Note: Descriptions are shown in the official language in which they were submitted.
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1
AEROSOL GENERATION
Technical Field
5
The present invention relates to a method of
making an amorphous solid, the
amorphous solid obtainable or obtained by said method, and articles and non-
combustible aerosol-provision systems incorporating said amorphous solid.
Background
10
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 or similar.
One example of such a product is a heating device which release compounds by
heating, but not burning, a solid aerosol-generating material. This solid
aerosol-
generating material may, in some cases, contain a tobacco material. The
heating
volatilises at least one component of the material, typically forming an
inhalable
20
aerosol. These products may be referred to as
heat-not-bum devices, tobacco heating
devices or tobacco heating products. Various different arrangements for
volatilising at
least one component of the solid aerosol-generating material are known.
As another example, there are hybrid devices. These hybrid devices contain a
25
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
aerosol-generating 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.
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Summary
A first aspect of the invention provides a method of making an amorphous solid
comprising:
(a) forming a slurry comprising:
5 -0.5-60 wt% of a gelling agent; and
- 5-80 wt% of an aerosol forming material;
- 0-60 wt% of an active constituent and/or flavourant;
wherein these weights are calculated on a dry weight basis;
(b) shaping the slurry;
10 (c) applying a setting agent to a surface of the slurry so that
the slurry sets to
form a gel; and
(d) drying the gel to form an amorphous solid;
wherein the amorphous solid has a substantially constant concentration of
setting agent throughout.
The inventors have established that ensuring that the setting agent is
distributed
evenly through the amorphous solid results in a homogenous solid with a
consistent
release profile on heating.
20 A second aspect of the invention provides an amorphous solid
obtainable or
obtained by methods of the first aspect.
A third aspect of the invention provides an amorphous solid comprising:
- 0.5-60 wt% of a gelling agent;
25 - 5-80 wt% of an aerosol forming material;
- a setting agent; and
- 0-60 wt% of an active constituent and/or flavourant;
wherein these weights are calculated on a dry weight basis;
wherein the amorphous solid has a substantially constant concentration of
30 setting agent throughout.
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A fourth of the invention provides an article for use in a non-combustible
aerosol provision system, the article comprising an amorphous solid according
to the
second or third aspect. Such articles may also be referred to herein as
aerosol-
generating articles.
A fifth aspect of the invention provides a non-combustible aerosol provision
system comprising the article according to the fourth aspect and a non-
combustible
aerosol provision device, the non-combustible aerosol provision device
comprising an
aerosol-generation device to generate aerosol from the article when the
article is used
with the non-combustible aerosol provision device In some cases, the device
may
comprise a heater which heats the amorphous solid, without burning. The system
may
also be referred to herein as an aerosol generating assembly.
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 shows a section view of an example of an article.
Figure 2 shows a perspective view of the article of Figure 1.
Figure 3 shows a sectional elevation of an example of an article.
Figure 4 shows a perspective view of the article of Figure 3.
Figure 5 shows a perspective view of an example of a non-combustion aerosol
provision system
Figure 6 shows a section view of an example of a non-combustion aerosol
provision system.
Figure 7 shows a perspective view of an example of a non-combustion aerosol
provision system.
Figure 8a shows an elemental map showing calcium distribution through an
amorphous solid obtained by methods according to the invention, wherein the
amorphous solid comprises a gelling agent, the gelling agent comprising
alginate and
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pectin. The amorphous solid extends across the full width of the figure and is
in the
vertical section of the image marked between the double-headed arrow at the
right-hand
edge. The white marks indicate calcium sites.
Figure 8b shows an elemental map showing calcium distribution through an
5 amorphous solid obtained by methods according to the invention, wherein
the
amorphous solid comprises alginate as the gelling agent. The amorphous solid
extends
across the full width of the figure and is in the vertical section of the
image marked
between the double-headed arrow at the right-hand edge. The white marks
indicate
calcium sites.
Detailed Description
The method described herein generates an "amorphous solid", which may
alternatively be referred to as a "monolithic solid" (i.e+ non-fibrous), or as
a "dried gel".
15 The amorphous solid is a solid material that may retain some fluid, such
as liquid, within
it.
As described above, the invention provides a method of making an amorphous
solid comprising:
20 (a) forming a slurry comprising:
- 0.5-60 wt% of a gelling agent; and
- 5-80 wt% of an aerosol forming material;
- 0-60 wt% of an active constituent and/or flavourant;
wherein these weights are calculated on a dry weight basis;
25 (b) shaping the slurry;
(c) applying a setting agent to a surface of the slurry so that the slurry
sets to
form a gel; and
(d) drying the gel to form an amorphous solid;
wherein the amorphous solid has a substantially constant concentration of
30 setting agent throughout.
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Surprisingly, the inventors have found that even though the setting agent is
applied to the slurry surface in step (c) and thereby initiates setting of the
slurry at that
surface, the setting agent is nevertheless found distributed evenly through
the resulting
5
amorphous solid. No mixing is required to
achieve this even distribution; the setting
agent appears to be absorbed by the slurry and results in an even
distribution.
By "substantially constant" it is meant that the amount of setting agent per
cubic
millimetre in the amorphous solid varies throughout the solid by no more than
40% of
10
the mean amount of setting agent per cubic
millimetre, suitably by no more than 30%,
20% or 15%.
In some cases, the setting agent is applied to the slurry by spraying onto a
surface thereof
In some cases, the setting agent comprises calcium. In some cases, the setting
agent is a calcium source which includes Ca' cations and one or more
counterions.
The one or more counterions are anionic.
20
In some cases, the total amount of setting
agent added to the slurry may be from
0.5-5wt%, calculated on a dry weight basis. Suitably, the total amount may be
from
about lwt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5vvt%. 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
25
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.
When the amorphous solid does not contain tobacco, a higher amount of setting
30
agent may need to be applied. In some cases the
total amount of setting agent may
therefore be from 0.5-12wt% such as 5-10w0/0, calculated on a dry weight
basis.
