Note: Descriptions are shown in the official language in which they were submitted.
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AEROSOL GENERATION
Technical Field
The present invention relates to aerosol generation.
Background
Smoking articles such as cigarettes, cigars and the like burn tobacco during
use
to create tobacco smoke. Alternatives to these types of 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 assemblies.
One example of such a product is a heating device which release compounds by
heating, but not burning, a solid aerosolisable material. This solid
aerosolisable
material may, in some cases, contain a tobacco material. The heating
volatilises at least
one component of the material, typically forming an inhalable aerosol. These
products
may be referred to as heat-not-burn devices, tobacco heating devices or
tobacco heating
products. Various different arrangements for volatilising at least one
component of the
solid aerosolisable material are known.
As another example, there are e-cigarette / tobacco heating product hybrid
devices, also known as electronic tobacco hybrid devices. These hybrid devices
contain
a liquid source (which may or may not contain nicotine) which is vaporised by
heating
to produce an inhalable vapour or aerosol. The device additionally contains a
solid
aerosolisable material (which may or may not contain a tobacco material) and
components of this material are entrained in the inhalable vapour or aerosol
to produce
the inhaled medium.
Summary
A first aspect of the invention provides an aerosol generating material
comprising an aerosol-forming layer, the aerosol-forming layer comprising an
amorphous solid, wherein the aerosol-forming layer has a thickness of 0.015mm
to
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1.0mm. In one embodiment, the aerosol-forming layer has a thickness of from
0.05mm
to 1.0mm.
In one embodiment, the amorphous solid comprises one or more of an active
substance, an aerosol generating agent, a flavourant and a gelling agent. In a
particular
embodiment, the amorphous solid comprises one or more of nicotine, a tobacco
material, an aerosol generating agent, a flavourant and a gelling agent
A second aspect of the invention provides an aerosol generating assembly
comprising an aerosol generating material according to the first aspect of the
invention
and a heater configured to heat but not burn the aerosol generating material.
A third aspect of the invention provides an aerosol generating article for use
in
an aerosol generating assembly, the article comprising an aerosol generating
material
according to the first aspect.
A fourth aspect of the invention provides a method of making an aerosol
generating material according to the first aspect.
Further aspects of the invention described herein may provide the use of the
aerosol generating material, the aerosol generating article or the aerosol
generating
assembly, in the generation of an inhalable aerosol.
Further 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 is an exploded schematic diagram of an aerosol generating material.
Figure 2 shows a section view of an example of an aerosol generating article.
Figure 3 shows a perspective view of the article of Figure 2.
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Figure 4 shows a sectional elevation of an example of an aerosol generating
article.
Figure 5 shows a perspective view of the article of Figure 4.
Figure 6 shows a perspective view of an example of an aerosol generating
assembly.
Figure 7 shows a section view of an example of an aerosol generating assembly.
Figure 8 shows a perspective view of an example of an aerosol generating
assembly.
Detailed Description
The aerosol-forming layer described herein comprises an "amorphous solid",
which may alternatively be referred to as a "monolithic solid" (i.e. non-
fibrous), or as
a "dried gel". The amorphous solid is a solid material that may retain some
fluid, such
as liquid, within it. In some cases, the aerosol-forming layer comprises from
about
50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of
amorphous solid. In some cases, the aerosol-forming layer consists of
amorphous solid.
As described above, the invention provides an aerosol generating material
comprising an aerosol-forming layer, the aerosol-forming layer comprising an
amorphous solid, and wherein the aerosol-forming layer has a thickness of
about
0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about
0.05mm,
0.1mm or 0.15mm to about 0.5mm or 0.3mm. The inventors have found that a
material
having a thickness of 0.2mm is particularly suitable. The aerosol-forming
layer may
comprise more than one layer, and the thickness described herein refers to the
aggregate
thickness of those layers.
The inventors have established that if the aerosol-forming layer is too thick,
then
heating efficiency is compromised. This adversely affects the power
consumption and
the timing of aerosol delivery in use. Conversely, if the aerosol-forming
layer is too
thin, it is difficult to manufacture and handle; a very thin material is
harder to cast and
may be fragile, compromising aerosol formation in use.
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The inventors have established that the layer thicknesses stipulated herein
optimise the material properties in view of these competing considerations.
The thickness stipulated herein is a mean thickness for the material. In some
cases, the amorphous solid thickness may vary by no more than 25%, 20%, 15%,
10%,
5% or 1%.
In some cases, the aerosol generating material may comprise embedded heating
means, such as resistive or inductive heating elements. For example, the
heating means
may be embedded in the amorphous solid.
The aerosol generating material may comprise a carrier on which the amorphous
solid is provided. Figure 1 provides a schematic illustration of such an
aerosol
generating material. The laminate structure (indicated by dotted lines)
includes a carrier
layer 4 and an amorphous solid layer 2.
The carrier functions as a support on which the amorphous solid layer forms,
easing manufacture. The carrier may provide tensile strength to the amorphous
solid
layer, easing handling.
The carrier may be any suitable material which can be used to support an
amorphous solid. In some cases, the carrier may be formed from materials
selected
from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon
allotropes such
as graphite and graphene, plastic, cardboard, wood or combinations thereof. In
some
cases, the carrier may comprise or consist of a tobacco material, such as a
sheet of
reconstituted tobacco. In some cases, the carrier may be formed from materials
selected
from metal foil, paper, cardboard, wood or combinations thereof In some cases,
the
carrier itself be a laminate structure comprising layers of materials selected
from the
preceding lists. In some cases, the carrier may also function as a flavour
carrier. For
example, the carrier may be impregnated with a flavourant or with tobacco
extract.
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In some cases, the carrier may be magnetic. This functionality may be used to
fasten the carrier to the assembly in use, or may be used to generate
particular
amorphous solid shapes. In some cases, the aerosol generating material may
comprise
one or more magnets which can be used to fasten the material to an induction
heater in
5 use.
In some cases, the carrier may be substantially or wholly impermeable to gas
and/or aerosol. This prevents aerosol or gas passage through the carrier
layer, thereby
controlling the flow and ensuring it is delivered to the user. This can also
be used to
prevent condensation or other deposition of the gas/aerosol in use on, for
example, the
surface of a heater provided in an aerosol generating assembly. Thus,
consumption
efficiency and hygiene can be improved in some cases.
In one case, the surface of the carrier that abuts the amorphous solid may be
.. porous. For example, in some cases, the carrier comprises paper. The
inventors have
found that a porous carrier such as paper is particularly suitable for the
present
invention; the porous layer abuts the amorphous solid layer and forms a strong
bond.
