substrate according to any of the preceding claims, wherein the amorphous solid comprises: - 1-60% by weight of a gelling agent; I - 5-80% by weight of an aerosol generating agent; I - 10-60% by weight of an active substance; - and optionally, a flavoring; where these weights are calculated on a dry weight basis. 7. An aerosol-generating substrate according to claim 6, wherein the amorphous solid is a hydrogel and comprises less than about 20% by weight of water calculated on a wet weight basis. 8. An aerosol generating substrate according to claim 6 or claim 7, wherein the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches and starch derivatives, celluloses and cellulose derivatives, gums, silica or silicone compounds, clays, polyvinyl. alcohol and combinations thereof. 9. An aerosol generating substrate according to any of the preceding claims, comprising approximately 0.1-80% by weight of flavoring, calculated on a dry weight basis. 10. An aerosol generating substrate according to any of claims 6 to 9, wherein the tobacco extract is an aqueous extract, obtained by extraction with water. 11. An aerosol generating substrate according to any of the preceding claims, wherein the carrier comprises a metal sheet. 12. An aerosol generating article comprising an aerosol generating substrate according to any of the preceding claims. 13. An aerosol generating assembly comprising an aerosol generating substrate according to any of claims 1 to 11 or an article according to claim 12, and a heater that is configured to heat, but not burn, the aerosol generating substrate.