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Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt%
or
10wt%. In this case the amorphous solid will not generally contain any
tobacco.
In some cases, the amount of setting agent applied depends on the solids
content
5 of the slurry. For a given slurry with a solids content of Xwt%
(calculated on a wet
weight basis), the amount of calcium added (mmol of calcium ions per kg of
slurry)
may suitably be in the range of from about 0.3X or 0.35X to about 0.45X or
0.4X. That
is, in some embodiments:
Solid Content of Moles calcium ions to add
Slurry (mmol/kg
of slurry)
(wt%, WWB)
6 2.331
8 3.106
3.888
12 4.663
5.813
In some cases, the shaping the slurry may comprise spraying, casting or
extruding the slurry, for example. In some cases, (b) may comprise forming a
layer of
the slurry. In some cases, the setting agent is applied to the slurry by
spraying it onto a
top surface of the layer. In some cases, the slurry layer is formed by casting
the slurry.
15 In some cases, shaping may simply be the act of arranging slurry in a
position ready for
gelling.
In some cases, the setting agent has an average molar mass of less than about
400 gruel. The inventors have identified that using a calcium source which has
a lower
20 average molar mass may mean that a smaller mass of setting agent can be
used in the
manufacturing process while maintaining a relatively high amount of Ca',
thereby
reducing manufacturing costs and/or processing issues.
In some embodiments, the setting agent may have an average molar mass of less
25 than about 300gmo1-1, or less than about 200 gmo1-1. In some
embodiments, the setting
agent may have an average molar mass of greater than about 80 gime, or greater
than
about 100 grnoti, or greater than about 120 grno1-1. In some embodiments, the
setting
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agent may have an average molar mass of from about 80 gime to about 400 gmo1-
1, or
from about 100 gmo1-1 to about 300 grad', or from about 120 gmo1-1 to about
200 grno1-1.
5 In some embodiments, each counterion present in the setting
agent has a molar
mass of less than about 250 gmott. The inventors have identified that using a
calcium
source wherein the counterion(s) has a smaller molar mass may allow for a
higher
effective Ca' concentration in the setting agent by mass. In some embodiments,
each
counterion present in the setting agent has a molar mass of less than about
150 gine',
10 or less than about 100 gmo14, or less than about 80 gmorl. In some
embodiments, each
counterion present in the setting agent has a molar mass of greater than about
30 gmorl,
or greater than about 40 gmo1-1. In some embodiments, each counterion present
in the
setting agent has a molar mass of from about 30 grno1-1 to 150 gmol-1, or from
about
40 gmorl to 150 gmol-1, or from about 40 gmott to about 100 gmol-1, or from
about 40
15 gmoti to about 80 gmo1-1.
As used herein, the molar mass of "each" counterion refers to the molar mass
of
1 equivalent anion to Ca". For example, where the empirical formula of a
setting agent
includes a plurality of anions, then the mass of "each" counterion refers to
the mass of
20 a single anion. For example, the empirical formula of calcium acetate is
Ca(C2H302)2:
the molar mass of each counterion is 59 gmo1-1, i.e. the molar mass of an
acetate anion
[C211302].
In some embodiments, Ca' is present in the setting agent in an amount of at
25 least 15wt% of the molar mass of Ca' ions and counterions of the setting
agent taken
together. The inventors have identified that a higher proportion of Ca' ions
in the
setting agent may mean that a smaller amount of setting agent may be used to
achieve
the same setting effect. In some embodiments, Ca' is present in the setting
agent in an
amount of at least about 25wt%. In some embodiments, Ca' is present in the
setting
30 agent in an amount of less than about 40wt%, or less than about 30wt%.
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In some embodiments, the one or more counterions of the setting agent comprise
acetate, formate, carbonate, hydrogencarbonate (also known as bicarbonate),
lactate,
chloride, citrate, or a combination thereof.
5 In some embodiments, the one or more counterions of the setting
agent comprise
acetate, formate, carbonate, hydrogencarbonate (also known as bicarbonate),
lactate,
chloride, or a combination thereof.
In some embodiments, the one or more counterions of the setting agent comprise
10 acetate, formate, carbonate, hydrogencarbonate (also known as
bicarbonate), lactate, or
a combination thereof
In some embodiments, the one or more counterions of the setting agent comprise
acetate, formate, hydrogencarbonate (also known as bicarbonate), lactate, or
15 combinations thereof
Suitably, the one or more counterions of the setting agent comprise acetate,
formate, hydrogencarbonate (also known as bicarbonate), or a combination
thereof In
these embodiments the setting agent may comprise calcium acetate, calcium
formate,
20 calcium hydrogencarbonate, or a combination thereof
In some embodiments the one or more counterions are composed of carbon,
oxygen and optionally hydrogen. In particular embodiments, the one or more
counterions are organic anions. The inventors have identified that using a
setting agent
25 which includes carbon-based counterions may provide an amorphous solid
which, when
heated, provides fewer undesirable components in the inhalable aerosol
produced
compared with amorphous solids which have been prepared with a setting agent
which
includes non-carbon-based counterions. In some embodiments, the one or more
counterions does not include chloride.
In one embodiment, the setting agent may be provided by combining a calcium
source with an acid (suitably a weak acid) to provide the setting agent. In
one
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embodiment, calcium carbonate is treated with a weak acid such as benzoic acid
or
lactic acid to provide calcium hydrogencarbonate (also known as bicarbonate).
This
embodiment uses a relatively inexpensive calcium source and converts it to a
more
soluble setting agent.
In some embodiments, the setting agent is supplied to the slurry in an aqueous
vehicle. For example, the setting agent may be provided in an aqueous setting
agent
suspension, and/or solution. Preferably, the setting agent has a solubility
such that at
least some of the setting agent is dissolved in an aqueous solvent.
