Note: Descriptions are shown in the official language in which they were submitted.
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CONSUMABLE COMPRISING TWO DIFFERENT AEROSOL-GENERATING
MATERIALS FOR NON-COMBUSTIBLE AEROSOL PROVISION DEVICE
Technical Field
The present invention relates to consumables for use with a non-
5
combustible aerosol provision device, the
consumables comprising an aerosol-
generating material comprising an amorphous solid.
Background
Smoking consumables such as cigarettes, cigars and the like bum tobacco
10
during use to create tobacco smoke.
Alternatives to these types of consumables 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
consumables or aerosol generating assemblies.
15
One example of such a product is a heating
device which releases compounds
by heating, but not burning, a solid aerosol-generating material. This solid
aerosol-
generating material may, in some cases, comprise a tobacco material. The
heating
volatilises at least one component of the material, typically forming an
inhalable
aerosol. These products may be referred to as heat-not-bum devices, tobacco
heating
20
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 comprise a liquid source
(which may or may not comprise nicotine) which is vaporised by heating to
produce an
25
inhalable vapour or aerosol. The device
additionally comprises a solid aerosol-
generating material (which may or may not comprise a tobacco material) and
components of this material are entrained in the inhalable vapour or aerosol
to produce
the inhaled medium.
30 Summary
The invention provides a consumable for use with a non-combustible aerosol
provision device, the consumable comprising:
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a first aerosol-generating material, and
a second aerosol-generating material,
wherein each of the first and second aerosol-generating materials comprise an
amorphous solid, the amorphous solid comprising:
5 -0,5 - 60 wt % of a gelling agent;
-0- 80 wt % of an aerosol-former; and
- 0 - 60 wt % of at least one of an active substance, flavourant and an
acid;
wherein these weights are calculated on a dry weight basis and wherein the
amorphous
solid of the first aerosol-generating material has a composition different
from a
10 composition of the amorphous solid of the second aerosol-generating
material.
The invention also provides a method of manufacturing a consumable for use
with a non-combustible aerosol provision device, the method comprising:
providing a support;
15 depositing on the support at least two discrete portions of
slurry comprising a
gelling agent, an aerosol former material and at least one of an active
substance,
flavourant and an acid;
drying the at least two discrete portions of slurry to provide a first aerosol-
generating material and a second aerosol-generating material, wherein the
first and
20 second aerosol-generating materials are attached to the support;
forming the consumable;
wherein each of the first and second aerosol-generating materials comprise an
amorphous solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent;
25 -0- 80 wt % of an aerosol-former material; and
- 0 - 60 wt % of at least one of an active substance, flavourant and an
acid;
wherein these weights are calculated on a dry weight basis and wherein the
amorphous
solid of the first aerosol-generating material has a composition different
from a
composition of the amorphous solid of the second aerosol-generating material.
In a further aspect of the invention, there is provided a non-combustible
aerosol
provision system comprising a consumable of the invention and a non-
combustible
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aerosol provision device, the non-combustible aerosol provision device
comprising an
aerosol-generation device arranged to generate aerosol from the consumable
when the
consumable is used with the non-combustible aerosol provision device.
5 The invention also pertains to a use of a consumable as
described herein in a
non-combustible aerosol provision device, wherein the device is arranged to
generate
aerosol from the consumable when the consumable is used with the non-
combustible
aerosol provision device.
10 Further features and advantages of the invention will become
apparent from the
following description of preferred embodiments of the invention, given by way
of
example only, which is made with reference to the accompanying drawings.
Brief Description of the Drawings
15 Figure 1 shows a section view of an example of a consumable.
Figure 2 shows a perspective view of the consumable of Figure 1.
Figure 3 shows a sectional elevation of an example of a consumable.
Figure 4 shows a perspective view of the consumable of Figure 3.
Figure 5 shows a perspective view of an example of a non-combustible aerosol
20 provision system
Figure 6 shows a section view of an example of a non-combustible aerosol
provision system.
Figure 7 shows a perspective view of an example of a non-combustible aerosol
provision system.
Detailed Description
As discussed above, one aspect of the invention provides a consumable for use
with a non-combustible aerosol provision device, the consumable comprising:
a first aerosol-generating material; and
30 a second aerosol-generating material,
wherein each of the first and second aerosol-generating materials comprises an
amorphous solid, the amorphous solid comprising:
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- 0.5 - 60 wt % of a gelling agent;
-0 - 80 vitt % of an aerosol-former material; and
-0 - 60 wt % of at least one of an active substance, a flavourant and an acid;
wherein these weights are calculated on a dry weight basis and wherein the
5 amorphous solid of the first aerosol-generating material has a
composition different
from a composition of the amorphous solid of the second aerosol-generating
material.
In this aspect of the invention the percentage by weight of the at least one
active
substance, flavourant and acid represents the combined total weight of any
combination
10 of active substance, flavourant and acid described herein.
In one embodiment the amorphous solid of the first aerosol-generating material
comprises the active substance and the amorphous solid of the second aerosol-
generating material comprises the flavourant. In certain such cases, the
amorphous
15 solid of the first aerosol-generating material is free from the
flavourant and the acid. In
some embodiments the amorphous solid of the first aerosol-generating material
does
not comprise the flavourant contained in the second aerosol-generating
material and
does not comprise the acid. In other embodiments the amorphous solid of the
first
aerosol-generating material also comprises the flavourant and/or the acid. In
some
20 cases, the amorphous solid of the second aerosol-generating material is
free from the
active substance and the acid. In some embodiments the amorphous solid of the
second
aerosol-generating material does not comprise the active substance contained
in the first
aerosol-generating material and does not comprise the acid.
In alternative
embodiments, the amorphous solid of the second aerosol-generating material
also
25 comprises the active substance and/or the acid
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In these embodiments, the amorphous solid of the first aerosol-generating
material, comprising the active substance comprises:
- 0.5-60 wt% of a gelling agent;
- 5 - 80 wt% of an aerosol-former material; and
5 - 0.1 - 60 wt% of at least one active substance,
wherein these weights are calculated on a dry weight basis.
In this embodiment, the amorphous solid of the first aerosol-generating
material
may have the following composition provided as percentages of the total dry
weight,
10 La, dry weight basis (all calculated on a dry weight basis): the gelling
agent in an
amount of from about 5wt% to about 40wt%, or about lOwt% to 30wt%, or about
15wt% to about 25w0/0; the aerosol-former material in an amount of from about
lOwt%
to about 70wt%, or from about 20wr/o to about 60wt%, or from about 25wt% to
about
40wt% (all calculated on a dry weight basis), the active substance in an
amount of from
15 about 0.5 wt% to about 50 wt%, or from about 1 wt% to 40 wt%, or from
about 2 wt%
to about 30 wt%, or from about 5 wr/o to about 20 wt %, or from about 2 wr/o
to about
wt%. Suitably, the amorphous solid of the first aerosol-generating material
may
have the following composition (all calculated on a dry weight basis): the
gelling agent
in an amount of from about 30wr/o to about 60wt%; the aerosol-former material
in an
20 amount of from about 20wt% to about 60wt%; and the active substance in
an amount
of from about 0.1 wt% to about 10 wt%. In some of these embodiments the
amorphous
solid of the first aerosol-generating material is free from the flavourant
contained in the
second aerosol-generating material and the acid. In alternative embodiments,
the
amorphous solid of the first aerosol-generating material also comprises the
flavourant
25 and/or the acid.
In this embodiment, the amorphous solid of the second aerosol-generating
material, comprising the flavourant comprises:
- 0.5-60 wt% of a gelling agent;
30 - 0-80 wt% of an aerosol-former material; and
- 5-60 wt% of the flavourant,
wherein these weights are calculated on a dry weight basis;
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In this embodiment, the amorphous solid of the second aerosol-generating
material may have the following composition (all calculated on a dry weight
basis): the
gelling agent in an amount of from about 5wt% to about 40wt%, or about lOwt%
to
30wt%, or about 15wt% to about 25w1%; the aerosol-former material in an amount
of
5 from about 10wr/o to about 70w0/0, or from about 20wt% to about 60wt%,
or from
about 25wt% to about 40wt% (all calculated on a dry weight basis), flavourant
in an
amount of from about lOwt% to about 50wt%, or from about 20wt% to 40wt%, or
from
about 25wt% to about 30wt%. Suitably, the amorphous solid of the second
aerosol-
generating material may have the following composition (all calculated on a
dry weight
10 basis). the gelling agent in an amount of from about 30wt% to about
60wt%; the
aerosol-former material in an amount of from about lOwt% to about 40wt%; and
the
flavourant in an amount of from about 20 wt% to about 50 wt%. In some
embodiments
the amorphous solid of the second aerosol-generating material is free from the
active
substance contained in the amorphous solid of the first aerosol-generating
material, and
15 the acid. In some embodiments, the amorphous solid of the second aerosol-
generating
material also comprises the active substance and/or the acid.
In a further embodiment, the amorphous solid of the first aerosol-generating
material comprises the active substance and the amorphous solid of the second
aerosol-
20 generating material comprises the acid. In certain such embodiments the
amorphous
solid of the first aerosol-generating material is free from the flavourant and
the acid. In
some embodiments, the amorphous solid of the first aerosol-generating material
does
not comprise the acid contained in the second aerosol-generating material and
does not
comprise the flavourant. In other embodiments the amorphous solid of the first
aerosol-
25 generating material also comprises the acid and/or the flavourant. In
certain such
embodiments the amorphous solid of the second aerosol-generating material is
free
from the active substance and the flavourant. In some embodiments, the
amorphous
solid of the second aerosol-generating material does not comprise the active
substance
contained in the first aerosol-generating material and does not comprise the
flavourant.
30 In other embodiments the amorphous solid of the second aerosol-
generating material
also comprises the active substance and/or the flavourant.