The amorphous solid is formed by drying a gel and, without being limited by
theory, it
is thought that the slurry from which the gel is formed partially impregnates
the porous
carrier (e.g. paper) so that when the gel sets and forms cross-links, the
carrier is partially
bound into the gel. This provides a strong binding between the gel and the
carrier (and
between the dried gel and the carrier). The porous layer (e.g. paper) may also
be used
to carry flavours. In some cases, the porous layer may comprise paper,
suitably having
a porosity of 0-300 Coresta Units (CU), suitably 5-100 CU or 25-75 CU.
Additionally, surface roughness may contribute to the strength of bond between
the amorphous material and the carrier. The inventors have found that the
paper
roughness (for the surface abutting the carrier) may suitably be in the range
of 50-1000
Bekk seconds, suitably 50-150 Bekk seconds, suitably 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
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the time (in seconds) for a fixed volume of air to seep between these surfaces
is the
"Bekk smoothness")
Conversely, the surface of the carrier facing away from the amorphous solid
may be arranged in contact with the heater, and a smoother surface may provide
more
efficient heat transfer. Thus, in some cases, the carrier is disposed so as to
have a
rougher side abutting the amorphous material and a smoother side facing away
from
the amorphous material.
In one particular case, the carrier may be a paper-backed foil; the paper
layer
abuts the amorphous solid 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 amorphous solid.
In another case, the foil layer of the paper-backed foil abuts the amorphous
solid. The foil is substantially impermeable, thereby preventing water
provided in the
amorphous solid to be absorbed into the paper which could weaken its
structural
integrity.
In some cases, the carrier is formed from or comprises metal foil, such as
aluminium foil. A metallic carrier may allow for better conduction of thermal
energy to
the amorphous solid. Additionally, or alternatively, a metal foil may function
as a
susceptor in an induction heating system. In particular embodiments, the
carrier
comprises a metal foil layer and a support layer, such as cardboard. In these
embodiments, the metal foil layer may have a thickness of less than 20gm, such
as from
about lgm to about 10gm, suitably about Sum.
In some cases, the carrier may have a thickness of between about 0.010mm, and
about 2.5mm, suitably from about 0.015mm, 0.017mm 0.02mm, 0.05mm or 0.1mm to
about 1.5mm, 1.0mm, or 0.5mm.
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AEROSOL-FORMING MATERIAL COMPOSITION
In some cases, the amorphous solid may comprise 1-60wt% of a gelling agent
wherein these weights are calculated on a dry weight basis.
Suitably, the amorphous solid may comprise from about lwt%, 5wt%, 1 Owt%,
15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or
27wt% of a gelling agent (all calculated on a dry weight basis). For example,
the
amorphous solid may comprise 1-50wt%, 5-40wt%, 10-30wt% or 15-27wt% 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 or silicones compounds, 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,
carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose,
acacia
gum, 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 formation of the amorphous
solid. In
some cases, the amorphous solid may comprise a calcium-crosslinked alginate
and/or a
calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises alginate, and the alginate is
present in the amorphous solid in an amount of from 10-30wt% of the amorphous
solid
(calculated on a dry weight basis). In some embodiments, alginate is the only
gelling
agent present in the amorphous solid. In other embodiments, the gelling agent
comprises alginate and at least one further gelling agent, such as pectin.
In some embodiments the amorphous solid may include gelling agent
comprising carrageenan.
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Suitably, the amorphous solid may comprise from about 5wt%, lOwt%, 15wt%,
or 20wt% to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt%
of an aerosol generating agent (all calculated on a dry weight basis). The
aerosol
generating agent may act as a plasticiser. For example, the amorphous solid
may
comprise 10-60wt%, 15-50wt% or 20-40wt% of an aerosol generating agent. In
some
cases, the aerosol generating agent comprises one or more compound 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 content of the plasticiser is too high,
the
amorphous solid may absorb water resulting in a material that does not create
an
appropriate consumption experience in use. The inventors have established that
if the
plasticiser content is too low, the amorphous solid may be brittle and easily
broken.
The plasticiser content specified herein provides an amorphous solid
flexibility which
allows the amorphous solid sheet to be wound onto a bobbin, which is useful in
manufacture of aerosol generating articles.
In some cases, the amorphous solid may comprise a flavour. Suitably, the
amorphous solid may comprise up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%,
lOwt% or 5wt% of a flavour. In some cases, the amorphous solid may comprise at
least
about 0.1wt%, 0.5wt%, lwt%, 2wt%, 5wt% lOwt%, 20wt% or 30wt% of a flavour (all
calculated on a dry weight basis). For example, the amorphous solid may
comprise 0.1-
60wt%, 1-60wt%, 5-60wt%, 10-60wt%, 20-50wt% or 30-40wt% of a flavour. In some
cases, the flavour (if present) comprises, consists essentially of or consists
of menthol.
In some cases, the amorphous solid does not comprise a flavour.
In some cases, the amorphous solid additionally comprises an active substance.
For example, in some cases, the amorphous solid additionally comprises a
tobacco
material and/or nicotine. For example, the amorphous solid may additionally
comprise
powdered tobacco and/or nicotine and/or a tobacco extract. In some cases, the
amorphous solid may comprise from about lwt%, 5wt%, 1 Owt%, 15wt%, 20wt% or
25wt% to about 70wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis)
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of active substance. In some cases, the amorphous solid may comprise from
about
lwt%, 5wt%, lOwt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%,
45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material and/or
nicotine.
In some cases, the amorphous solid comprises an active substance such as
tobacco extract. In some cases, the amorphous solid may comprise 5-60wt%
(calculated on a dry weight basis) of tobacco extract. In some cases, the
amorphous
solid may comprise from about lwt%, 5wt%, 1 Owt%, 15wt%, 20wt% or 25wt% to
about 55wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) tobacco
extract. For example, the amorphous solid may comprise 5-60wt%, 10-55wt% or 25-
5 5wt% of tobacco extract. The tobacco extract may contain nicotine at a
concentration
such that the amorphous solid comprises lwt% 1.5wt%, 2wt% or 2.5wt% to about
6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In
some
cases, there may be no nicotine in the amorphous solid other than that which
results
from the tobacco extract.
In some embodiments the amorphous solid comprises no tobacco material but
does comprise nicotine. In some such cases, the amorphous solid may comprise
from
about lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, 1 Owt% or 5wt%
(calculated on a dry weight basis) of nicotine. For example, the amorphous
solid may
comprise 1-20wt% or 2-5wt% of nicotine.