In some embodiments, the setting agent has an aqueous solubility of greater
than
or equal to about 1 g/100mL at 20 C (i.e. 0.1 g/L at 20 C). In some
embodiments, the
setting agent has an aqueous solubility of greater than or equal to about 5
g/100mL at
C, or about 10 g/100mL at 20 C. In some embodiments, the setting agent has an
15 aqueous solubility of less than about 80 g/100mL at 20
C, or less than about 50
g/100mL at 20 C. The inventors have identified that using a setting agent
having a
higher solubility to prepare an amorphous solid may allow for better
application of the
setting agent to the slurry. On the other hand, using a setting agent with too
high a
solubility may result in reduced setting activity.
In some cases, the setting agent comprises calcium and is provided in an
aqueous solution, and wherein the calcium concentration in the aqueous
solution is
between about 0.2 and 0.8 mol.dm-3, suitably between about 0.3 and 0.7 mol.dm-
3,
suitably between about 0.4 and 0.6 mol.dm-3, suitably about 0.5 mol.dm-3.
The table below provides physical characteristics of a range of setting
agents.
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Setting Formula Molar Ca2+ Counterion Solubility
agent mass
wt% molar mass (g/100mL at
(gmo1-1)
(gmo1-1) 20 C)
Calcium Ca(C2H302)2 158
25% 59 34.7
acetate
Calcium Ca(CH002 130 31% 45
16.6
formate
Calcium CaCO3 100
40% 60 6.17x10
carbonate
Calcium Ca(CH03)2 162 25% 61
16.6
bicarbonate
Calcium Ca(C3H503)2 218
18% 89 ND
lactate
Calcium CaCl2 111
36% 35.5 74.5
chloride
Calcium Ca3(C611507)2 498
24% 189 0.095 (25 C)
citrate
In examples, the setting agent comprises or consists of calcium acetate,
calcium
formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride,
calcium
lactate, or a combination thereof In some examples, the setting agent
comprises or
5
consists of calcium formate and/or calcium
lactate. In particular examples, the setting
agent comprises or consists of calcium formate. The inventors have identified
that,
typically, employing calcium formate as a setting agent results in an
amorphous solid
having a greater tensile strength and greater resistance to elongation.
10
The temperature of the slurry when the setting
agent is applied may be in the
range of about 42 C to about 70 C. The temperature of the setting agent when
applied
to the slurry may be in the range of about 20 C to about 60 C.
In some cases, the setting agent is applied to the slurry and a period of up
to two
15
minutes occurs prior to beginning of the
drying. In some cases, the total time from
application of the setting agent to the end of the drying is from about 10 to
about 15
minutes.
In some cases, the drying comprises heating the gel to a temperature in the
range
20
of about 80 C to about 140 C for a period of
less than 60 minutes. (Note that these
temperatures are the conditions to which the gel is exposed rather than the
temperature
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which the gel reaches.) In some cases, (d) comprises flowing air over the gel,
wherein
the air temperature is in the range of about 80 C to about 140 C, for a period
of less
than 60 minutes. In some cases, the air flow speed is less than about 30m/s,
and is
suitably in the range of 10m/s to 30m/s. In some cases, the air flow speed is
about 20
5
m/s. In some cases, the second period comprises
flowing air of the gel for less than
about 40 minutes, 30 minutes or 20 minutes. In some cases, it comprises
heating the
gel for at least about 10 minutes. In some cases, the air temperature is in
the range of
about 80 C, 85 C or 90 C to about 130 C, 120 C or 110 C.
10
In some cases, (b) comprises shaping the slurry
on a thermally-conductive
support, and wherein the drying (d) comprises heating the thermally-conductive
support. In some cases, the support is heated to at least 100 C. In some such
cases, the
support is a metallic band.
15
In some cases, the drying (d) comprises (di)
heating the thermally-conductive
support to at least about 100 C, (dii) flowing air over the gel, wherein the
air
temperature is in the range of about 80 C to about 140 C, and (diii) heating
the
thermally-conductive support to at least about 100 C, wherein (di) and (dii)
occur
simultaneously or sequentially and (diii) occurs after (dii) has concluded. In
some
20
cases, there are three drying zones
corresponding to (di), (dii) and (diii), and the gel is
moved between the zones over time. In particular, the support material may be
a band
which is driven over rollers, thereby moving the gel between zones.
In some cases, the thermally-conductive support may be heated by contact with
25
hot air/steam, for example (where that air/steam
does not contact the gel). In other
cases, the thermally-conductive support may be such that it is heated on
application on
an electric current.
In some cases, the drying (d) may, in some cases, remove from about 50wr/o,
30
60wt%, 70wr/o, 80wt% or 90wt% to about 80wt%,
90wr/o or 95wt% (WWB) of water
in the slurry.
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In some cases, the resulting amorphous solid comprises from about hut% to
about 15wt% water, calculated on a wet weight basis. Suitably, the resulting
amorphous
solid comprises from about 5w0/0% to about 15wt% water, calculated on a wet
weight
basis (WWB). Suitably, the water content of the amorphous solid may be from
about
5
5w1%, 7wt% or 9-vvt% to about 15wr/o, 13wt% or 1
lwt% (WWB), most suitably about
lOwt%.
The inventors have established that the drying process is important as it
controls
the final water content of amorphous solid. In particular, if the water
content of the
10
amorphous solid is too high, its performance in
use is compromised. The high heat
capacity of water means that if the water content is too high, more energy is
needed to
generate an aerosol, reducing operating efficiency. Further, if the water
content is too
high, the puff profile may be less satisfactory to the consumer due to the
generation of
hot and humid puffs (a sensation known in the field as "hot puff"). Moreover,
if the
15
water content is too high, microbial growth may
occur. Conversely, if the water content
is too low, the material may be brittle and difficult to handle. The
hygroscopic nature
of the aerosol forming material may mean that water is drawn into the material
from
the atmosphere if the water content is too low, destabilising the material.
20
The inventors have also established that if the
drying process occurs too quickly,
the amorphous solid has been observed to crack. The aerosol generated from a
cracked
amorphous solid on heating is less consistent as compared to a solid that is
not cracked.