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In this embodiment, the amorphous solid of the first aerosol-generating
material, comprising the active substance comprises:
- 0.5-60 wt% of a gelling agent;
- 5 - 80 wt% of an aerosol-former material; and
5 - 0.1 - 60 wt% of at least one active substance,
wherein these weights are calculated on a dry weight basis.
In this embodiment, the amorphous solid of the first aerosol-generating
material
may have the following composition (all calculated on a dry weight basis): the
gelling
10 agent in an amount of from about 5wt% to about 40wt%, or about lOwt% to
30wt%, or
about 15wt% to about 25wt%; the aerosol-former material in an amount of from
about
lOwt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt%
to about 35vvt% (all calculated on a dry weight basis), the active substance
in an amount
of from about 1 wt% to about 50 we/0, or from about 2 wt% to 40 wt%, or from
about
15 5 wt% to about 30 wr/o. Suitably, the amorphous solid of the first
aerosol-generating
material may have the following composition (all calculated on a dry weight
basis): the
gelling agent in an amount of from about 30wt% to about 60wt%; the aerosol-
former
material in an amount of from about 20wt% to about 60wt%; and the active
substance
in an amount of from about 0.1 wr/o to about 10 wt%. In some embodiments the
20 amorphous solid of the first aerosol-generating material is free from
the acid and the
flavourant. In alternative embodiments, the amorphous solid of the first
aerosol-
generating material also comprises the flavourant and/or the acid.
In this embodiment, the amorphous solid of the second aerosol-generating
25 material, comprising the acid, comprises:
- 0.5-60 wt% of the gelling agent;
- 5-80 wt% of the aerosol-former material; and
-0.1 -10 wt% of the acid,
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the second aerosol-generating
material may have the following composition (calculated on a dry weight
basis): the
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gelling agent in an amount of from about 5wt% to about 40wt%, or about lOwt%
to
30wt%, or about 15wt% to about 25wt%; the aerosol-former material in an amount
of
from about 10wt% to about 50w0/0, or from about 20w0/0 to about 40wt%, or from
about 25wt% to about 35wt% (all calculated on a dry weight basis), the acid in
an
5 amount of from about 0. 1 wt% to about 8 wt%, or from about 0.5wt% to
7wt%, or from
about lwt% to about 5w0/0, or form about 1 wt% to about 3wt%. Suitably, the
amorphous solid of the second aerosol-generating material may have the
following
composition (all calculated on a dry weight basis): the gelling agent in an
amount of
from about 40wt% to about 70wt%; the aerosol-former material in an amount of
from
10 about 20wt% to about 50wt%; and the acid in an amount of from about 0.1
wt% to
about 5 wt%. In some embodiments the amorphous solid of the second aerosol-
generating material is free from the active substance and the flavourant. In
alternative
embodiments, the amorphous solid of the second aerosol-generating material
also
comprises the active substance and/or the flavourant.
In a still further embodiment, the amorphous solid of the first aerosol-
generating
material comprises the flavourant and the amorphous solid of the second
aerosol-
generating material comprises the acid. In certain such embodiments, the
amorphous
solid of the first aerosol-generating material is free from the acid and the
active
20 substance. In some embodiments, the amorphous solid of the first aerosol-
generating
material does not comprise the acid contained in the second aerosol-generating
material
and does not comprise the active substance. In other embodiments the amorphous
solid
of the first aerosol-generating material also comprises the acid and/or the
active
substance. In certain embodiments, the amorphous solid of the second aerosol-
25 generating material is free from the flavourant and the active
substance. In some
embodiments, the amorphous solid of the second aerosol-generating material
does not
comprise the flavourant contained in the first aerosol-generating material and
does not
comprise the active substance. In other embodiments the amorphous solid of the
second
aerosol-generating material also comprises the flavourant and/or the active
substance
In this embodiment, the amorphous solid of the first aerosol-generating
material, comprising the flavourant comprises:
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- 0.5-60 wt% of a gelling agent;
- 0-80 wt% of an aerosol-former material; and
- 5-60 wt% of the flavourant,
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the first aerosol-generating
material
may have the following composition (all calculated on a dry weight basis):
gelling agent
in an amount of from about 5w1% to about 40wt%, or about lOwt% to 30wt%, or
about
15w0/0 to about 25wt%; aerosol-former material in an amount of from about
lOvvt% to
about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about
35wt% (all calculated on a dry weight basis), flavourant in an amount of from
about
30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to
about
50wt%. Suitably, the amorphous solid of the first aerosol-generating material
may have
the following composition (all calculated on a dry weight basis): the gelling
agent in an
amount of from about 30wt% to about 60wt%; the aerosol-former material in an
amount
of from about 10wrY0 to about 40wt%; and the flavourant in an amount of from
about
10 wt% to about 50 wt%. In some embodiments the amorphous solid of the first
aerosol-generating material is free from the acid and the active substance. In
alternative
embodiments, the amorphous solid of the first aerosol-generating material also
comprises the acid and/or the active substance.
In this embodiment, the amorphous solid of the second aerosol-generating
material, comprising the acid comprises:
- 0.5-60 wt% of the gelling agent;
- 5-80 wt% of the aerosol-former material, and
-0.1 -10 vvt% of the acid,
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the second aerosol-generating
material may have the following composition (all calculated on a dry weight
basis): the
gelling agent in an amount of from about 5wt% to about 40wt%, or about lOwt%
to
30wt%, or about 15wt% to about 25wt%; the aerosol-former material in an amount
of
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from about lOwt% to about 50w0/0, or from about 20wt% to about 40wt%, or from
about 25wt% to about 35w0/0 (all calculated on a dry weight basis), the acid
in an
amount of from about 0.1wt% to about 8 wt%, or from about 0.5vvt% to 7wt%, or
from
about lwt% to about 5wt%, or form about 1 wt% to about 3wt%. Suitably, the
5 amorphous solid of the second aerosol-generating material may have the
following
composition (all calculated on a dry weight basis): the gelling agent in an
amount of
from about 40wt% to about 70-vv-t%; the aerosol-former material in an amount
of from
about 20wt% to about 50wt%; and the acid in an amount of from about 0.1 wt% to
about 5 wt%, In some embodiments the amorphous solid of the second aerosol-
10 generating material is free from the active substance or the flavourant.
In alternative
embodiments, the amorphous solid of the second aerosol-generating material
also
comprises the active substance and/or the flavourant.
In further embodiments, the amorphous solid of one of the first or second
15 aerosol-generating materials is free from the active substance, the
flavourant and the
acid. In some embodiments, the amorphous solid of the first aerosol generating
material
does not comprise the active substance, the flavourant or the acid. In this
embodiment
the aerosol-generating material which is free from the active substance,
flavourant and
acid is provided for the purposes of providing a source of aerosol-former
material, e.g.
20 a humectant, As such, in this embodiment, the amorphous solid of the
aerosol-
generating material which is free from the active substance, flavourant and
acid
comprises at least 5% by weight of aerosol-former material; for example, in an
amount
of from about 'Om-% to about 50wt%, or from about 20wt% to about 40wt%, or
from
about 25wt% to about 35wt% (all calculated on a dry weight basis). In an
exemplary
25 embodiment, the first aerosol-generating material comprises:
- 0.5 - 60 wt % of a gelling agent;
-5 - 80 wt % of an aerosol-former material;
and is free from an active substance, a flavourant and an acid;
and the second aerosol-generating material comprises 0.1 -60 wt % of at least
30 one of an active substance, flavourant and an acid;
wherein these weights are calculated on a dry weight basis.
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In some such embodiments, the consumable of the invention comprises such a
first aerosol-generating material in combination with any other second aerosol-
generating material described herein.
5
In some embodiments, the amorphous solid of the
first and second aerosol-
generating materials both comprise an active substance. hi some such
embodiments,
the amorphous solid of the first and second aerosol-generating materials
comprise the
same active substance. In some such embodiments the active substance is
present in
different quantities. When used herein "quantity" can mean that the amorphous
solid
10
contains 0% of the active substance, in other
words the amorphous solid of the first or
second aerosol-generating material is free from the active substance present
in the
amorphous solid of the other aerosol-generating material.
In some embodiments the amorphous solid of the first and second aerosol-
15
generating materials both comprise an active
substance. In some such embodiments,
the amorphous solid of the first and second aerosol-generating materials
comprise the
same active substance, wherein the amorphous solid of the first aerosol-
generating
material comprises a greater quantity of the active substance than the
quantity of the
active substance present in the amorphous solid of the second aerosol-
generating
20
material. In some embodiments, the amorphous
solid of the first and second aerosol-
generating materials comprise the same active substance, wherein the amorphous
solid
of the first aerosol-generating material comprises a lesser quantity of the
active
substance than the quantity of the active substance present in the amorphous
solid of
the second aerosol-generating material.
In some such embodiments, the amorphous solids of both the first and second
aerosol-generating materials comprise a quantity of the active substance which
is
greater than 0.1% (all calculated on a dry weight basis); for example, the
amorphous
solids of both the first and second aerosol-generating materials comprise at
least 0.2,
30
0.5, 1.0, 1.5 or 2% of the active substance. In
an exemplary embodiment the amorphous
solid of the first aerosol-generating material comprises from 0 ¨ 30 wt% of
the active
substance present therein, and the amorphous solid of the second aerosol-
generating
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material comprises from 31 ¨ 60 wt% of the active substance present therein.
Suitably,
the amorphous solid of the first aerosol-generating material comprises from 0
¨ 20 wt%
of the active substance present therein (for example, I ¨ 15 wt% or 5 ¨ 10
wt%) and the
amorphous solid of the second aerosol-generating material comprises from 30 ¨
60 wt%
5 of the active substance present therein (for example, 30 ¨ 50 wt%, or 40
¨ 60 wt%). In
some such embodiments the amorphous solid of the first aerosol-generating
material
comprises the same active substance as the active substance present in the
amorphous
solid of the second aerosol-generating material. In some such embodiments the
amorphous solid of the first aerosol-generating material comprises a different
active
10 substance from the active substance present in the amorphous solid of
the second
aerosol-generating material.