In some cases, the total content of active substance and/or flavour may be at
least about 0.1wt%, lwt%, 5wt%, lOwt%, 20wt%, 25wt% or 30wt%. In some cases,
the total content of active substance and/or flavour may be less than about
70wt%,
60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
In some cases, the total content of tobacco material, nicotine and flavour may
be at least about 0.1wt%, lwt%, 5wt%, 1 Owt%, 20wt%, 25wt% or 30wt%. In some
cases, the total content of tobacco material, nicotine and flavour may be less
than about
70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
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In some embodiments, the amorphous solid is a hydrogel and comprises less
than about 20wt% of water calculated on a wet weight basis. In some cases, the
hydrogel may comprise less than about 15wt%, 12wt% or lOwt% of water
calculated
5 on a wet weight basis (WWB). In some cases, the hydrogel may comprise at
least about
lwt%, 2wt% or at least about 5wt% of water (WWB).
The amorphous solid may be made from a gel, and this gel may additionally
comprise a solvent, included at 0.1-50wt%. However, the inventors have
established
10 that the inclusion of a solvent in which the flavour is soluble may
reduce the gel stability
and the flavour may crystallise out of the gel. As such, in some cases, the
gel does not
include a solvent in which the flavour is soluble.
In some embodiments, the amorphous solid comprises less than 60wt% of a
filler, such as from lwt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or
lOwt%
to 20wt%.
In other embodiments, the amorphous solid comprises less than 20wt%, suitably
less than 1 Owt% or less than 5wt% of a filler. In some cases, the amorphous
solid
comprises less than lwt% of a filler, and in some cases, comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials,
such
as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal
silica,
magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable
inorganic
sorbents, such as molecular sieves. The filler may comprise one or more
organic filler
materials such as wood pulp, cellulose and cellulose derivatives. In
particular, in some
cases, the amorphous solid comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For
example,
the filler may be a fibrous organic filler material such as wood pulp, hemp
fibre,
cellulose or cellulose derivatives. Without wishing to be bound by theory, it
is believed
that including fibrous filler in an amorphous solid may increase the tensile
strength of
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the material. This may be particularly advantageous in examples wherein the
amorphous solid is provided as a sheet, such as when an amorphous solid sheet
circumscribes a rod of aerosolisable material.
In some embodiments, the amorphous solid does not comprise tobacco fibres.
In particular embodiments, the amorphous solid does not comprise fibrous
material.
In some embodiments, the aerosol generating material does not comprise
tobacco fibres. In particular embodiments, the aerosol generating material
does not
comprise fibrous material.
In some embodiments, the aerosol generating substrate does not comprise
tobacco fibres. In particular embodiments, the aerosol generating substrate
does not
comprise fibrous material.
In some embodiments, the aerosol generating article does not comprise tobacco
fibres. In particular embodiments, the aerosol generating article does not
comprise
fibrous material.
In some cases, the amorphous solid may consist essentially of, or consist of a
gelling agent, an aerosol generating agent, an active substance, water, and
optionally a
flavour.
In some cases, the amorphous solid may consist essentially of, or consist of a
gelling agent, an aerosol generating agent, tobacco material and/or a nicotine
source,
water, and optionally a flavour.
The aerosol generating material comprising the amorphous solid may have any
suitable area density, such as from 30 g/m2 to 120 g/m2. In some embodiments,
aerosol
generating material may have an area density of from about 30 to 70 g/m2, or
about 40
to 60 g/m2. In some embodiments, the amorphous solid may have an area density
of
from about 80 to 120 g/m2, or from about 70 to 110 g/m2, or particularly from
about 90
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to 110 g/m2. Such area densities may be particularly suitable where the
aerosol-
generating material is included in an aerosol generating article/assembly in
sheet form,
or as a shredded sheet (described further hereinbelow).
AEROSOL GENERATING ARTICLE AND ASSEMBLY
A second aspect of the invention provides an aerosol generating assembly
comprising an aerosol generating material according to the first aspect of the
invention
and a heater configured to heat but not burn the aerosol generating material.
In some cases, the heater may heat, without burning, the aerosolisable
material(s) to between 120 C and 350 C in use. In some cases, the heater may
heat,
without burning, the aerosolisable material(s) to between 140 C and 250 C in
use. In
some cases in use, substantially all of the amorphous solid is less than about
4mm,
3mm, 2mm or lmm from the heater. In some cases, the amorphous solid is
disposed
between about 0.017mm and 2.0mm from the heater, suitably between about 0.1mm
and 1.0mm. In some cases, a surface of the amorphous solid may directly abut
the
heater.
The heater is configured to heat 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 which undergoes an
exothermic
reaction to product heat in use. The aerosol generating assembly may comprise
a
plurality of heaters. The heater(s) may be powered by a battery.
The aerosol generating assembly may additionally comprise a cooling element
and/or a filter. The cooling element, if present, may act or function to cool
gaseous or
aerosol components. In some cases, it may act to cool gaseous components such
that
they condense to form an aerosol. It may also act to space the very hot parts
of the
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apparatus from the user. The filter, if present, may comprise any suitable
filter known
in the art such as a cellulose acetate plug.
In some cases, the aerosol generating assembly may be a heat-not-burn device.
That is, it may contain a solid tobacco-containing material (and no liquid
aerosolisable
material). In some cases, the amorphous solid may comprise the tobacco
material. A
heat-not-burn device is disclosed in WO 2015/062983 A2, which is incorporated
by
reference in its entirety.
In some cases, the aerosol generating assembly may be an electronic tobacco
hybrid device. That is, it may contain a solid aerosolisable material and a
liquid
aerosolisable 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. The
separate aerosolisable materials may be heated by separate heaters, the same
heater or,
in one case, a downstream aerosolisable material may be heated by a hot
aerosol which
is generated from the upstream aerosolisable material. An electronic tobacco
hybrid
device is disclosed in WO 2016/135331 Al, which is incorporated by reference
in its
entirety.
The invention also provides an aerosol generating article for use in an
aerosol
generating assembly comprising an aerosol generating material according to the
first
aspect of the invention. The article (which may be referred to herein as an
aerosol
generating article, a cartridge or a consumable) may be adapted for use in a
THP, an
electronic tobacco hybrid device or another aerosol generating device. In some
cases,
the article may additionally comprise a filter and/or cooling element (which
have been
described above). In some cases, the aerosol generating article may be
circumscribed
by a wrapping material such as paper.
The aerosol generating article may additionally comprise ventilation
apertures.