The drying process is therefore important as it affects the aerosol generation
and user
satisfaction.
Further, the inventors have established that if the drying temperature is too
high,
the content of desired components (e.g. the aerosol forming material, active
constituent
and/or flavourant) of the amorphous solid may be reduced beyond desired
levels.
30
Thus, there are a number of competing objectives
that must be balanced when
attempting to dry the gel to form an amorphous solid. The claimed processes
have been
found by the inventors to be particularly suitable.
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In some cases, the drying results in an amorphous solid which has a thickness
that is between about 5% and 20% of the slurry thickness, suitably about 10%.
In some
cases, the amorphous solid may have a thickness of about 0.015mm to about
1.0mm.
5 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 amorphous solid may comprise more than
one
layer, and the thickness described herein refers to the aggregate thickness of
those
layers.
In some cases, the method comprises forming a layer of the slurry which is
less
than about 4mm thick. Suitably, the thickness of the slurry layer is in the
range of about
1 mm to about 3mm, suitably about 1.5mm to about 2.5mm. In some cases, the
thickness of the slurry layer is about 2mm.
The inventors have found that if the slurry layer is too thick, it can be
difficult
to dry to form an amorphous solid with the required water content, whilst
minimising
cracking of the solid on drying.
20 The inventors have established that if the aerosol-forming
amorphous solid is
too thick, then heating efficiency is compromised. This adversely affects the
power
consumption in use. Conversely, if the aerosol-forming amorphous solid is too
thin, it
is difficult to manufacture and handle; a very thin material is harder to cast
and may be
fragile, compromising aerosol formation in use.
The inventors have established that the amorphous solid thicknesses stipulated
herein optimise the material properties in view of these competing
considerations.
Any thickness stipulated herein is a mean thickness. In some cases, the
30 thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.
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In some cases, the surface temperature of the gel during drying does not
exceed
about 100 C.
Alginate salts are derivatives of alginic acid and are typically high
molecular
5 weight polymers (10-600 kDa). Alginic acid is a copolymer of13-D-
mannuronic (M)
and a-L-guluronic acid (G) units (blocks) linked together with (1,4)-
glycosidic bonds
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
10 therefore, the slurry 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.
In some cases, a carrier is provided and in (b), the slurry is shaped on the
carrier.
15 The carrier functions as a support on which the amorphous solid layer
forms, easing
manufacture. The carrier may provide rigidity 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
20 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 comprises paper. In some cases, the carrier itself be a laminate
structure
25 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.
Suitably, the thickness of the carrier layer may be in the range of about
lOpm,
30 15pm, 17pm, 20pm, 23pm, 25pm, 50pm, 75pm or 0.1mm to about 2.5mm, 2.0mm,
1.5mm, 1.0mm or 0.5mm. The carrier may comprise more than one layer, and the
thickness described herein refers to the aggregate thickness of those layers.
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In some cases, the carrier may be non-magnetic.
In some cases, the carrier may be magnetic. This functionality may be used to
5 fasten the carrier to the assembly in use, or may be used to generate
particular
amorphous solid shapes. In some cases, the amorphous solid may comprise one or
more
magnets which can be used to fasten the solid to an induction heater in use.
In some cases, the carrier may be substantially or wholly impermeable to gas
10 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 a non-combustion aerosol provision system.
Thus,
consumption efficiency and hygiene can be improved in some cases.
In some cases, the surface of the carrier that abuts the amorphous solid may
be
porous. For example, in one case, the carrier comprises paper. The inventors
have
found that a porous carrier such as paper is particularly suitable for the
present
invention; the porous (e.g. paper) layer abuts the amorphous solid layer and
forms a
20 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).
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
30 over an air pressure interval of 50.66-48.00 1cPa). (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
5
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.
10
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, both during drying and in use.
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, during drying and in use. Additionally, or alternatively,
a metal
foil may function as a susceptor in an induction heating system. In particular
25
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 5itm.
In some cases, the carrier may have a thickness of between about 0.017mm and
30
about 2.0mm, suitably from about 0.02mm, 0.05mm
or 0.1mm to about 1.5mm, 1.0mm,
or 0.5mm.
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In some cases, the slurry may comprise 1-60wt% of a gelling agent wherein
these weights are calculated on a dry weight basis. Suitably, the slurry may
comprise
from about 1wr/o, 5wt%, 10wt%, 15w0/0, 20wt% or 25wt% to about 60wt%, 50w0/0,
45wt%, 40w1%, 35wt%, 30wt% or 27wt% of a gelling agent (all calculated on a
dry
5 weight basis). For example, the slurry may comprise 1-50wr/o, 5-40wt%,
10-30wt%
or 15-27wt% of a gelling agent.
In some cases, the gelling agent comprises a hydrocolloid. In some cases, the
gelling agent comprises one or more compounds selected from the group
comprising
10 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,
15 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-
crossl i nked pectin.
In some cases, 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 cases, alginate is the only
gelling agent
present in the amorphous solid. In other embodiments, the gelling agent
comprises
25 alginate and at least one further gelling agent, such as pectin.
In some cases, the slurry may include a gelling agent comprising carrageenan.
The gelling agent may comprise one or more compounds selected from
30 cellulosic gelling agents, non-cellulosic gelling agents, guar gum,
acacia gum and
mixtures thereof.
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In some embodiments, the cellulosic gelling agent is selected from the group
consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl
cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (1-
IPMC),
methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate
butyrate
5 (CAB), cellulose acetate propionate (CAP) and combinations thereof
In some embodiments, the gelling agent comprises (or is) one or more of
hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose
(FIPMC), carboxymethylcellulose, guar gum, or acacia gum.
In some embodiments, the gelling agent comprises (or is) one or more non-
cellulosic gelling agents, including, but not limited to, agar, xanthan gum,
gum Arabic,
guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and
combinations
thereof In preferred embodiments, the non-cellulose based gelling agent is
alginate or
15 agar.