In such embodiments, two aerosol-generating materials may comprise
substantially the same ingredients, except that the quantity of active
substance present
15 in each of the two aerosol-generating materials is different, In a non-
limiting example,
a consumable in accordance with the invention comprises
a first aerosol-generating material; and
a second aerosol-generating material,
wherein the first aerosol-generating material comprises an amorphous solid,
the
20 amorphous solid comprising
- 0,5 -60 wt% of a gelling agent;
-0-80 wt% of an aerosol-former material; and
- 0 - 5 wt% of an active substance, wherein these weights are calculated on
a dry weight
basis; and the second aerosol-generating material comprises an amorphous
solid, the
25 amorphous solid comprising
- 0.5 - 60 wt% of a gelling agent;
-0-80 wt% of an aerosol-former material; and
- 5 ¨ 10 wt% of an active substance, wherein these weights are calculated
on a dry
weight basis. Suitably the amorphous solid of the first aerosol-generating
material
30 comprises from 0.1 ¨ 2 wt% of the active substance contained therein and
the
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amorphous solid of the second aerosol-generating material comprises from 2 ¨
10 wt%
of the active substance contained therein. Suitably the active substance is
nicotine.
In such embodiments the first and second aerosol-generating material may
5 further comprise flavourant and/or acid in variable quantities. In other
embodiments
the first and/or second aerosol-generating material is free from (does not
comprise)
flavourant and/or acid.
In the above embodiments, suitably, the active substance is nicotine and the
10 amorphous solid of the first aerosol-generating material comprises 0.1 -
5 wt% of
nicotine, for example 0.5 ¨ 4 wt%, 1 - 3 wt% or 2 ¨ 5 wt% of nicotine, and the
amorphous solid of the second aerosol-generating material comprises 5 - 10 wt%
of
nicotine, for example 6 ¨ 9 wt% or 7 ¨ 8 wt% of nicotine, wherein these
weights are
calculated on a dry weight basis and wherein the amorphous solid of the first
aerosol-
15 generating material comprises a different quantity of nicotine from the
quantity of
nicotine contained in the amorphous solid of the second aerosol-generating
material.
In some embodiments the amorphous solid of the first aerosol-generating
material comprises a different active substance from the active substance
present in the
20 amorphous solid of the second aerosol-generating material
In some embodiments, the amorphous solid of the first aerosol-generating
material comprises a different flavourant from the flavourant present in the
amorphous
solid of the second aerosol-generating material.
In some cases, the amorphous solid of at least one aerosol-generating material
mentioned above comprises more than one of a flavourant, active substance
andVor acid.
For example, in some embodiments the amorphous solid of the first and
or/second
aerosol-generating material comprises the flavourant and the active substance,
but is
30 free from the acid. In other cases the amorphous solids of the first
and/or second
aerosol-generating materials comprises the acid and the active substance, but
are free
from the flavourant. In other cases, the amorphous solids of the first and/or
second
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aerosol-generating materials comprise the flavourant and the acid, but are
free from the
active substance.
It is also envisaged that the consumable of the invention comprises aerosol-
5 generating materials as discussed above which differ from each other by
type of
flavourant. In such embodiments the amorphous solid of the first aerosol-
generating
material comprises a different flavourant from the flavourant contained in the
amorphous solid of the second aerosol-generating material. In such
embodiments, two
aerosol-generating materials (for example the first and second aerosol-
generating
10 materials) may comprise substantially the same ingredients, except that
the amorphous
solid of the first aerosol-generating material comprises a flavourant which is
different
from a flavourant present in the amorphous solid of the second aerosol
generating
material. In a non-limiting example, the amorphous solids of two aerosol-
generating
materials comprise an active substance, acid and flavourant, wherein the
flavourant in
15 the amorphous solid of the first aerosol-generating material is
different from the
flavourant in the amorphous solid of the second aerosol-generating material.
In some
embodiments, the consumable of the invention may comprise more than two
aerosol-
generating materials, wherein the amorphous solid of each aerosol-generating
material
comprises a different flavourant from a flavourant present in at least one
other
20 amorphous solid of another aerosol-generating material in the consumable
of the
invention.
It is also envisaged that aerosol-generating materials in the consumable of
the
invention differ from each other by type of active substance. In such
embodiments, the
25 amorphous solids of two aerosol-generating materials may comprise
substantially the
same ingredients, except that the active substance present in the amorphous
solid is
different. In one embodiment, the amorphous solid of the first aerosol-
generating
material comprises a different active substance from the active substance
present in the
amorphous solid of the second aerosol-generating material. In some
embodiments, the
30 consumable of the invention comprises more than two aerosol-generating
materials,
wherein the amorphous solid of each aerosol-generating material comprises a
different
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active substance from the active substance present in the amorphous solid of
at least
one other aerosol-generating material in the consumable.
It is also envisaged that aerosol-generating materials in consumables of the
5 invention differ from each other by quantity of flavourant, or acid. In
some such
embodiments the flavourant of the amorphous solid of the first aerosol-
generating
material is present in a different quantity from a quantity of the flavourant
in the
amorphous solid of the second aerosol-generating material. For example, the
quantity
of flavourant present in the amorphous solid of the first aerosol-generating
material is
10 greater than the quantity of the flavourant present in the second
aerosol-generating
material. In some such embodiments the acid of the amorphous solid of the
first
aerosol-generating material is present in a different quantity from a quantity
of the acid
in the amorphous solid of the second aerosol-generating material. For example,
the
quantity of acid present in the amorphous solid of the first aerosol-
generating material
15 is greater than the quantity of the acid present in the second aerosol-
generating material.
It will be appreciated that there are very many combinations of aerosol-
generating materials which can be included in a consumable of the present
invention.
All combinations of active substance, flavourant and acid are included within
the scope
20 of the invention.
In some embodiments the consumable comprises a third aerosol-generating
material comprising an amorphous solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent;
25 - 0 - 80 wt % of an aerosol-former material; and
- 0 - 60 wt % of at least one of an active substance, a flavourant and an
acid;
wherein these weights are calculated on a dry weight basis and wherein the
amorphous solid of the third aerosol-generating material has a different
composition
from a composition of the amorphous solid of the first aerosol-generating
material
30 and/or the second aerosol-generating material.
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In some embodiments the consumable comprises a fourth aerosol-generating
material comprising an amorphous solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent;
- 0- 80 wt % of an aerosol-former material; and
5 -0-60 wt % of at least one of an active substance, a
flavourant and an acid;
wherein these weights are calculated on a dry weight basis and wherein the
amorphous
solid of the fourth aerosol-generating material has a different composition
from a
composition of the amorphous solid of at least one of the first, second or
third aerosol-
generating materials.
In some embodiments the consumable comprises more than four aerosol-
generating materials having the features described above. Suitably, the
amorphous
solid of each additional aerosol-generating material has a different
composition from
the composition of the amorphous solid of at least one other aerosol-
generating material
15 contained in the consumable. Indeed, the consumable, in some
embodiments,
comprises five, six, seven, eight, nine or ten aerosol-generating materials,
each of which
comprises an amorphous solid having a different composition from an amorphous
solid
of at least one other aerosol-generating material contained in the consumable.
In such
embodiments each of the additional aerosol-generating materials comprises an
20 amorphous solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent;
- 0- 80 wt % of an aerosol-former material; and
-0-60 wt % of at least one of an active substance, a flavourant and an acid;
wherein these weights are calculated on a dry weight basis and wherein the
25 amorphous solid of the fifth, sixth, seventh, eighth, ninth or tenth
aerosol-generating
materials has a composition different from the amorphous solid of at least one
other
aerosol-generating material contained in the consumable.
In some cases the amorphous solid of each aerosol-generating material
30 comprises one of a flavourant, acid, active substance, or is free from
flavourant, acid
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and active substance, such that it contributes only humectant when subject to
aerosolization.
In a non-limiting and exemplary embodiment, a consumable in accordance with
5 the invention comprises
a first aerosol-generating material;
a second aerosol-generating material;
a third aerosol-generating material; and
a fourth aerosol-generating material
10 wherein each of the first to fourth aerosol-generating materials
comprises an amorphous
solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent;
-0- 80 wt % of an aerosol-former; and
- 0 - 60 wt % of at least one of an active substance, flavourant and an acid;
15 wherein these weights are calculated on a dry weight basis and wherein
the amorphous
solid of the first aerosol-generating material is free from the active
substance, the
flavourant and the acid;
the amorphous solid of the second aerosol-generating material comprises the
flavourant, but is free from the active substance and the acid;
20 the amorphous solid of the third aerosol-generating material comprises
the active
substance, but is free from the flavourant and the acid; and
the amorphous solid of the fourth aerosol-generating material comprises the
acid, but is
free from the active substance and the flavourant.
25 In this embodiment, the amorphous solid of the first aerosol-
generating
material, free from the flavourant, the active substance and the acid may
comprise:
- 0.5-60 wt% of a gelling agent; and
- 5-80 wt% of an aerosol-former material;
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the first aerosol-generating
material
may have the following composition (all calculated on a dry weight basis):
gelling agent
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in an amount of from about 5wt% to about 40wt%, or about lOwt% to 30wt%, or
about
15wt% to about 25w0/0; the aerosol-former material in an amount of from about
lOwt%
to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to
about
35wt% (all calculated on a dry weight basis).