These may be provided in the sidewall of the article. In some cases, the
ventilation
apertures may be provided in the filter and/or cooling element. These
apertures may
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allow cool air to be drawn into the article during use, which can mix with the
heated
volatilised components thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised
components from the article when it is heated in use. The heated volatilised
components are made visible by the process of cooling the heated volatilised
components such that supersaturation of the heated volatilised components
occurs. The
heated volatilised components then undergo droplet formation, otherwise known
as
nucleation, and eventually the size of the aerosol particles of the heated
volatilised
components increases by further condensation of the heated volatilised
components and
by coagulation of newly formed droplets from the heated volatilised
components.
In some cases, the ratio of the cool air to the sum of the heated volatilised
components and the cool air, known as the ventilation ratio, is at least 15%.
A
ventilation ratio of 15% enables the heated volatilised components to be made
visible
by the method described above. The visibility of the heated volatilised
components
enables the user to identify that the volatilised components have been
generated and
adds to the sensory experience of the smoking experience.
In another example, the ventilation ratio is between 50% and 85% to provide
additional cooling to the heated volatilised components. In some cases, the
ventilation
ratio may be at least 60% or 65%.
In some cases, the aerosol generating material may be included in the
article/assembly in sheet form. In some cases, the aerosol generating material
may be
included as a planar sheet. In some cases, the aerosol generating material may
be
included as a planar sheet, as a bunched or gathered sheet, as a crimped
sheet, or as a
rolled sheet (i.e. in the form of a tube). In some such cases, the amorphous
solid of these
embodiments may be included in an aerosol generating article/assembly as a
sheet, such
as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco). In
some other
cases, the aerosol generating material may be formed as a sheet and then
shredded and
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incorporated into the article. In some cases, the shredded sheet may be mixed
with cut
rag tobacco and incorporated into the article.
In some examples, the amorphous solid in sheet form may have a tensile
5 strength of from around 200 N/m to around 900 N/m. In some examples, such
as where
the amorphous solid does not comprise a filler, the amorphous solid may have a
tensile
strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.
Such
tensile strengths may be particularly suitable for embodiments wherein the
aerosol
generating material is formed as a sheet and then shredded and incorporated
into an
10 aerosol generating article. In some examples, such as where the
amorphous solid
comprises a filler, the amorphous solid may have a tensile strength of from
600 N/m to
900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths
may
be particularly suitable for embodiments wherein the aerosol generating
material is
included in an aerosol generating article/assembly as a rolled sheet, suitably
in the form
15 of a tube.
Referring to Figures 2 and 3, there are shown a partially cut-away section
view
and a perspective view of an example of an aerosol generating article 101. 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 6 to 8, described below. In use, the article 101 may be removably
inserted into
the device shown in Figure 6 at an insertion point 20 of the 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 a 0.2mm thick layer
of
aerosol-forming amorphous solid. In the illustrated embodiment, the aerosol
generating
material has been incorporated as a rolled sheet (i.e. in tube form). In other
embodiments, the aerosol generating material may be incorporated in other
forms as
described above, including without limitation, as a flat sheet, as a bunched
or gathered
sheet, as a crimped sheet or in shredded form.
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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 end or a proximal end and a second end 115, also known as a
distal
end. The body of aerosol generating material 103 is located towards the distal
end 115
of the article 101. In one example, the cooling segment 107 is located
adjacent the body
of aerosol generating material 103 between the body of aerosol generating
material 103
and the filter segment 109, such that the cooling segment 107 is in an
abutting
relationship with the aerosol generating material 103 and the filter segment
103. In
other examples, there may be a separation between the body of aerosol
generating
material 103 and the cooling segment 107 and between the body of aerosol
generating
material 103 and the filter segment 109. The filter segment 109 is located in
between
the cooling segment 107 and the mouth end segment 111. The mouth end segment
111
is located towards the proximal end 113 of the article 101, adjacent the
filter segment
109. In one example, the filter segment 109 is in an abutting relationship
with the mouth
end segment 111. In one embodiment, the total length of the filter assembly
105 is
between 37mm and 45mm, more preferably, the total length of the filter
assembly 105
is 41mm.
In one example, the rod of aerosol generating material 103 is between 34mm
and 50mm in length, suitably between 38mm and 46mm in length, suitably 42mm in
length.
In one example, the total length of the article 101 is between 71mm and 95mm,
suitably between 79mm and 87mm, suitably 83mm.
An axial end of the body of aerosol generating material 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) covering the axial end
of the
body of aerosol generating material 103.
The body of aerosol generating material 103 is joined to the filter assembly
105
by annular tipping paper (not shown), which is located substantially around
the
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circumference of the filter assembly 105 to surround the filter assembly 105
and extends
partially along the length of the body of aerosol generating material 103. In
one
example, the tipping paper is made of 58GSM standard tipping base paper. In
one
example the tipping paper has a length of between 42mm and 50mm, suitably of
46mm.
In one example, the cooling segment 107 is an annular tube and is located
around and defines an air gap within the cooling segment. The air gap provides
a
chamber for heated volatilised components generated from the body of aerosol
generating material 103 to flow. The cooling segment 107 is hollow to provide
a
chamber for aerosol accumulation yet rigid enough to withstand axial
compressive
forces and bending moments that might arise during manufacture and whilst the
article
101 is in use during insertion into the device 51. In one example, the
thickness of the
wall 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 across the length
of 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
volatilised
component entering a first end of the cooling segment 107 and a heated
volatilised
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 volatilised component entering a first end of
the
cooling segment 107 and a heated volatilised component exiting a second end of
the
cooling segment 107. This temperature differential across the length of the
cooling
element 107 protects the temperature sensitive filter segment 109 from the
high
temperatures of the aerosol generating material 103 when it is heated by the
device 51.
If the physical displacement was not provided between the filter segment 109
and the
body of aerosol generating material 103 and the heating elements of the device
51, then
the temperature sensitive filter segment may 109 become damaged in use, so it
would
not perform its required functions as effectively.
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In one example the length of the cooling segment 107 is at least 15mm. In one
example, the length of the cooling segment 107 is between 20mm and 30mm, more
particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.
The cooling segment 107 is made of paper, which means that it is comprised of
a material that does not generate compounds of concern, for example, toxic
compounds
when in use adjacent to the heater of the device 51. In one example, the
cooling segment
107 is manufactured from a spirally wound paper tube which provides a hollow
internal
chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able
to meet
the tight dimensional accuracy requirements of high-speed manufacturing
processes
with respect to tube length, outer diameter, roundness and straightness.