Suitably, the amorphous solid may comprise from about 5wr/o, lOwt%, 15wt%,
or 20wt% to about 80wt%, 70wt%, 60wt%, 55wr/o, 50wt%, 45wt% 40wt%, or 35wt%
of an aerosol forming material (all calculated on a dry weight basis). The
aerosol
20 forming material may act as a plasticiser. For example, the slurry may
comprise 10-
60wt%, 15-50w0/0 or 20-40wt% of an aerosol forming material. In some cases,
the
aerosol forming material comprises one or more compound selected from
erythritol,
propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases,
the aerosol
forming material comprises, consists essentially of or consists of glycerol.
The
25 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
30 allows the amorphous solid sheet to be wound onto a bobbin, which is
useful in
manufacture of articles for use in aerosol generation.
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In some embodiments, the aerosol forming material comprises one or more
polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-
butanediol and
glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or
triacetate; and/or
aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl
dodecanedioate
5 and dimethyl tetradecanedioate.
In some cases, the slurry 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
0.5w0/0,
10 lwt%, 2wr/o, 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%, 20-50w0/0 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 slurry comprises an active constituent. For example, in
some
cases, the slurry additionally comprises a tobacco material and/or nicotine.
For
example, the slurry may additionally comprise powdered tobacco and/or nicotine
and/or
a tobacco extract. In some cases, the slurry may comprise from about lwt%,
5wt%,
20 lOwt%, 15vvf/o, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt% or 40wt%
(calculated on a dry weight basis) of active constituent. In some cases, the
slurry may
comprise from about lwt%, 5wt%, lOwt%, 15wt%, 20wt% or 25w0/0 to about 60wt%,
50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material
and/or
nicotine.
In some cases, the slurry comprises an active constituent 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 slurry may comprise from about
lwt%,
5wt%, lOwt%, 15wr/o, 20wt% or 25wt% to about 55wt%, 50wt%, 45wt% or 4Owte/ci
30 (calculated on a dry weight basis) tobacco extract. For example, the
slurry may
comprise 5-60wt%, 10-55wt% or 25-55wt% of tobacco extract. The tobacco extract
may contain nicotine at a concentration such that the slurry comprises lwt%
1.5wt%,
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2wt /o 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 slurry
other than that
which results from the tobacco extract.
5 In some embodiments the slurry comprises no tobacco material
but does
comprise nicotine. In some such cases, the slurry may comprise from about
lwt%,
2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, lOwt% or 5wt% (calculated on a dry
weight basis) of nicotine. For example, the slurry may comprise 1-20wt% or 2-
5wt%
of nicotine.
In some cases, the total content of active constituent and/or flavour may be
at
least about 0.1wt%, lwt%, 5wt%, 10w0/0, 20wt%, 25wt% or 30wt%. In some cases,
the total content of active constituent and/or flavour may be less than about
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%, 10wr/o, 20wt%, 25wt% or 30wt%. In some
cases, the total content of tobacco material, nicotine and flavour may be less
than about
60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
The amorphous solid may comprise an acid. The acid may be an organic acid.
In some of these embodiments, the acid may be at least one of a monoprotic
acid, a
diprotic acid and a triprotic acid. In some such embodiments, the acid may
contain at
least one carboxyl functional group. In some such embodiments, the acid may be
at
25 least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid,
tricarboxylic
acid and keto acid. In some such embodiments, the acid may be an alpha-kern
acid.
In some such embodiments, the acid may be at least one of succinic acid,
lactic
acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid,
acetic acid,
30 malic acid, formic acid, sorbic acid, benzoic acid, propanoic and
pyruvic acid.
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Suitably the acid is lactic acid. In other embodiments, the acid is benzoic
acid.
In other embodiments the acid may be an inorganic acid. In some of these
embodiments
the acid may be a mineral acid. In some such embodiments, the acid may be at
least one
of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some
5 embodiments, the acid is levulinic acid.
The inclusion of an acid is particularly preferred in embodiments in which the
amorphous solid comprises nicotine. In such embodiments, the presence of an
acid
may stabilise dissolved species in the slurry from which the amorphous solid
is formed.
10 The presence of the acid may reduce or substantially prevent evaporation
of nicotine
during drying of the slurry, thereby reducing loss of nicotine during
manufacturing.
In certain embodiments, the amorphous solid comprises a gelling agent
comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent,
an active
15 constituent and an acid.
The amorphous solid may comprise a colourant. The addition of a colourant
may alter the visual appearance of the amorphous solid. The presence of
colourant in
the amorphous solid may enhance the visual appearance of the amorphous solid
and an
20 aerosol-generating material comprising the amorphous solid. By adding a
colourant to
the amorphous solid, the amorphous solid may be colour-matched to other
components
of the aerosol-generating material or to other components of an article
comprising the
amorphous solid.
25 A variety of colourants may be used depending on the desired
colour of the
amorphous solid. The colour of amorphous solid may be, for example, white,
green,
red, purple, blue, brown or black. Other colours are also envisaged. Natural
or
synthetic colourants, such as natural or synthetic dyes, food-grade colourants
and
pharmaceutical-grade colourants may be used In certain embodiments, the
colourant
30 is caramel, which may confer the amorphous solid with a brown
appearance. In such
embodiments, the colour of the amorphous solid may be similar to the colour of
other
components (such as tobacco material) in an aerosol-generating material
comprising
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the amorphous solid. In some embodiments, the addition of a colourant to the
amorphous solid renders it visually indistinguishable from other components in
the
aerosol-generating material.
5
The colourant may be incorporated during the
formation of the amorphous solid
(e.g. when forming a slurry comprising the materials that form the amorphous
solid) or
it may be applied to the amorphous solid after its formation (e.g. by spraying
it onto the
amorphous solid).
10
In some embodiments, the slurry comprises less
than 60wt% of a filler, such as
from Iwt% to 60w04, or 5wt% to 50wt%, or 5wt% to 30wt%, or lOwt% to 2Owt% (all
calculated on a dry weight basis).