In this embodiment, the amorphous solid of the second aerosol-generating
material, comprising the flavourant, but free from the active substance and
the acid may
comprise:
- 0.5-60 wt% of a gelling agent;
- 0-80 wt% of an aerosol-former material; and
- 5-60 wt% of the flavourant,
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the second aerosol-generating
material may have the following composition (all calculated on a dry weight
basis):
gelling agent in an amount of from about 5wt% to about 40wt%, or about lOwt%
to
30w0/0, or about 15wt% to about 25wt%; aerosol-former material in an amount of
from
about lOwt% to about 50wt%, or from about 20wr/0 to about 40wt%, or from about
25wt% to about 35wt% (all calculated on a dry weight basis), flavourant in an
amount
of from about 30wt% to about 60wt%, or from about 40wt% to 55vvt%, or from
about
45wt% to about 50wt%. Suitably, the amorphous solid of the second aerosol-
generating
material may have the following composition (all calculated on a dry weight
basis): the
gelling agent in an amount of from about 30w0/0 to about 60vvt%; the aerosol-
former
material in an amount of from about lOwt% to about 40w1%; and the flavourant
in an
amount of from about 10 wt% to about 50 wt%.
In this embodiment, the amorphous solid of the third aerosol-generating
material, comprising the active substance, and free from the flavourant and
acid
comprises:
- 0.5-60 wt% of a gelling agent;
- 5-80 wt% of an aerosol-former material; and
- 5-60 wt% of at least one active substance,
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wherein these weights are calculated on a dry weight basis.
In this embodiment, the amorphous solid of the third aerosol-generating
material may have the following composition (all calculated on a dry weight
basis): the
5 gelling agent in an amount of from about 5wt% to about 40wt%, or about
lOwt% to
30wt%, or about 15wr/o to about 25w1%; the aerosol-former material in an
amount of
from about lOwt% to about 50wt%, or from about 20wt% to about 40wt%, or from
about 25wt% to about 35w0/0 (all calculated on a dry weight basis), the active
substance
in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%,
10 or from about 45wt% to about 50wt% Suitably, the amorphous solid of the
first
aerosol-generating material may have the following composition (all calculated
on a
dry weight basis): the gelling agent in an amount of from about 30wt% to about
60wt%;
the aerosol-former material in an amount of from about 20wr/o to about 60wt%;
and
the active substance in an amount of from about 0.1 wt% to about 10 wrA.
In this embodiment, the amorphous solid of the fourth aerosol-generating
material, comprising the acid, but free from the active substance and the
flavourant
comprises:
- 0.5-60 wt% of the gelling agent;
20 - 5-80 wrA of the aerosol-former material; and
-0.1 -10 vvt% of the acid,
wherein these weights are calculated on a dry weight basis;
In this embodiment, the amorphous solid of the fourth aerosol-generating
25 material may have the following composition (all calculated on a dry
weight basis). the
gelling agent in an amount of from about 5wt% to about 40wt%, or about lOwt%
to
30wt%, or about 15wt% to about 25wt%; the aerosol-former material in an amount
of
from about 10wt% to about 50w0/0, or from about 20w0/0 to about 40wt%, or from
about 25wt% to about 35wt% (all calculated on a dry weight basis), the acid in
an
30 amount of from about 0.1wt% to about 8 wt%, or from about 0.5wt% to
7wt%, or from
about lwt% to about 5wt%, or form about 1 wt% to about 3wt%. Suitably, the
amorphous solid of the fourth aerosol-generating material may have the
following
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composition (all calculated on a dry weight basis): the gelling agent in an
amount of
from about 40wt% to about 70wt%, the aerosol-former material in an amount of
from
about 20wt% to about 50wt%; and the acid in an amount of from about 0.1 wt% to
about 5 wt%.
5
FORMULATIONS
The following formulations represent exemplary component amounts of each
excipient in the aerosol-generating materials contained in consumables of the
invention.
In embodiments wherein the amorphous solid of the aerosol-generating material
in the consumable comprises an active substance, the amorphous solid, in some
such
embodiments comprises:
- 0.5-60 wt% of a gelling agent;
-0- 80 wt% of an aerosol-former material; and
- 0.1 - 60 wt% of at least one active substance,
wherein these weights are calculated on a dry weight basis.
In these embodiments, the amorphous solid of the aerosol-generating material
may have the following composition (all calculated on a dry weight basis): the
gelling
agent in an amount of from about 5wt% to about 40wt%, or about lOwt% to
30v44/0, or
about 15wr/o to about 25wt%; the aerosol-former material in an amount of from
about
10w0/0 to about 70vvt%, or from about 20wt% to about 60wt%, or from about
25wt%
to about 40vvt% (all calculated on a dry weight basis), the active substance
in an amount
of from about 0.5 wt% to about 50 wt%, or from about 1 wt% to 40 wt%, or from
about
2 wt% to about 30 wt%, or from about 5 wt% to about 20 wt %, or from about 2
wt%
to about 10 wt%. Suitably, the amorphous solid of the aerosol-generating
material may
have the following composition (all calculated on a dry weight basis): the
gelling agent
in an amount of from about 30w0/0 to about 60wt%; the aerosol-former material
in an
amount of from about 20wt% to about 60wt%; and the active substance in an
amount
of from about 0.1 wt% to about 10 wt%.
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In embodiments wherein the amorphous solid of the aerosol-generating material
in the consumable comprises flavourant, in some such embodiments the amorphous
solid comprises:
- 0.5-60 wt% of a gelling agent;
5 - 0-80 wt% of an aerosol-former material; and
- 5-60 wt% of the flavourant,
wherein these weights are calculated on a dry weight basis;
In these embodiments, the amorphous solid the aerosol-generating material may
10 have the following composition (all calculated on a dry weight basis):
the gelling agent
in an amount of from about 5wt% to about 40wt%, or about 10w1% to 30wt%, or
about
15wt% to about 25w0/0; the aerosol-former material in an amount of from about
10wt%
to about 70wt%, or from about 20wt% to about 60wr/o, or from about 25wt% to
about
40wt% (all calculated on a dry weight basis), flavourant in an amount of from
about
15 lOwt% to about 50vvt%, or from about 20wt% to 40wt%, or from about 25wt%
to about
30wt%. Suitably, the amorphous solid of the second aerosol-generating material
may
have the following composition (all calculated on a dry weight basis): the
gelling agent
in an amount of from about 30wt% to about 60wt%; the aerosol-former material
in an
amount of from about lOwt% to about 40wt%; and the flavourant in an amount of
from
20 about 20wt% to about 50 wt%.
In embodiments wherein the amorphous solid of the aerosol-generating material
in the consumable comprises an acid, in some such embodiments the amorphous
solid
comprises:
25 - 0.5-60 wt% of the gelling agent;
- 5-80 wr/o of the aerosol-former material; and
-0.1 -10 wt% of the acid,
wherein these weights are calculated on a dry weight basis;
30 In these embodiments, the amorphous solid may have the
following
composition (all calculated on a dry weight basis): the gelling agent in an
amount of
from about 5vvt% to about 40wt%, or about lOvvt% to 30wt%, or about 15wt% to
about
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25w0/0; the aerosol-former material in an amount of from about lOwt% to about
50wt%,
or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (all
calculated on a dry weight basis), the acid in an amount of from about 0.1wt%
to about
8 wt%, or from about 0.5vvt% to 7wt%, or from about 1 wt% to about 5w0/0, or
form
5 about 1wr/o to about 3wt%. Suitably, the amorphous solid of the second
aerosol-
generating material may have the following composition (all calculated on a
dry weight
basis): the gelling agent in an amount of from about 40w0/0 to about 70wt%;
the
aerosol-former material in an amount of from about 20wt% to about 50wt%; and
the
acid in an amount of from about 0.1 wt% to about 5 wt%,
AMORPHOUS SOLID COMPOSITION
The following discussion of the amorphous solid composition applies
independently to the amorphous solid in each of the aerosol-generating
materials
15 present in the consumable of the invention.
In some cases, the amorphous solid may have a thickness of about 0.015mm to
about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm,
0.1mm or
0.15mm to about 0.5mm, 0.3mm or 0.2mm. The inventors have found that an
20 amorphous solid having a thickness of 0.2mm is particularly suitable, In
some
embodiments the amorphous solid may have a thickness of about 0.1-0.2 mm. The
amorphous solid may comprise more than one layer, and the thickness described
herein
refers to the aggregate thickness of those layers.
25 The inventors have established that if the amorphous solid is
too thick, then
heating efficiency is compromised. This adversely affects the power
consumption in
use. Conversely, if the 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. The
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thickness stipulated herein is a mean thickness for the material. In some
cases, the
amorphous solid thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or
1%.
In some cases, the amorphous solids may be heated to generate aerosol once. In
5 some cases, the amorphous solids may be heated to generate aerosol more
than once,
such as twice or three times.
Where an amorphous solid is to be heated more than once a thicker amorphous
solid may be used. For example, in some embodiments the thickness may be 0.2-
0.5
10 mm,
In some cases, the amorphous solid may comprise 1-60wt% of a gelling agent
wherein these weights are calculated on a dry weight basis.
15 In some embodiments, the gelling agent comprises a
hydrocolloid. In some
embodiments, the gelling agent comprises one or more compounds selected from
the
group comprising alginates, pectins, starches (and derivatives), celluloses
(and
derivatives such as methylcellulose, hydroxypropyl cellulose, and
carboxymethyl
cellulose (CMC)), gums, silica or silicones compounds, clays, polyvinyl
alcohol and
20 combinations thereof. For example, in some embodiments, the gelling
agent comprises
one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl
cellulose,
carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose,
acacia
gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In
some
cases, the gelling agent comprises alginate and/or pectin, and may be combined
with a
25 setting agent (such as a calcium source) during formation of the
amorphous solid. In
some cases, the amorphous solid may comprise a calcium-crosslinked alginate
and/or a
calcium-crosslinked pectin.
In some cases, the gelling agent may be combined with a setting agent (such as
30 a calcium source) during formation of the amorphous solid.
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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
consists of calcium formate and/or calcium lactate. In particular examples,
the setting
5
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.