In another example, the cooling segment 107 is a recess created from stiff
plug
wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to
have a
rigidity that is sufficient to withstand the axial compressive forces and
bending
moments that might arise during manufacture and whilst the article 101 is in
use during
insertion into the device 51.
The filter segment 109 may be formed of any filter material sufficient to
remove
one or more volatilised compounds from heated volatilised components from the
aerosol generating material. In one example the filter segment 109 is made of
a mono-
acetate material, such as cellulose acetate. The filter segment 109 provides
cooling and
irritation-reduction from the heated volatilised components without depleting
the
quantity of the heated volatilised components to an unsatisfactory level for a
user.
In some embodiments, a capsule (not illustrated) may be provided in filter
segment 109. It may be disposed substantially centrally in the filter segment
109, both
across the filter segment 109 diameter and along the filter segment 109
length. In other
cases, it may be offset in one or more dimension. The capsule may in some
cases,
where present, contain a volatile component such as a flavourant or aerosol
generating
agent.
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The density of the cellulose acetate tow material of the filter segment 109
controls the pressure drop across the filter segment 109, which in turn
controls the draw
resistance of the article 101. Therefore the selection of the material of the
filter segment
109 is important in controlling the resistance to draw of the article 101. In
addition, the
filter segment performs a filtration function in the article 101.
In one example, the filter segment 109 is made of a 8Y15 grade of filter tow
material, which provides a filtration effect on the heated volatilised
material, whilst also
reducing the size of condensed aerosol droplets which result from the heated
volatilised
material.
The presence ofthe filter segment 109 provides an insulating effect by
providing
further cooling to the heated volatilised components that exit the cooling
segment 107.
This further 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 6mm to lOmm in length,
suitably 8mm.
The mouth end segment 111 is an annular tube and is located around and defines
an air gap within the mouth end segment 111. The air gap provides a chamber
for
heated volatilised components that flow from the filter segment 109. The mouth
end
segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid
enough
to withstand axial compressive forces and bending moments that might arise
during
manufacture and whilst the article is in use during insertion into the device
51. In one
example, the thickness of the wall of the mouth end segment 111 is
approximately
0.29mm. In one example, the length of the mouth end segment 111 is between 6mm
to lOmm, suitably 8mm.
The mouth end segment 111 may be manufactured from a spirally wound paper
tube which provides a hollow internal chamber yet maintains critical
mechanical
rigidity. Spirally wound paper tubes are able to meet the tight dimensional
accuracy
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requirements of high-speed manufacturing processes with respect to tube
length, outer
diameter, roundness and straightness.
The mouth end segment 111 provides the function of preventing any liquid
5 condensate that accumulates at the exit 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 of a single tube and the filter segment
109 is
10 located within that tube separating the mouth end segment 111 and the
cooling segment
107.
Referring to Figures 4 and 5, there are shown a partially cut-away section and
perspective views of an example of an article 301. The reference signs shown
in Figures
15 4 and 5 are equivalent to the reference signs shown in Figures 2 and 3,
but with an
increment of 200.
In the example of the article 301 shown in Figures 4 and 5, a ventilation
region
317 is provided in the article 301 to enable air to flow into the interior of
the article 301
20 from the exterior of the article 301. In one example the ventilation
region 317 takes the
form of one or more ventilation holes 317 formed through the outer layer of
the article
301. The ventilation holes may be located in the cooling segment 307 to aid
with the
cooling of the article 301. In one example, the ventilation 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 one example, there are between one to four rows of ventilation holes to
provide ventilation for the article 301. Each row of ventilation holes may
have between
12 to 36 ventilation holes 317. The ventilation holes 317 may, for example, be
between
100 to 500 m in diameter. In one example, an axial separation between rows of
ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.
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In one example, the ventilation holes 317 are of uniform size. In another
example, the ventilation holes 317 vary in size. The ventilation holes can be
made using
any suitable technique, for example, one or more of the following techniques:
laser
technology, mechanical perforation of the cooling segment 307 or pre-
perforation of
the cooling segment 307 before it is formed into the article 301. The
ventilation holes
317 are positioned so as to provide effective cooling to the article 301.
In one example, the rows of ventilation holes 317 are located at least 1 lmm
.. from the proximal end 313 of the article, suitably between 17mm and 20mm
from the
proximal end 313 of the article 301. The location of the ventilation holes 317
is
positioned such that user does not block the ventilation holes 317 when the
article 301
is in use.
Providing the rows of ventilation holes between 17mm and 20mm from the
proximal end 313 of the article 301 enables the ventilation holes 317 to be
located
outside of the device 51, when the article 301 is fully inserted in the device
51, as can
be seen in Figures 7 and 8. By locating the ventilation holes outside of the
device, non-
heated air is able to enter the article 301 through the ventilation holes from
outside the
device 51 to aid with the cooling of the article 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 article 301 is fully
inserted into the
device 51. The length of the cooling segment 307 provides a first function of
providing
a physical gap between the heater arrangement of the device 51 and the heat
sensitive
filter arrangement 309, and a second function of enabling the ventilation
holes 317 to
be located in the cooling segment, whilst also being located outside of the
device 51,
when the article 301 is fully inserted into the device 51. As can be seen from
Figures
7 and 8, 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 out of the
device
51. It is in this portion of the cooling element 307 that extends out of the
device 51 in
which the ventilation holes 317 are located.
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Referring now to Figures 6 to 8 in more detail, there is shown an example of a
device 51 arranged to heat aerosol generating material to volatilise at least
one
component of said aerosol generating material, typically to form an aerosol
which can
be inhaled. The device 51 is a heating device which 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 allow the device
51 as a
whole to be switched on and off as desired by a user.
The device 51 comprises a housing 59 for locating and protecting various
internal components of the device 51. In the example shown, the housing 59
comprises
a uni-body sleeve 11 that encompasses the perimeter of the device 51, capped
with a
top panel 17 which defines generally the 'top' of the device 51 and a bottom
panel 19
which defines generally the 'bottom' of the device 51. In another example the
housing
comprises a front panel, a rear panel and a pair of opposite side panels in
addition to
the top panel 17 and the bottom panel 19.
The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-
body sleeve 11, to permit easy access to the interior of the device 51, or may
be
"permanently" fixed to the uni-body sleeve 11, for example to deter a user
from
accessing the interior of the device 51. In an example, the panels 17 and 19
are made
of a plastics material, including for example glass-filled nylon formed by
injection
moulding, and the uni-body sleeve 11 is made of aluminium, though other
materials
and other manufacturing processes may be used.
The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the
device 51 through which, in use, the article 101, 301 including the aerosol
generating
material may be inserted into the device 51 and removed from the device 51 by
a user.