In other embodiments, the slurry comprises less than 20wt%, suitably less than
15
10wt% or less than 5wt% of a filler. In some
cases, the slurry 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,
20
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 cases,
the amorphous solid comprises no calcium carbonate such as chalk.
25
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
the material. This may be particularly advantageous in examples wherein the
30
amorphous solid is provided as a sheet, such as
when an amorphous solid sheet
circumscribes a rod of aerosol-generating material.
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In some embodiments, the slurry does not comprise tobacco fibres. In
particular
embodiments, the slurry does not comprise fibrous material.
In some cases, the slurry may consist essentially of, or consist of, a gelling
agent,
5
an aerosol forming material, a tobacco material
and/or a nicotine source, water, and
optionally a flavour.
The resulting amorphous solid may have any suitable area density, such as from
30 g/m2 to 120 g/m2, suitably about 30 to 70 g/m2, or about 40 to 60 g/m2. In
some
10
embodiments, the resulting 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 to
110 g/m2.
Such area densities may be particularly suitable where the amorphous solid is
included
in an aerosol-generating article/non-combustion aerosol provision system in
sheet form,
or as a shredded sheet (described further hereinbelow).
As noted above, further aspects of the invention provide
- an amorphous solid obtainable or obtained by methods of the first aspect,
- an article for use in a non-combustible aerosol provision system, the
article
comprising an amorphous solid obtainable or obtained by methods of the
20 first aspect, and
- a non-combustible aerosol provision system comprising the article
according to the third aspect and a non-combustible aerosol provision
device, the non-combustible aerosol provision device comprising an
aerosol-generation device to generate aerosol from the article when the
25
article is used with the non-combustible aerosol
provision device. In some
cases, the device includes a heater which is configured to heat the
amorphous solid, without burning.
In some cases, the heater may heat, without burning, the amorphous solid to
30
between 120 C and 350 C in use. In some cases,
the heater may heat, without burning,
the amorphous solid 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
1mm
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from the heater. In some cases, the solid is disposed between about 0.010mm
and
2.0mm from the heater, suitably between about 0.02mm and 1.0mm, suitably 0.1mm
to
0.5mm. These minimum distances may, in some cases, reflect the thickness of a
carrier
that supports the amorphous solid. In some cases, a surface of the amorphous
solid may
5 directly abut the heater.
The heater is configured to heat not burn the amorphous solid. The heater may
be, in some cases, an electrically resistive heater such as a thin-film,
electrically
resistive heater. In other cases, the heater may comprise an induction heater
or the like.
10 The heater may be a combustible heat source or a chemical heat source
which undergoes
an exothermic reaction to product heat in use. The non-combustion aerosol
provision
system may comprise a plurality of heaters. The heater(s) may be powered by a
battery.
The non-combustion aerosol provision system may additionally comprise a
15 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 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 non-combustion aerosol provision system may be a heat-not-
burn device. That is, it may contain a solid tobacco-containing material (and
no liquid
aerosol-generating 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
25 is incorporated by reference in its entirety_
In some cases, the non-combustion aerosol provision system may be a hybrid
system. That is, it may contain a solid aerosol-generating material and a
liquid aerosol-
generating material. In some cases, the amorphous solid may comprise nicotine.
In
30 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 aerosol-generating materials may be heated by separate heaters, the
same
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heater or, in one case, a downstream aerosol-generating material may be heated
by a
hot aerosol which is generated from the upstream aerosol-generating material.
A hybrid
device is disclosed in WO 2016/135331 Al, which is incorporated by reference
in its
entirety.
5
The article aspect for use in a non-combustible aerosol provision system
(which
may be referred to herein as an aerosol generating article, a cartridge or a
consumable)
may be adapted for use in a THP, a hybrid device or another aerosol generating
device.
In some cases, the article may additionally comprise a filter and/or cooling
element
10 (which have been described above). In some cases, the
article may comprise an aerosol-
generating material circumscribed by a wrapping material such as paper.
The article may additionally comprise ventilation apertures. These may be
provided in the sidewall of the article. In some cases, the ventilation
apertures may be
15 provided in the filter and/or cooling element These
apertures may allow cool air to be
drawn into the article during use, which can mix with the heated volatilised
components
thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised
20 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
25 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
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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
5 additional cooling to the heated volatilised components. In some cases,
the ventilation
ratio may be at least 60% or 65%.
In some cases, the amorphous solid may be included in the article/non-
combustion aerosol provision system in sheet form. In some cases, the
amorphous solid
10 may be included as a planar sheet. In some cases, the amorphous solid
may be included
as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a
rolled sheet
(e.g. in the form of a tube). In some such cases, the amorphous solid may be
included
in an aerosol-generating article/non-combustion aerosol provision system as a
sheet,
such as a sheet circumscribing a rod of aerosol-generating material (e.g.
tobacco). In
15 some other cases, the amorphous solid may be formed as a sheet and then
shredded and
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
20 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
amorphous
solid is formed as a sheet and then shredded and incorporated into an article.
In some
25 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 amorphous solid is included in an article/non-combustion aerosol
provision
system as a rolled sheet, suitably in the form of a tube.
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The non-combustion aerosol provision system may comprise an integrated
article and heater, or may comprise a heater device into which the article is
inserted in
use.
5
Referring to Figures 1 and 2, 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 5 to 7, described below. In use, the article 101 may be removably
inserted into
10 the device shown in Figure 5 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 the amorphous solid
15
described herein. In some embodiments, it may
be included in sheet form. In some
embodiments it may be included in the form of a shredded sheet. In some
embodiments,
the aerosol-generating material described herein may be incorporated in sheet
form and
in shredded form.
20
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
25
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
30
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
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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
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.
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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
5 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 C
10 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
15 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.
20 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
25 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
30 with respect to tube length, outer diameter, roundness and straightness.
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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
5 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-
10 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
15 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
forming
material.
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
25 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
30 material.