The total amount of the setting agent, such as a calcium source, may be 0.5-
10
5w0/0 (calculated on a dry weight basis)
Suitably, the total amount may be from about
lwt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5w1%. The inventors have found that
the
addition of too little setting agent may result in an amorphous solid which
does not
stabilise the amorphous solid components and results in these components
dropping out
of the amorphous solid. The inventors have found that the addition of too much
setting
15
agent results in an amorphous solid that is very
tacky and consequently has poor
handl eabi lity .
When the amorphous solid does not contain tobacco, a higher amount of setting
agent may need to be applied. In some cases the total amount of setting agent
may
20
therefore be from 0.5-12wt% such as 5-10vvt%,
calculated on a dry weight basis.
Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about
12w0/0 or
1 Owt%. In this case the amorphous solid will not generally contain any
tobacco.
In some embodiments, the gelling agent comprises alginate, and the alginate is
25
present in the amorphous solid in an amount of
from 10-30wt% of the amorphous solid
(calculated on a dry weight basis). In some embodiments, alginate is the only
gelling
agent present in the amorphous solid. In other embodiments, the gelling agent
comprises alginate and at least one further gelling agent, such as pectin.
30
In some embodiments the gelling agent comprises
a mixture of alginate and
carboxymethylcellulose (CMC). Suitably the gelling agent comprises a greater
quantity
of CMC than alginate; for example in some cases the ratio of CMC to alginate
is about
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5 : 1, about 3 : 1, about 2: 1, or about 1.5 : 1; for example is in the range
of 5 : 1 ¨ 1.5
: 1.
In some embodiments the amorphous solid may include gelling agent
5 comprising carrageenan.
In some embodiments, the gelling agent may comprise one or more compounds
selected from cellulosic gelling agents, non-cellulosic gelling agents, guar
gum, acacia
gum and mixtures thereof.
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-
1PMC),
methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate
butyrate
15 (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
(I-IPMC), 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
25 agar.
Suitably, the amorphous solid may comprise from about 5wt%, lOwt%, 15wt%,
or 20wt% to about 80wt%, 70wt%, 60w1%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt%
of an aerosol-former material (all calculated on a dry weight basis). The
aerosol-former
30 material may act as a plasticiser. For example, the amorphous solid may
comprise 10-
60wt%, 15-50wt% or 20-40wt% of an aerosol-former material. In some cases, the
aerosol-former material comprises one or more compound selected from
erythritol,
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propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases,
the aerosol-
former material comprises, consists essentially of or consists of glycerol.
The inventors
have established that if the content of the aerosol-former material is too
high, the
amorphous solid may absorb water resulting in a material that does not create
an
5
appropriate consumption experience in use. The
inventors have established that if the
aerosol-former material content is too low, the amorphous solid may be brittle
and
easily broken.
In some embodiments, the aerosol former comprises one or more polyhydric
10
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
di methyl tetradecanedioate.
15
In embodiments in which the amorphous solid
comprises a flavourant, suitably,
the amorphous solid comprises up to about 60wt%, 50wt%, 40vvt%, 30wr/o, 20wt%,
10w0/0 or 5wt% of the flavourant. In some cases, the amorphous solid may
comprise
at least about 0.5wt%, lwr/o, 2wt%, 5wt% lOwt%, 20wt% or 30wt% of the
flavourant
(all calculated on a dry weight basis). For example, the amorphous solid may
comprise
20
0.1-60wt%, 1-60wt%, 5-60wt%, 10-60wt%, 20-50wt%
or 30-40wt% of the flavourant.
In some cases, the flavourant (if present) comprises, consists essentially of
or consists
of menthol. In some cases, the amorphous solid is free from flavourant.
In embodiments in which an aerosol-generating material of the invention
25
comprises an active substance, in some cases,
the amorphous solid comprises a tobacco
material and/or nicotine. For example, the amorphous solid may comprise
powdered
tobacco and/or nicotine and/or a tobacco extract. In some cases, the amorphous
solid
may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about
70w0/0, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of an active
30
substance. In some cases, the amorphous solid
may comprise from about lwt%, 5wt%,
1 Owt%, 15wt%, 20wt% or 25w01/0 to about 70wr/o, 60wt%, 50wt%, 45wt% or 40wt%
(calculated on a dry weight basis) of a tobacco material and/or nicotine.
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In embodiments in which the aerosol-generating material comprises an active
substance such as tobacco extract; in some cases, the amorphous solid may
comprise 5-
60wt% (calculated on a dry weight basis) of tobacco extract In some cases, the
5
amorphous solid may comprise from about 5wt%,
10wt%, 15wr/o, 20wt% or 25wt% to
about 55wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) tobacco
extract. For example, the amorphous solid may comprise 5-60wt%, 10-55wt% or 25-
55wt% of tobacco extract The tobacco extract may comprise nicotine at a
concentration such that the amorphous solid comprises lwt% 1.5wt%, 2vvt% or
2.5wt%
10
to about 6wt%, 5wt%, 4 5vvt% or 4wt% (calculated
on a dry weight basis) of nicotine.
In some cases, there may be no nicotine in the amorphous solid other than that
which
results from the tobacco extract.
In some embodiments the amorphous solid comprises no tobacco material but
15
does comprise nicotine. In some such cases, the
amorphous solid may comprise from
about lwt%, 2vvt-%, 3wt% or 4wt% to about 20wt%, 15wr/o, lOwt% or 5wt%
(calculated on a dry weight basis) of nicotine. For example, the amorphous
solid may
comprise 1-20wt% or 2-5wt% of nicotine.
20
In embodiments where the amorphous solid
comprises an acid, the amorphous
solid may comprise 1-20wt%, 5-15wt% or 8-12wt% (calculated on a dry weight
basis)
of acid, for example, lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, lOwt% or
5wt% (calculated on a dry weight basis) of acid.
25
Without wishing to be bound by theory, it is
believed that including an acid in
the amorphous solid protonates the nicotine and results in an aerosol which
some users
of smoking devices find more satisfying.
The aerosol-generating material or amorphous solid may comprise an acid.
The inclusion of an acid is particularly preferred in embodiments in which the
aerosol-generating material or amorphous solid comprises nicotine. In such
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embodiments, the presence of an acid may stabilise dissolved species in the
slurry from
which the aerosol-generating material or amorphous solid is formed. 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 some such embodiments, the acid may contain an acidic fimctional group
which has a pKa value ranging from 2 to 6, for example ranging from 3 to 6 or
ranging
from 4 to 5, when measured at 25 C.
In some such embodiments, the acid may have a boiling point ranging from
70 C to 450 C, for example, ranging from 100 C to 320 C.
In some such embodiments, the amorphous solid comprises from 1 - 20wt% of
acid, wherein the acid has a functional group which has a p.Ka value ranging
from 2 to
6 when measured at 25 C and wherein the acid has a boiling point ranging from
70 C
to 350 C.
In some such embodiments, the acid may be an organic acid.
In some of these embodiments, the acid may be at least one of a monoprotic
acid, diprotic acid and 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 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-keto acid.
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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,
malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic
acid.
5 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 embodiments, the acid is levulinic acid.
In embodiments where the amorphous solid comprises an acid, the amorphous
solid may comprise lwtto, 2wt%, 3wt% or 4wt% to about 20wt%, 15w0/0, 1 Owt% or
15 5wt% (calculated on a dry weight basis) of an organic acid.
In embodiments where the amorphous solid comprises an acid, the amorphous
solid may comprise lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 15wt%, 1 Owt% or
5wt% (calculated on a dry weight basis) of an acid comprising a carboxyl
functional
20 group.
In embodiments where the amorphous solid comprises an acid, the amorphous
solid may comprise 1w0/0, 2wt%, 3wt% or 4w0/0 to about 20wt%, 15wt%, 10w0/0 or
5wt% (calculated on a dry weight basis) of an acid containing an acidic
functional group
25 which has a pKa value of between 2 and 6, when measured at 25 C.
In certain embodiments, the aerosol-generating material or amorphous solid
comprises a gelling agent comprising a cellulosic gelling agent and/or a non-
cellulosic
gelling agent, an active substance and an acid.
The amorphous solid may, in some cases, be a hydrogel and comprises less than
about 20wt%, 15wt%, 12wt% or 1 Owt% of water calculated on a wet weight basis
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(WWB). In some cases, the amorphous solid may comprise at least about lwt%,
2wt%
or 5wt% of water (WWB). The amorphous solid comprises from about lwt% to about
15wt% water, or from about 5wt% to about 15wt% calculated on a wet weight
basis.
Suitably, the water content of the amorphous solid may be from about 5wt%,
7wt% or
5 9wri/o to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wr/o.
The amorphous solid may be made from a gel, and this gel may additionally
comprise a solvent, included at 0.1-50w0/0. However, the inventors have
established
that the inclusion of a solvent in which the flavourant is soluble may reduce
the gel
10 stability and the flavourant may crystallise out of the gel As such, in
some cases, the
gel does not include a solvent in which the flavourant is soluble.
In some cases, the amorphous solid comprises from 1 ¨ 60wt% of a filler, for
example, 5 ¨ 50wt%, 10 ¨ 40 wt% or 15 ¨30 wt% of a filler. In some such cases
the
15 amorphous solid comprises at least 1 wt% of a filler, for example, at
least 5 wt%, at
least 10wr/o, at least 20wt% at least 30wr/o, at least 40wr/o, or at least
50wt% of a
filler.
In some embodiments, the amorphous solid comprises less than 60wt% of a
20 filler, such as from lwt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30vvt%,
or lOvvt%
to 20wt%.
In other embodiments, the amorphous solid comprises less than 20wt%, suitably
less than lOvvt% or less than 5wt% of a filler. In some cases, the amorphous
solid
25 comprises less than lwt4/0 of a filler, and in some cases, is free from
filler.
The filler, if present, may comprise one or more inorganic filler materials,
such
as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal
silica,
magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable
inorganic
30 sorbents, such as molecular sieves. The filler may comprise one or more
organic filler
materials such as wood pulp, cellulose and cellulose derivatives (such as
methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).