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The housing 59 has located or fixed therein a heater arrangement 23, control
circuitry 25 and a power source 27. In this example, the heater arrangement
23, the
control circuitry 25 and the power source 27 are laterally adjacent (that is,
adjacent
when viewed from an end), with the control circuitry 25 being located
generally
between the heater arrangement 23 and the power source 27, though other
locations are
possible.
The control circuitry 25 may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the aerosol
generating
material in the article 101, 301 as discussed further 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 required and under control of
the
control circuitry 25 to heat the aerosol generating material in the article
(as discussed,
to volatilise 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 may be used without
causing
the device 51 as a whole to be unduly lengthy. As will be understood, in
general a
physically large power source 25 has a higher capacity (that is, the total
electrical energy
that can be supplied, often measured in Amp-hours or the like) and thus the
battery life
for the device 51 can 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 in use.
Different
arrangements for the heater arrangement 23 are possible. For example, the
heater
arrangement 23 may comprise a single heating element or may be formed of
plural
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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 part-annular or
part-
tubular around its circumference. In an 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
ceramics material. Examples of suitable ceramics materials include alumina and
aluminium nitride and silicon nitride ceramics, which may be laminated and
sintered.
Other heating arrangements are possible, including for example inductive
heating,
infrared heater elements, which heat by emitting infrared radiation, or
resistive heating
elements formed by for example a resistive electrical winding.
In one 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 dimensioned so that substantially the whole of the body of aerosol
generating
material 103, 303 of the article 101, 301 is inserted into the heater
arrangement 23 when
the article 101, 301 is inserted into the device 51.
The or each heating element may be arranged so that selected zones of the
aerosol generating material can be independently heated, for example in turn
(over time,
as discussed above) or together (simultaneously) as desired.
The heater arrangement 23 in this example is surrounded along at least part of
its length by a thermal insulator 31. The insulator 31 helps to reduce heat
passing from
the heater arrangement 23 to the exterior of the device 51. This helps to keep
down the
power requirements for the heater arrangement 23 as it reduces heat losses
generally.
The insulator 31 also helps to 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 which provides a low pressure region between the two walls of the
sleeve. That
is, the insulator 31 may be for example a "vacuum" tube, i.e. a tube that has
been at
least partially evacuated so as to minimise heat transfer by conduction and/or
convection. Other arrangements for the insulator 31 are possible, including
using heat
insulating materials, including for example a suitable foam-type material, in
addition to
or instead of a double-walled sleeve.
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The housing 59 may further comprises various internal support structures 37
for
supporting all internal components, as well as the heating arrangement 23.
5 The
device 51 further comprises a collar 33 which extends around and projects
from the opening 20 into the interior of the housing 59 and a generally
tubular chamber
which is located between the collar 33 and one end of the vacuum sleeve 31.
The
chamber 35 further comprises a cooling structure 35f, which in this example,
comprises
a plurality of cooling fins 35f spaced apart along the outer surface of the
chamber 35,
10 and
each arranged circumferentially around outer surface of the chamber 35. There
is
an air gap 36 between the hollow chamber 35 and the article 101, 301 when it
is inserted
in the device 51 over at least part of the length of the hollow chamber 35.
The air gap
36 is around all of the 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 which project into the opening 20.
The
ridges 60 take up space within the opening 20 such that the open span of the
opening
at the locations of the ridges 60 is less than the open span of the opening 20
at the
20
locations without the ridges 60. The ridges 60 are configured to engage with
an article
101, 301 inserted into the device to assist in securing it within the device
51. Open
spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and
the article
101, 301 form ventilation paths around the exterior of the article 101, 301.
These
ventilation paths allow hot vapours that have escaped from the article 101,
301 to exit
the device 51 and allow cooling air to flow into the device 51 around the
article 101,
301 in the air gap 36.
In operation, the article 101, 301 is removably inserted into an insertion
point
20 of the device 51, as shown in Figures 6 to 8. Referring particularly to
Figure 7, in
one example, the body of aerosol generating material 103, 303, which is
located towards
the distal end 115, 315 of the article 101, 301, is entirely received within
the heater
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arrangement 23 of the device 51. The proximal end 113, 313 of the 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
volatilise
at least one component of the aerosol generating material from the body of
aerosol
generating material 103, 303.
The primary flow path for the heated volatilised components from the body of
aerosol generating material 103, 303 is axially through the article 101, 301,
through the
chamber inside the cooling segment 107, 307, through the filter segment 109,
309,
through the mouth end segment 111, 313 to the user. In the illustrated
example, the
flow path also passes through the tube formed by the rolled aerosol generating
material
103, 303.
In one example, the temperature of the heated volatilised components that are
generated from the body of aerosol generating material is between 60 C and 250
C,
which may be above the acceptable inhalation temperature for a user. As the
heated
volatilised component travels through the cooling segment 107, 307, it will
cool and
some volatilised components will condense on the inner surface of the cooling
segment
107, 307.
In the examples of the article 301 shown in Figures 4 and 5, cool air will be
able
to enter the cooling segment 307 via the ventilation holes 317 formed in the
cooling
segment 307. This cool air will mix with the heated volatilised components to
provide
additional cooling to the heated volatilised components.
METHOD OF MANUFACTURE
A fourth aspect of the invention provides a method of making an aerosol
generating material according to the first aspect.
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The method may comprise (a) forming a slurry comprising components of the
amorphous solid or precursors thereof, (b) forming a layer of the slurry, and
(c) setting
the slurry to form a gel and (d) drying to form an amorphous solid.
The step (b) of forming a layer of the slurry may comprise spraying, casting
or
extruding the slurry, for example. In some cases, the layer is formed by
electrospraying
the slurry. In some cases, the layer is formed by casting the slurry.
In some cases, the slurry is applied to a carrier.
In some examples, the slurry has a viscosity of from about 10 to about 20 Pas
at 46.5 C, such as from about 14 to about 16 Pas at 46.5 C.
In some cases, the steps (b) and/or (c) and/or (d) may, at least partially,
occur
simultaneously (for example, during electrospraying). In some cases, these
steps may
occur sequentially.