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The presence of the 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 10mm 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 10mm, 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
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
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
located within that tube separating the mouth end segment 111 and the cooling
segment
107.
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Referring to Figures 3 and 4, there are shown a partially cut-away section and
perspective views of an example of an article 301. The reference signs shown
in Figures
3 and 4 are equivalent to the reference signs shown in Figures 1 and 2, but
with an
5 increment of 200.
In the example of the article 301 shown in Figures 3 and 4, a ventilation
region
317 is provided in the article 301 to enable air to flow into the interior of
the article 301
from the exterior of the article 301. In one example the ventilation region
317 takes the
10 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
15 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
20 100 to 500pm in diameter. In one example, an axial separation between
rows of
ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.
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
25 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.
30 In one example, the rows of ventilation holes 317 are located
at least 1 1 mm
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
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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
5 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 frilly inserted in the
device 51, as can
be seen in Figures 6 and 7. 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
15 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
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 out of the
device
20 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.
Referring now to Figures 5 to 7 in more detail, there is shown an example of a
device 51 arranged to heat aerosol-generating material to volatilise at least
one
25 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
30 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 ordoff button 57 to allow the device
51 as a
whole to be switched on and off as desired by a user.
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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
5
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_
10
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
15
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
20
material may be inserted into the device 51 and
removed from the device 51 by a user.
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
25
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
30
arrangement, configured and arranged to control
the heating of the aerosol-generating
material in the article 101, 301 as discussed further below.
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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
5 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).
10 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
15 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
20 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
healing 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
25 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
30 elements formed by for example a resistive electrical winding.
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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
5 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.
15 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
20 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.
The housing 59 may further comprises various internal support structures 37
for
25 supporting all internal components, as well as the heating arrangement
23.
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
35 which is located between the collar 33 and one end of the vacuum sleeve 31.
The
30 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,
and each arranged circumferentially around outer surface of the chamber 35.
There is
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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
20 at the locations of the ridges 60 is less than the open span of the opening
20 at the
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
of the device 51, as shown in Figures 5 to 7. Referring particularly to Figure
6, in
20 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 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 one example, the
temperature
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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
5 condense on the inner surface of the cooling segment 107, 307.
In the examples of the article 301 shown in Figures 3 and 4, 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
10 additional cooling to the heated volatilised components.
EXEMPLARY EMBODIMENTS
Description of a number of exemplary embodiments follows. Each refers to an
15 amorphous solid obtainable by the methods of the invention. Where the
amorphous
solid composition is given (DWB), the slurry may have the same DWB composition
as
the amorphous solid (i.e. it includes additional water only).
In some embodiments, the amorphous solid comprises menthol.
Particular embodiments comprising a menthol-containing amorphous solid may
be particularly suitable for including in an article/non-combustion aerosol
provision
system as a shredded sheet. In these embodiments, the amorphous solid may have
the
following composition (DWB): gelling agent (preferably comprising alginate,
more
25 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 forming material
(preferably comprising glycerol) in an amount of from about 'Owl% to about
30wt%,
or from about 15wt% to about 25wt% (DWB). Figure 8a shows calcium distribution
30 in such an amorphous solid comprising a gelling agent, the gelling agent
comprising
alginate and pectin. Figure 8b shows calcium distribution in such an amorphous
solid
comprising alginate as the gelling agent. In each of figures 8a and 8b, the
image shows
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a section through the solid (where the upper surface of the solid is show
higher in the
image, and this upper surface corresponds to the top surface of the slurry
onto which
the calcium setting agent was applied).
5
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 forming material (DWB).
The amorphous solid of these embodiments may have any suitable water
10
content. For example, the amorphous solid may
have a water content of from about
2wt% to about 10wt%, or from about 5wt% to about 8wt%, or about 6wt%.
As noted above, the amorphous solid of these embodiments may be included in
an article/non-combustion aerosol provision system as a shredded sheet. The
shredded
15
sheet may be provided in the article/non-
combustion aerosol provision system 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.
20
Particular embodiments of the menthol-containing
amorphous solid may be
particularly suitable for including in an article/non-combustion aerosol
provision
system as a sheet, such as a sheet circumscribing a rod of aerosol-generating
material
(e.g. tobacco). In these embodiments, the amorphous solid may have the
following
composition (DWB): gelling agent (preferably comprising alginate, more
preferably
25
comprising a combination of alginate and pectin)
in an amount of from about 5wt% to
about 40wt%, or about 10wt% to 30wt%; menthol in an amount of from about 10wt%
to about 50wt%, or from about 15wr/o to 40w0/0; aerosol forming material
(preferably
comprising glycerol) in an amount of from about 5wt% to about 40wt%, or from
about
10w0/0 to about 35wt%; and optionally filler in an amount of up to arwt% - for
30
example, in an amount of from 5wt% to 20wt%, or
from about 40wt% to 60wt%
(DWB).
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In one of these embodiments, the amorphous solid comprises about 11wr/0 of
an alginate/pectin gelling agent blend, about 56wt% woodpulp filler, about 18%
menthol flavourant and about 15w0/0 glycerol (DWB).
5 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).
As noted above, the amorphous solid of these embodiments may be included as
10 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.
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
15 of amorphous solid has a thickness of from about 0.015mm to about 1mm.
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
20 amount of from about 5 to about 40w0/0, or from about 10vvt% to about
35wt%, or from
about 20wt% to about 35vvt%; flavourant in an amount of from about 0. lwt% to
about
40wt%, of from about lwt% to about 30wt%, or from about lwt% to about 20wt%,
or
from about 5wt% to about 20wt%; aerosol forming material (preferably
comprising
glycerol) in an amount of from 15wt% to 75wt%, or from about 30wt% to about
70wt%,
25 or from about 50wt% to about 65wt%; and optionally filler (suitably
woodpulp) in an
amount of less than about 60w0/0, or about 20wt%, or about 10wt%, or about
5wt%
(preferably the amorphous solid does not comprise filler) (DWB).