In
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some cases, the amorphous solid comprises less than lwt% of a filler, and in
some
cases, comprises no filler. In particular, in some cases, the amorphous solid
comprises
no calcium carbonate such as chalk.
5
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 (such as methylcellulose,
hydroxypropyl
cellulose, and carboxymethyl cellulose (CMC)). Without wishing to be bound by
theory, ills believed that including fibrous filler in an amorphous solid may
increase
10 the tensile strength of the material.
In some embodiments, the amorphous solid does not comprise tobacco fibres.
In particular embodiments, the amorphous solid does not comprise fibrous
material.
15
In some embodiments, the aerosol-generating
material does not comprise
tobacco fibres. In particular embodiments, the aerosol-generating material
does not
comprise fibrous material.
In some embodiments, the aerosol-generating material does not comprise
20
tobacco fibres, In particular embodiments, the
aerosol-generating material does not
comprise fibrous material.
In some embodiments, the consumable does not comprise tobacco fibres. In
particular embodiments, the consumable does not comprise fibrous material.
The aerosol-generating material comprising the amorphous solid may have any
suitable area density, such as from 30 g/m2 to 120 g/m2. In some embodiments,
aerosol
generating material may have an area density of from about 30 to 70 g/m2, or
about 40
to 60 g/m2. In some embodiments, the amorphous solid may have an area density
of
30
from about 80 to 120 g/m2, or from about 70 to
110 g/m2, or particularly from about 90
to 110 g/m2.
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In some examples, the amorphous solid in sheet form may have a tensile
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, 01 200 N/m to 300 N/m, or about 250 N/m.
hi
5 some examples, such as where the amorphous solid comprises a filler, the
amorphous
solid may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m
to 900
N/m, or around 800 N/m.
The amorphous solid may comprise a colourant. The addition of a
10 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 the aerosol-generating material. 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
15 the amorphous solid.
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
20 or synthetic colourants, such as natural or synthetic dyes, food-grade
colourants
and pharmaceutical-grade colourants may be used. In certain embodiments, the
colourant 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-
25 generating material comprising 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.
The colourant may be incorporated during the formation of the amorphous solid
30 (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).
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METHOD OF M4NUFACTUR1NG A CONSUMABLE
The invention also provides a method of manufacturing a consumable for use
with a
5 non-combustible aerosol provision device, the method comprising:
providing a support;
depositing on the support at least two discrete portions of slurry comprising
a
gelling agent, an aerosol former and at least one of an active substance,
flavourant and
an acid;
10 drying the at least two discrete portions of slurry to provide
a first aerosol-
generating material and a second aerosol-generating material, wherein the
first and
second aerosol-generating materials are attached to the support;
forming the consumable;
wherein each of the first and second aerosol-generating materials comprise an
15 amorphous solid, the amorphous solid comprising:
- 0.5 -60 wt % of a gelling agent,
-0- 80 wt % of an aerosol-former material; and
-0 - 60 wt % of at least one of an active substance, flavourant and an acid;
wherein these weights are calculated on a dry weight basis and wherein the
amorphous
20 solid of the first aerosol-generating material has a composition
different from a
composition of the amorphous solid of the second aerosol-generating material.
The embodiments described throughout the application in relation to the
consumable of the present invention also apply mutatis mu/ant/is to the method
of
25 manufacturing a consumable.
The present invention also includes the use of a consumable as described
throughout the present application in a non-combustible aerosol provision
device,
wherein the device is arranged to generate aerosol from the consumable when
the
30 consumable is used with the non-combustible aerosol provision device.
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The embodiments described throughout the application in relation to the
consumable of the present invention also apply mutatis mutant/is to the use of
the
consumable.
5 CONSUMABLE
In some cases, the aerosol-generating materials (for example, the first and
second aerosol-generating materials) are attached to a support.
Advantageously, the
support is a planar support. In some cases, the support may be substantially
or wholly
10 impermeable to gas and/or aerosol_ This prevents aerosol or gas passage
through the
support, thereby controlling the flow and ensuring good delivery to the user.
This can
also be used to prevent condensation or other deposition in use of the
gas/aerosol on,
for example, the surface of a heater provided in non-combustible aerosol
provision
system. Thus, consumption efficiency and hygiene can be improved in some
cases.
Thus, in certain embodiments the invention provides a consumable for use
within a non-combustible aerosol provision system, the consumable comprising:
a support;
a first aerosol-generating material attached to the support; and
20 a second aerosol-generating material attached to the support,
wherein each aerosol-generating material comprises an amorphous solid, the
amorphous solid comprising:
- 0.5-60 wt% of a gelling agent;
- 0-80 wt% of an aerosol-former material; and
25 - 0-60 wt% of at least one of an active substance, flavourant
and an acid;
wherein these weights are calculated on a dry weight basis; and
wherein the amorphous solid of the first aerosol-generating material has a
composition
different from the amorphous solid of the second aerosol-generating material.
30 The support may be at least partially porous in the region of a
surface abutting
the amorphous solid. The inventors have found that such a support is
particularly
suitable for the present invention; the porous section of the support abuts
the amorphous
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solid and forms a strong bond. The amorphous solid is formed by drying a gel
and,
without being limited by theory, it is thought that a slurry from which the
amorphous
solid is formed partially impregnates porous material of the support so that
when the
amorphous solid sets and forms cross-links, the support is partially bound
into the
5 amorphous solid. This provides a strong binding between the amorphous
solid and the
support.
Additionally, surface roughness may contribute to the strength of bond between
the amorphous solid and the support. The inventors have found that the paper
10 roughness (for the surface abutting the aerosol-generating material) may
suitably be in
the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100
Bekk
seconds (measured over an air pressure interval of 50.66-481)0 Wa). (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
15 sample, and the time (in seconds) for a fixed volume of air to seep
between these
surfaces is the "Bekk smoothness")
Conversely, the surface of the support facing away from the amorphous solid
may be arranged in contact with a heater, and a smoother surface may provide
more
20 efficient heat transfer. Thus, in some cases, the support is disposed so
as to have a
rougher side abutting the amorphous solid and a smoother side facing away from
the
amorphous solid.
In one particular case, the support may itself be a laminate structure. For
25 example, it may comprise a cardboard-backed foil; a cardboard layer
abuts the
amorphous solid and the properties discussed in the previous paragraphs are
afforded
by this abutment. A foil backing is substantially impermeable, providing
control of the
aerosol flow path. A metal foil backing may also serve to conduct heat to the
amorphous solid.
In another case, a foil layer of the cardboard-backed foil abuts the amorphous
solid. The foil is substantially impermeable, thereby preventing water
provided in the
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amorphous solid to be absorbed into the paper which could weaken its
structural
integrity.
In some cases, the support is formed from or comprises metal foil, such as
5 aluminium foil. A metallic support may allow for better conduction of
thermal energy
to the amorphous solid. Additionally, or alternatively, a metal foil may
function as a
susceptor in an induction heating system. In particular embodiments, the
support
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 20pm, such
as from
10 about 1pm to about lOpm, suitably about 5pm.
The consumable may alternatively be referred to herein as a cartridge. The
consumable may be adapted for use in a THP, a hybrid device or another aerosol
generating device. In some cases, the consumable may be in the form of a rod.
In some
15 cases, the consumable may additionally comprise a filter and/or cooling
element, as
described previously. In some cases, the consumable may be circumscribed by a
wrapping material such as paper.
The consumable may additionally comprise ventilation apertures. These may
20 be provided in the sidewall of the consumable. In some cases, the
ventilation apertures
may be provided in the filter and/or cooling element. These apertures may
allow cool
air to be drawn into the consumable during use, which can mix with the heated
volatilised components thereby cooling the aerosol.
25 The ventilation enhances the generation of visible heated
volatilised
components from the consumable 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
30 nucleation, and eventually the size of the aerosol particles of the
heated volatilised
components increases by further condensation of the heated volatilised
components and
by coagulation of newly formed droplets from the heated volatilised
components.
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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
5 by the method described above. The visibility of the heated volatilised
components
enables the user to identify that the volatilised components have been
generated and
adds to the sensory experience of the smoking experience.
In another example, the ventilation ratio is between 50% and 85% to provide
10 additional cooling to the heated volatilised components In some cases,
the ventilation
ratio may be at least 60% or 65%.
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 consumable 101.
The
15 consumable 101 is adapted for use with a device having a power source
and a heater.
The consumable 101 of this embodiment is particularly suitable for use with
the device
51 shown in Figures 5 to 7, described below. In use, the consumable 101 may be
removably inserted into the device shown in Figure 5 at an insertion point 20
of the
device 51.
The consumable 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
material described herein. In some embodiments, it may be included in sheet
form. In
25 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.
The filter assembly 105 includes three segments, a cooling segment 107, a
filter
30 segment 109 and a mouth end segment 111. The consumable 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
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end 115 of the consumable 101. In one example, the cooling segment 107 is
located
adjacent the body of aerosol-generating material 103 between the body of
aerosol
generating material 103 and the filter segment 109, such that the cooling
segment 107
is in an abutting relationship with the aerosol-generating material 103 and
the filter
5 segment 103. In other examples, there may be a separation between the
body of aerosol-
generating material 103 and the cooling segment 107 and between the body of
aerosol-
generating material 103 and the filter segment 109. The filter segment 109 is
located
in between the cooling segment 107 and the mouth end segment 111. The mouth
end
segment 111 is located towards the proximal end 113 of the consumable 101,
adjacent
10 the filter segment 109. In one example, the filter segment 109 is in an
abutting
relationship with the mouth end segment 111. In one embodiment, the total
length of
the filter assembly 105 is between 37mm and 45mm, more preferably, the total
length
of the filter assembly 105 is 41mm.
15 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 consumable 101 is between 71mm and
20 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 consumable 101. However, in other embodiments, the
distal end
115 of the consumable 101 may comprise an end member (not shown) covering the
25 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
30 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.