The step (c) of setting the gel may comprise the addition of a setting agent
to
the slurry. For example, the slurry may comprise sodium, potassium or ammonium
alginate as a gel-precursor, 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 0.5-
5wt% (calculated on a dry weight basis). The inventors have found that the
addition of
too little setting agent may result in an amorphous solid which does not
stabilise the
amorphous solid components and results in these components dropping out of the
amorphous solid. The inventors have found that the addition of too much
setting agent
results in an amorphous solid that is very tacky 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 I3-D-mannuronic
(M)
and a-L-guluronic acid (G) units (blocks) linked together with (1,4)-
glycosidic bonds
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to form a polysaccharide. On addition of calcium cations, the alginate
crosslinks to
form a gel. The inventors have determined that alginate salts with a high G
monomer
content more readily form a gel on addition of the calcium source. In some
cases
therefore, the gel-precursor may comprise an alginate salt in which at least
about 40%,
45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-
L-
guluronic acid (G) units.
The drying step may cause the cast material thickness to reduce by at least
80%,
suitably 85% or 87%. For instance, the slurry may be cast at a thickness of
2mm, and
the resulting dried amorphous solid material may have a thickness of 0.2mm.
The slurry itself may also form part of the invention. In some cases, the
slurry
solvent may consist essentially of or consist of water. In some cases, the
slurry may
comprise from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
In cases where the solvent consists of water, the dry weight content of the
slurry
may match the dry weight content of the amorphous solid. Thus, the discussion
herein
relating to the solid composition is explicitly disclosed in combination with
the slurry
aspect of the invention.
EXEMPLARY EMBODIMENTS
In some embodiments, the amorphous solid comprises menthol.
Particular embodiments comprising a menthol-containing amorphous solid may
be particularly suitable for including in an aerosol generating
article/assembly as a
shredded sheet. 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 from about
20wt% to
about 40wt%, or about 25wt% to 35wt%; menthol in an amount of from about 35wt%
to about 60wt%, or from about 40wt% to 55wt%; aerosol generating agent
(preferably
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comprising glycerol) in an amount of from about lOwt% to about 30wt%, or from
about
15wt% to about 25wt% (DWB).
In one embodiment, the amorphous solid comprises about 32-33wt% of an
alginate/pectin gelling agent blend; about 47-48wt% menthol flavourant; and
about 19-
20wt% glycerol aerosol generating agent (DWB).
As noted above, the amorphous solid of these embodiments may be included in
an aerosol generating article/assembly as a shredded sheet. The shredded sheet
may be
provided in the article/assembly blended with cut tobacco. Alternatively, the
amorphous solid may be provided as a non-shredded sheet. Suitably, the
shredded or
non-shredded sheet has a thickness of from about 0.015mm to about lmm,
preferably
from about 0.02mm to about 0.07mm.
Particular embodiments of the menthol-containing amorphous solid may be
particularly suitable for including in an aerosol generating article/assembly
as a sheet,
such as a sheet circumscribing a rod of aerosolisable 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 from about 5wt% to about
40wt%,
or about lOwt% to 30wt%; menthol in an amount of from about lOwt% to about
50wt%,
or from about 15wt% to 40wt%; aerosol generating agent (preferably comprising
glycerol) in an amount of from about 5wt% to about 40wt%, or from about lOwt%
to
about 35wt%; and optionally filler in an amount of up to 60wt% - for example,
in an
amount of from 5wt% to 20wt%, or from about 40wt% to 60wt% (DWB).
In one of these embodiments, the amorphous solid comprises about 1 lwt% of
an alginate/pectin gelling agent blend, about 56wt% woodpulp filler, about 18%
menthol flavourant and about 15wt% glycerol (DWB).
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In another of these embodiments, the amorphous solid comprises about 22wt%
of an alginate/pectin gelling agent blend, about 12wt% woodpulp filler, about
36%
menthol flavourant and about 30wt% glycerol (DWB).
5 As
noted above, the amorphous solid of these embodiments may be included as
a sheet. In one embodiment, the sheet is provided on a carrier comprising
paper. In one
embodiment, the sheet is provided on a carrier comprising metal foil, suitably
aluminium metal foil. In this embodiment, the amorphous solid may abut the
metal foil.
10 In one
embodiment, the sheet forms part of a laminate material with a layer
(preferably comprising paper) attached to a top and bottom surface of the
sheet.
Suitably, the sheet of amorphous solid has a thickness of from about 0.015mm
to about
lmm.
15 In some
embodiments, the amorphous solid comprises a flavourant which does
not comprise menthol. In these embodiments, the amorphous solid may have the
following composition (DWB): gelling agent (preferably comprising alginate) in
an
amount of from about 5 to about 40wt%, or from about lOwt% to about 35wt%, or
from
about 20wt% to about 35wt%; flavourant in an amount of from about 0. lwt% to
about
20 40wt%,
of from about lwt% to about 30wt%, or from about lwt% to about 20wt%, or
from about 5wt% to about 20wt%; aerosol generating agent (preferably
comprising
glycerol) in an amount of from 15wt% to 75wt%, or from about 30wt% to about
70wt%,
or from about 50wt% to about 65wt%; and optionally filler (suitably woodpulp)
in an
amount of less than about 60wt%, or about 20wt%, or about 1 Owt%, or about
5wt%
25 (preferably the amorphous solid does not comprise filler) (DWB).
In one of these embodiments, the amorphous solid comprises about 27wt%
alginate gelling agent, about 14wt% flavourant and about 57wt% glycerol
aerosol
generating agent (DWB).
In another of these embodiments, the amorphous solid comprises about 29wt%
alginate gelling agent, about 9wt% flavourant and about 60wt% glycerol (DWB).
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The amorphous solid of these embodiments may be included in an aerosol
generating article/assembly as a shredded sheet, optionally blended with cut
tobacco.
Alternatively, the amorphous solid of these embodiments may be included in an
aerosol
generating article/assembly as a sheet, such as a sheet circumscribing a rod
of
aerosolisable material (e.g. tobacco). Alternatively, the amorphous solid of
these
embodiments may be included in an aerosol generating article/assembly as a
layer
portion disposed on a carrier.
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 from about 5wt%
to
about 40wt%, or about 1 Owt% to 30wt%, or about 15wt% to about 25wt%; tobacco
extract in an amount of from about 30wt% to about 60wt%, or from about 40wt%
to
55wt%, or from about 45wt% to about 50wt%; aerosol generating agent
(preferably
comprising glycerol) in an amount of from about lOwt% to about 50wt%, or from
about
20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).
In one embodiment, the amorphous solid comprises about 20wt% alginate
gelling agent, about 48wt% Virginia tobacco extract and about 32wt% 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 from
about
5wt% to about 15wt%, or from about 7wt% to about 13wt%, or about lOwt%.
The amorphous solid of these embodiments may be included in an aerosol
generating article/assembly as a shredded sheet, optionally blended with cut
tobacco.