In one of these embodiments, the amorphous solid comprises about 27w1%
30 alginate gelling agent, about 14wt% flavourant and about 57wt% glycerol
aerosol
forming material (DWB).
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In another of these embodiments, the amorphous solid comprises about 29wt%
alginate gelling agent, about 9wt% flavourant and about 60wt% glycerol (DWB).
The amorphous solid of these embodiments may be included in an article/non-
5 combustion aerosol provision system as a shredded sheet, optionally
blended with cut
tobacco. Alternatively, the amorphous solid of these embodiments may be
included in
an article/non-combustion aerosol provision system as a sheet, such as a sheet
circumscribing a rod of aerosol-generating material (e.g. tobacco).
Alternatively, the
amorphous solid of these embodiments may be included in an article/non-
combustion
10 aerosol provision system 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
15 about 40wt%, or about lOwt% 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 forming material
(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
25 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 article/non-
combustion aerosol provision system as a shredded sheet, optionally blended
with cut
30 tobacco. Alternatively, the amorphous solid of these embodiments may be
included in
an article/non-combustion aerosol provision system as a sheet, such as a sheet
circumscribing a rod of aerosol-generating material (e.g. tobacco).
Alternatively, the
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amorphous solid of these embodiments may be included in an article/non-
combustion
aerosol provision system as a layer portion disposed on a carrier. Suitably,
in any of
these embodiments, the amorphous solid has a thickness of from about 50 gm to
about
200 gm, or about 50 p.m to about 100 gm, or about 60 gm to about 90 gm,
suitably
5 about 77 pm.
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
10 of about 5 to 600 Pa (also referred to as loss modulus).
DEFINITIONS
The active constituent as used herein may be a physiologically active
material,
15 which is a material intended to achieve or enhance a physiological
response. The active
constituent may for example be selected from nutraceuticals, nootropics,
psychoactives.
The active constituent may be naturally occurring or synthetically obtained.
The active
constituent may comprise for example nicotine, caffeine, taurine, theine,
vitamins such
as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or
20 combinations thereof. The active constituent may comprise one or more
constituents,
derivatives or extracts of tobacco, cannabis or another botanical.
In some embodiments, the active constituent comprises nicotine.
25 In some embodiments, the active constituent comprises caffeine,
melatonin or
vitamin 1312.
As noted herein, the active constituent 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
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release in the brain. Cannabinoids may be naturally occurring
(phytocannabinoids)
from plants such as cannabis, from animals (endocannabinoids), or artificially
manufactured (synthetic cannabinoids). Cannabis species express at least 85
different
phytocannabinoids, and are divided into subclasses, including cannabigerols,
5 cannabichromenes, cannabi di ol s, tetrahydrocannabinol s,
cannabinols and
cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis
include,
without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol
(CBD),
tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL),
cannabicyclol (CBL), cannabivatin (CBV), tetrahydrocannabivarin (THCV),
10
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).
15
In some embodiments, the active constituent
comprises one or more
cannabinoid compounds selected from the group consisting of cannabidiol (CBD),
tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic
acid
(CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC),
cannabicyclol (CBL), cannabivatin (CBV), tetrahydrocannabivarin (THCV),
20
cannabidivarin (CBDV), cannabichromevatin
(CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran
(CBT).
The active constituent may comprise one or more cannabinoid compounds
25 selected from the group consisting of cannabidiol (CBD) and THC
(tetrahydrocannabinol).
The active constituent may comprise cannabidiol (CBD).
30 The active constituent may comprise nicotine and cannabidiol
(CBD).
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The active constituent may comprise nicotine, cannabidiol (CBD), and THC
(tetrahydrocannabinol).
As noted herein, the active constituent may comprise or be derived from one or
5 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,
10 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
15 (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,
20 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 piper//a, Mentha
piperita
citrata c. v., Mentha piperita c. v., Mentha specula crispa, Mentha
cordifolia, Mentha
Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c. v. and
25 Mentha suaveolens.
In some embodiments, the botanical is selected from eucalyptus, star anise,
cocoa and hemp.
30 In some embodiments, the botanical is selected from rooibos and
fennel.
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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
5 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,
10 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,
15 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,
20 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
25 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.
The flavour may suitably comprise one or more mint-flavours suitably a mint
30 oil from any species of the genus Mentha. The flavour may suitably
comprise, consist
essentially of or consist of menthol.
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In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
5 blueberry, citrus fruits and/or redberry.
In some embodiments, the flavour comprises eugenol.
In some embodiments, the flavour comprises flavour components extracted
10 from tobacco.
In some embodiments, the flavour comprises flavour components extracted
from cannabis.
15 In some embodiments, the flavour may comprise a sensate, which
is intended to
achieve a somatosensorial sensation which are usually chemically induced and
perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in
addition to
or in place of aroma or taste nerves, and these may include agents providing
heating,
cooling, tingling, numbing effect. A suitable heat effect agent may be, but is
not limited
20 to, vanillyl ethyl ether and a suitable cooling agent may be, but not
limited to eucalyptol,
WS-3.
As used herein, the term "aerosol forming material" refers to an agent that
promotes the generation of an aerosol. An aerosol forming material may promote
the
25 generation of an aerosol by promoting an initial vaporisation and/or the
condensation
of a gas to an inhalable solid and/or liquid aerosol.
Suitable aerosol forming materials include, but are not limited to: a polyol
such
as erythritol, sorbitol, glycerol, and glycols like propylene glycol or
triethylene glycol;
30 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
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and aliphatic carboxylic acid esters such as methyl stearate, dimethyl
dodecanedioate
and dimethyl tetradecanedioate. The aerosol forming material may suitably have
a
composition that does not dissolve menthol. The aerosol forming material may
suitably
comprise, consist essentially of or consist of glycerol.
In some embodiments, the aerosol forming material comprises one or more
polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-
butanediol and
glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or
triacetate; and/or
aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl
dodecanedioate
and dimethyl tetradecanedioate.
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 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
5 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
15 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 of the invention, which is defined in the
accompanying claims.
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