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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-
5 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
consumable 101 is in use during insertion into the device 51. In one example,
the
thickness of the wall of the cooling segment 107 is approximately 0.29mm.
The cooling segment 107 provides a physical displacement between the aerosol-
generating material 103 and the filter segment 109. The physical displacement
provided
by the cooling segment 107 will provide a thermal gradient across the length
of the
cooling segment 107. In one example the cooling segment 107 is configured to
provide
15 a temperature differential of at least 40 degrees Celsius between a
heated volatilised
component entering a first end of the cooling segment 107 and a heated
volatilised
component exiting a second end of the cooling segment 107. In one example the
cooling segment 107 is configured to provide a temperature differential of at
least 60
degrees Celsius between a heated volatilised component entering a first end of
the
20 cooling segment 107 and a heated volatilised component exiting a second
end of the
cooling segment 107. This temperature differential across the length of the
cooling
element 107 protects the temperature sensitive filter segment 109 from the
high
temperatures of the aerosol-generating material 103 when it is heated by the
device 51.
If the physical displacement was not provided between the filter segment 109
and the
25 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.
In one example the length of the cooling segment 107 is at least 15mm. In one
30 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.
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The cooling segment 107 is made of paper, which means that it is comprised of
a material that does not generate compounds of concern, for example, toxic
compounds
when in use adjacent to the heater of the device 51. In one example, the
cooling segment
107 is manufactured from a spirally wound paper tube which provides a hollow
internal
5 chamber yet maintains mechanical rigidity. Spirally wound paper tubes
are able to meet
the tight dimensional accuracy requirements of high-speed manufacturing
processes
with respect to tube length, outer diameter, roundness and straightness.
In another example, the cooling segment 107 is a recess created from stiff
plug
10 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 consumable 101 is
in use
during insertion into the device 51.
15 The filter segment 109 may be formed of any filter material
sufficient to remove
one or more volatilised compounds from heated volatilised components from the
aerosol-generating material. In one example the filter segment 109 is made of
a mono-
acetate material, such as cellulose acetate. The filter segment 109 provides
cooling and
irritation-reduction from the heated volatilised components without depleting
the
20 quantity of the heated volatilised components to an unsatisfactory level
for a user.
In some embodiments, a capsule (not illustrated) may be provided in filter
segment 109. It may be disposed substantially centrally in the filter segment
109, both
across the filter segment 109 diameter and along the filter segment 109
length. In other
25 cases, it may be offset in one or more dimension. The capsule may in
some cases,
where present, contain a volatile component such as a flavourant or aerosol
generating
agent.
The density of the cellulose acetate tow material of the filter segment 109
30 controls the pressure drop across the filter segment 109, which in turn
controls the draw
resistance of the consumable 101. Therefore the selection of the material of
the filter
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41
segment 109 is important in controlling the resistance to draw of the
consumable 101.
In addition, the filter segment performs a filtration function in the
consumable 101.
In one example, the filter segment 109 is made of a 8Y15 wade of filter tow
5 material, which provides a filtration effect on the heated volatilised
material, whilst also
reducing the size of condensed aerosol droplets which result from the heated
volatilised
material.
The presence of the filter segment 109 provides an insulating effect by
providing
10 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 6mna to lOmm in length,
15 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
20 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 consumable 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
25 to lOmm, suitably 8mm.
The mouth end segment 111 may be manufactured from a spirally wound paper
tube which provides a hollow internal chamber yet maintains critical
mechanical
rigidity. Spirally wound paper tubes are able to meet the tight dimensional
accuracy
30 requirements of high-speed manufacturing processes with respect to tube
length, outer
diameter, roundness and straightness.
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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.
5
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
10
Referring to Figures 3 and 4, there are shown a
partially cut-away section and
perspective views of an example of a consumable 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 increment of 200.
15
In the example of the consumable 301 shown in
Figures 3 and 4, a ventilation
region 317 is provided in the consumable 301 to enable air to flow into the
interior of
the consumable 301 from the exterior of the consumable 301. In one example the
ventilation region 317 takes the form of one or more ventilation holes 317
formed
through the outer layer of the consumable 301. The ventilation holes may be
located in
20
the cooling segment 307 to aid with the cooling
of the consumable 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 consumable 301 in a
cross-section
that is substantially perpendicular to a longitudinal axis of the consumable
301.
25
In one example, there are between one to four
rows of ventilation holes to
provide ventilation for the consumable 301. Each row of ventilation holes may
have
between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for
example,
be between 100 to 500um 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
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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 consumable 301. The
ventilation
holes 317 are positioned so as to provide effective cooling to the consumable
301.
In one example, the rows of ventilation holes 317 are located at least 11mm
from the proximal end 313 of the consumable, suitably between 17mm and 20mm
from
the proximal end 313 of the consumable 301. The location of the ventilation
holes 317
is positioned such that user does not block the ventilation holes 317 when the
consumable 301 is in use.
Providing the rows of ventilation holes between 17mm and 20mm from the
proximal end 313 of the consumable 301 enables the ventilation holes 317 to be
located
outside of the device 51, when the consumable 301 is fully 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 consumable 301 through the ventilation
holes from
outside the device 51 to aid with the cooling of the consumable 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 consumable 301 is fully
inserted into
the device 51. The length of the cooling segment 307 provides a first function
of
providing a physical gap between the heater arrangement of the device 51 and
the heat
sensitive filter arrangement 309, and a second function of enabling the
ventilation holes
317 to be located in the cooling segment, whilst also being located outside of
the device
51, when the consumable 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
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
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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.
5
A first end 53 is sometimes referred to herein
as the mouth or proximal end 53
of the device 51 and a second end 55 is sometimes referred to herein as the
distal end
55 of the device 51. The device 51 has an on/off button 57 to allow the device
51 as a
whole to be switched on and off as desired by a user.
10
The device 51 comprises a housing 59 for
locating and protecting various
internal components of the device 51. In the example shown, the housing 59
comprises
a uni-body sleeve 11 that encompasses the perimeter of the device 51, capped
with a
top panel 17 which defines generally the 'top' of the device 51 and a bottom
panel 19
which defines generally the 'bottom' of the device 51. In another example the
housing
15
comprises a front panel, a rear panel and a pair
of opposite side panels in addition to
the top panel 17 and the bottom panel 19.
The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-
body sleeve 11, to permit easy access to the interior of the device 51, or may
be
20
"permanently" fixed to the uni-body sleeve 11,
for example to deter a user from
accessing the interior of the device 51. In an example, the panels 17 and 19
are made
of a plastics material, including for example glass-filled nylon formed by
injection
moulding, and the uni-body sleeve 11 is made of aluminium, though other
materials
and other manufacturing processes may be used.
The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the
device 51 through which, in use, the consumable 101, 301 including the aerosol-
generating 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
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control circuitry 25 and the power source 27 are laterally adjacent (that is,
adjacent
when viewed from an end), with the control circuitry 25 being located
generally
between the heater arrangement 23 and the power source 27, though other
locations are
possible.
5
The control circuitry 25 may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the aerosol-
generating
material in the consumable 101, 301 as discussed further below.
10
The power source 27 may be
for example a battery, which may be a rechargeable
battery or a non-rechargeable battery. Examples of suitable batteries include
for
example a lithium-ion battery, a nickel battery (such as a nickel¨cadmium
battery), an
alkaline battery and/ or the like. The battery 27 is electrically coupled to
the heater
arrangement 23 to supply electrical power when required and under control of
the
15 control circuitry 25 to heat the aerosol-generating material in the
consumable (as
discussed, to volatilise the aerosol-generating material without causing the
aerosol-
generating material to burn).
An advantage of locating the power source 27 laterally adjacent to the heater
20 arrangement 23 is that a physically large power source 25 may be
used without causing
the device 51 as a whole to be unduly lengthy. As will be understood, in
general a
physically large power source 25 has a higher capacity (that is, the total
electrical energy
that can be supplied, often measured in Amp-hours or the like) and thus the
battery life
for the device 51 can be longer.
In one example, the heater arrangement 23 is generally in the form of a hollow
cylindrical tube, having a hollow interior heating chamber 29 into which the
consumable 101, 301 comprising the aerosol-generating material is inserted for
heating
in use. Different arrangements for the heater arrangement 23 are possible. For
example,
the heater arrangement 23 may comprise a single heating element or may be
formed of
plural heating elements aligned along the longitudinal axis of the heater
arrangement
23. The or each heating element may be annular or tubular, or at least part-
annular or
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part-tubular around its circumference. In an example, the or each heating
element may
be a thin film heater. In another example, the or each heating element may be
made of
a ceramics material. Examples of suitable ceramics materials include alumina
and
aluminium nitride and silicon nitride ceramics, which may be laminated and
sintered.
5 Other heating arrangements are possible, including for example inductive
heating,
infrared heater elements, which heat by emitting infrared radiation, or
resistive heating
elements formed by for example a resistive electrical winding.
In one particular example, the heater arrangement 23 is supported by a
stainless
10 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 consumable 101, 301 is inserted into the heater
arrangement
23 when the consumable 101, 301 is inserted into the device 51.
15 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
20 its length by a thermal insulator 31. The insulator 31 helps to reduce
heat passing from
the heater arrangement 23 to the exterior of the device 51. This helps to keep
down the
power requirements for the heater arrangement 23 as it reduces heat losses
generally.
The insulator 31 also helps to keep the exterior of the device 51 cool during
operation
of the heater arrangement 23 In one example, the insulator 31 may be a double-
walled
25 sleeve which provides a low pressure region between the two walls of the
sleeve. That
is, the insulator 31 may be for example a "vacuum" tube, i.e. a tube that has
been at
least partially evacuated so as to minimise heat transfer by conduction and/or
convection. Other arrangements for the insulator 31 are possible, including
using heat
insulating materials, including for example a suitable foam-type material, in
addition to
30 or instead of a double-walled sleeve.