Alternatively, the amorphous solid of these embodiments may be included in an
aerosol
generating article/assembly as a sheet, such as a sheet circumscribing a rod
of
aerosolisable material (e.g. tobacco). Alternatively, the amorphous solid of
these
embodiments may be included in an aerosol generating article/assembly as a
layer
portion disposed on a carrier. Suitably, in any of these embodiments, the
amorphous
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solid has a thickness of from about 50 gm to about 200 gm, or about 50 gm to
about
100 gm, or about 60 gm to about 90 gm, suitably about 77 gm.
The slurry for forming this amorphous solid may also form part of the
invention.
In some cases, the slurry may have an elastic modulus of from about 5 to 1200
Pa (also
referred to as storage modulus); in some cases, the slurry may have a viscous
modulus
of about 5 to 600 Pa (also referred to as 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 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 tobacco, cannabis or another botanical.
In some embodiments, the active substance comprises nicotine.
In some embodiments, the active substance comprises caffeine, melatonin or
vitamin B12.
As noted herein, the active substance may comprise one or more constituents,
derivatives or extracts of cannabis, such as one or more cannabinoids or
terpenes.
Cannabinoids are a class of natural or synthetic chemical compounds which act
on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress
neurotransmitter
release in the brain. Cannabinoids may be naturally occurring
(phytocannabinoids)
from plants such as cannabis, from animals (endocannabinoids), or artificially
manufactured (synthetic cannabinoids). Cannabis species express at least 85
different
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phytocannabinoids, and are divided into subclasses, including cannabigerols,
cannabichromenes, cannabidio ls, tetrahydrocannabino
ls, cannabino ls and
cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis
include,
without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol
(CBD),
tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL),
cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV),
cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid
(CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO),
tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).
As noted herein, the active substance may comprise or be derived from one or
more botanicals 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, fibres, stems, roots, seeds, flowers, fruits,
pollen, husk, shells
or the like. Alternatively, the material may comprise an active compound
naturally
existing in a botanical, obtained synthetically. The material may be in the
form of liquid,
gas, solid, powder, dust, crushed particles, granules, pellets, shreds,
strips, sheets, or the
like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa,
cannabis,
fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger,
ginkgo
biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange
skin, papaya,
rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon,
coffee, aniseed
(anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano,
paprika,
rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla,
wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,
bergamot,
orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,
olive,
lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry,
ginseng,
theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab
or any
combination thereof The mint may be chosen from the following mint varieties:
Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita
citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia,
Mentha
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longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v.
and
Mentha suaveolens.
In some embodiments, the botanical is selected from eucalyptus, star anise,
cocoa and hemp.
In some embodiments, the botanical is selected from rooibos and fennel.
As used herein, the terms "flavour" and "flavourant" refer to materials which,
where local regulations permit, may be used to create a desired taste, aroma
or other
somatosensorial sensation in a product for adult consumers. They may include
naturally
occurring flavour materials, botanicals, extracts of botanicals, synthetically
obtained
materials, or combinations thereof (e.g., tobacco, cannabis, licorice
(liquorice),
hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek,
clove,
maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric,
Indian
spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry,
peach,
apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya,
rhubarb, grape,
durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie,
bourbon,
scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe
vera,
cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat,
naswar,
betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil,
orange
blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage,
fennel,
wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species
of the
genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo
biloba,
hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or
black tea, thyme,
juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,
saffron,
lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis,
valerian, pimento,
mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena,
tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor
site
blockers, sensorial receptor site activators or stimulators, sugars and/or
sugar
substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine,
cyclamates,
lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other
additives such as
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charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They
may be
imitation, synthetic or natural ingredients or blends thereof They may be in
any suitable
form, for example, liquid such as an oil, solid such as a powder, or gas.
5 The flavour may suitably comprise one or more mint-flavours suitably a
mint
oil from any species of the genus Mentha. The flavour may suitably comprise,
consist
essentially of or consist of menthol.
In some embodiments, the flavour comprises menthol, spearmint and/or
10 peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
blueberry, citrus fruits and/or redberry.
In some embodiments, the flavour comprises eugenol.
In some embodiments, the flavour comprises flavour components extracted
15 from tobacco.
In some embodiments, the flavour comprises flavour components extracted
from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to
20 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,
25 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 vaporisation and/or the
condensation
30 of a gas to an inhalable solid and/or liquid aerosol.
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Suitable aerosol generating agents include, but are not limited to: a polyol
such
as erythritol, sorbitol, glycerol, and glycols like propylene glycol or
triethylene glycol;
a non-polyol such as monohydric alcohols, high boiling point 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 aliphatic carboxylic acid esters 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 therefore. The term "tobacco material" may include one
or more
of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or
tobacco
substitutes. The tobacco material may comprise one or more of ground tobacco,
tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted
tobacco and/or
tobacco extract.
The tobacco used to produce tobacco material may be any suitable tobacco, such
as single grades or blends, cut rag or whole leaf, including Virginia and/or
Burley and/or
Oriental. It may also be tobacco particle 'fines' or dust, expanded tobacco,
stems,
expanded stems, and other processed stem materials, such as cut rolled stems.
The
tobacco material may be a ground tobacco or a reconstituted tobacco material.
The
reconstituted tobacco material may comprise tobacco fibres, and may be formed
by
casting, a Fourdrinier-based paper making-type approach with back addition of
tobacco
extract, or by extrusion.
All percentages by weight described herein (denoted wt%) are calculated on a
dry weight basis, unless explicitly stated otherwise. All weight ratios are
also calculated
on a dry weight basis. A weight quoted on a dry weight basis refers to the
whole of the
extract or slurry or material, other than the water, and may include
components which
by themselves are liquid at room temperature and pressure, such as glycerol.
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Conversely, a weight percentage quoted on a wet weight basis refers to all
components,
including water.
For the avoidance of doubt, where in this specification the term "comprises"
is
used in defining the invention or features of the invention, embodiments are
also
disclosed in which the invention or feature can be defined using the terms
"consists
essentially of' or "consists of' in place of "comprises". Reference to a
material
"comprising" certain features means that those features are included in,
contained in,
or held within the material.
The above embodiments are to be understood as illustrative examples of
the invention. It is to be understood that any feature described in relation
to any one
embodiment may be used alone, or in combination with other features described,
and
may also be used in combination with one or more features of any other of the
embodiments, or any combination of any other of the embodiments. Furthermore,
equivalents and modifications not described above may also be employed without
departing from the scope ofthe invention, which is defined in the accompanying
claims.