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The housing 59 may further comprises various internal support structures 37
for
supporting all internal components, as well as the heating arrangement 23.
The device 51 further comprises a collar 33 which extends around and projects
5 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
chamber 35 further comprises a cooling structure 35f, which in this example,
comprises
a plurality of cooling fins 351 spaced apart along the outer surface of the
chamber 35,
and each arranged circumferentially around outer surface of the chamber 35.
There is
10 an air gap 36 between the hollow chamber 35 and the consumable 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 consumable 101, 301 over
at least
part of the cooling segment 307.
15 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 a
20 consumable 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 consumable 101, 301 form ventilation paths around the exterior of the
consumable
101, 301. These ventilation paths allow hot vapours that have escaped from the
consumable 101, 301 to exit the device 51 and allow cooling air to flow into
the device
25 51 around the consumable 101,301 in the air gap 36.
In operation, the consumable 101, 301 is removably inserted into an insertion
point 20 of the device 51, as shown in Figures 5 to 7. Referring particularly
to Figure
6, in one example, the body of aerosol-generating material 103, 303, which is
located
30 towards the distal end 115, 315 of the consumable 101, 301, is entirely
received within
the heater arrangement 23 of the device 51. The proximal end 113, 313 of the
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consumable 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 consumable 101, 301 to
5 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 consumable 101,
301,
10 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 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
15 travels through the cooling segment 107, 307, it will cool and some
volatilised
components will condense on the inner surface of the cooling segment 107, 307,
In the examples of the consumable 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
20 cooling segment 307. This cool air will mix with the heated volatilised
components to
provide additional cooling to the heated volatilised components.
Advantageously, the consumable of the invention allows each of the first and
second aerosol-generating materials to be aerosolized separately. In other
words, the
25 generation of aerosol from each aerosol-generating material may be under
separate
control, such that the generation of aerosol produced by each aerosol-
generating
material can be varied individually. In an embodiment in which a non-
combustible
aerosol provision system uses heat to generate aerosol, each aerosol-
generating material
in the consumable could be under the control of a separate heat generation
arrangement.
30 In such an embodiment, the temperature of each aerosol-generating
material may be
controlled separately to stimulate the release of a desired quantity of
aerosol from each
aerosol-generating material. In this way, the non-combustible aerosol
provision system
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is adapted to allow a user to aerosolize the first and/or second aerosol-
generating
material according to personal preference. As a non-limiting example provided
to
illustrate the invention; the amorphous solid of the first aerosol-generating
material may
comprise a flavourant, and no active substance, whilst the amorphous solid of
the
5 second aerosol-generating material may comprise active substance and no
flavourant;
if the user would like to inhale flavour only, then the non-combustible
aerosol provision
system could allow this; for example, the user could programme the non-
combustible
aerosol provision device to aerosolize the first aerosol-generating material
(comprising
the flavourant), but not aerosolize the second aerosol-generating material
(comprising
10 the active substance). It will be appreciated that such a system could
be further
configured to allow a user to obtain a wide variety of smoking experiences
according
to preference.
In some embodiments, the aerosol-generating materials are be arranged in the
15 consumable such that they may be stimulated to generate aerosol under
separate control
from each other, when used within a non-combustible aerosol provision system.
An advantage of the consumable of the invention is that one production line or
facility can produce a single type of consumable, which is capable of
providing a variety
20 of experiences according to user preference.
In some cases, a heater (for example a heater in the non-combustible aerosol
provision system) may heat, without burning, the amorphous solids to between
120 C
and 350 C in use. In some cases the heater, may heat, without burning, the
amorphous
25 solids to between 140 C and 250 C in use.
The heater may comprise one or more electrically resistive heaters, including
for example one or more nichrome resistive heater(s) and/or one or more
ceramic
heater(s). The one or more heaters may comprise one or mom induction heaters
which
30 includes an arrangement comprising one or more susceptors which may form
a chamber
into which an article comprising aerosol-generating material is inserted or
otherwise
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located in use. Alternatively or in addition, one or more susceptors may be
provided in
the aerosol-generating material. Other heating arrangements may also be used.
EXEMPLARY EMBODIMENTS
5
The following embodiments are provided by way of example, to better explain
how the present invention may be implemented.
In one embodiment, there is provided a consumable for use with a non-
10 combustible aemsol provision device, the consumable
comprising.
a first aerosol-generating material; and
a second aerosol-generating material,
wherein the first aerosol-generating material comprises an amorphous solid,
the
amorphous solid comprising:
15 -30 - 60 wt% of a gelling agent;
- 15 - 60 wt% of an aerosol-former material; and
- 1 - 10 wt% of an active substance; and
wherein the second aerosol-generating material comprises an amorphous solid,
the amorphous solid comprising:
20 -30- 60 wt% of a gelling agent;
- 10 - 40 wt% of an aerosol-former material; and
-20- 50 wt% of a flavourant;
wherein these weights are calculated on a dry weight basis; and
wherein the amorphous solid of the first aerosol-generating material has a
25 composition different from the amorphous solid of the
second aerosol-generating
material.
In a further embodiment there is provided a consumable for use in a non-
combustible aerosol provision device, the consumable comprising:
30 a support
a first aerosol-generating material attached to the support; and
a second aerosol-generating material attached to the support,
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wherein each of the first and second aerosol-generating materials comprises an
amorphous solid, the amorphous solid comprising:
-30- 60 wt% of a gelling agent;
- 15 - 60 wt% of an aerosol-former material; and
5 - 0 - 60 wt% of at least one of nicotine, flavourant and acid,
wherein the acid
has a boiling point ranging from 100 C to 350 C and/or an acidic functional
group
which has a PKa value ranging from 3 to 7 when measured at 25 C;
wherein these weights are calculated on a dry weight basis; and
wherein the amorphous solid of the first aerosol-generating material has a
10 composition different from the amorphous solid of the second aerosol-
generating
material.
In a further embodiment there is provided a consumable for use in a non-
combustible aerosol provision device, the consumable comprising:
15 a support
a first aerosol-generating material attached to the support; and
a second aerosol-generating material attached to the support,
wherein each of the first and second aerosol-generating materials comprises an
amorphous solid, the amorphous solid comprising:
20 -30- 60 wt% of a gelling agent;
- 15 - 60 wt% of an aerosol-former material; and
-0-60 wt% of at least one of nicotine, flavourant and benzoic acid and/or
lactic
acid;
wherein these weights are calculated on a dry weight basis; and
25 wherein the amorphous solid of the first aerosol-generating
material has a
composition different from the amorphous solid of the second aerosol-
generating
material.
Exemplary and non-limiting formulations for four aerosol-generating materials
30 comprising an amorphous solid, which may be included in a consumable of
the
invention are provided in the table below.
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First
Second Third Fourth
aerosol-
aerosol- aerosol- aerosol-
generating generating generating generating
material
material material material
(Active
(Flavourant) (Aerosol- (Acid)
substance)
former
material)
Total Gelling agent 43% 43%
43% 56%
Alginate 12% 12%
12% 24%
CMC 31% 31%
31% 32%
Filler 0% 0%
0% 0%
Calcium 1% 1%
1% 2%
Flavourant 0% 37%
0% 0%
Glycerol 48% 19%
56% 39%
Nicotine 6% 0%
0% 0%
Benzoic acid 2% 0%
0% 3%
100% 100%
100% 100%
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DEFINITIONS
Delivery System
5 As used herein, the term "delivery system" is intended to
encompass systems
that deliver at least one substance to a user, and includes:
combustible aerosol provision systems, such as cigarettes, cigarillos, cigars,
and tobacco for pipes or for roll-your-own or for make-your-own cigarettes
(whether based on tobacco, tobacco derivatives, expanded tobacco,
reconstituted
10 tobacco, tobacco substitutes or other smokable material);
non-combustible aerosol provision systems that release compounds from
an aerosol-generating material without combusting the aerosol-generating
material, such as electronic cigarettes, tobacco healing products, and hybrid
systems to generate aerosol using a combination of aerosol-generating
materials;
15 and
aerosol-free delivery systems that deliver the at least one substance to a
user
orally, nasally, transdermally or in another way without forming an aerosol,
including but not limited to, lozenges, gums, patches, articles comprising
inhalable
powders, and oral products such as oral tobacco which includes snus or moist
snuff,
20 wherein the at least one substance may or may not comprise nicotine.
Non-Combustible Aerosol Provision System
According to the present disclosure, a "non-combustible" aerosol provision
system is one where a constituent aerosol-generating material of the aerosol
25 provision system (or component thereof) is not combusted or burned in
order to
facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol
provision system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an
electronic cigarette, also known as a vaping device or electronic nicotine
delivery
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system (END), although it is noted that the presence of nicotine in the
aerosol-
generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an
5 aerosol-generating material heating system, also known as a heat-not-bum
system.
An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a
hybrid system to generate aerosol using a combination of aerosol-generating
10 materials, one or a plurality of which may be heated Each of the aerosol-
generating materials may be, for example, in the form of a solid, liquid or
gel and
may or may not contain nicotine. In some embodiments, the hybrid system
comprises a liquid or gel aerosol-generating material and a solid aerosol-
generating
material. The solid aerosol-generating material may comprise, for example,
15 tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a
non-combustible aerosol provision device and a consumable for use with the non-
combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising
aerosol-generating material and configured to be used with non-combustible
aerosol provision devices. These consumables are sometimes referred to as
articles
throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such
as a non-combustible aerosol provision device thereof, may comprise a power
source and a controller. The power source may, for example, be an electric
power
source or an exothermic power source. In some embodiments, the exothermic
30 power source comprises a carbon substrate which may be energised so as
to
distribute power in the form of heat to an aerosol-generating material or to a
heat
transfer material in proximity to the exothermic power source.
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In some embodiments, the non-combustible aerosol provision system may
comprise an area for receiving the consumable, an aerosol generator, an
aerosol
generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying
5 agent.
In some embodiments, the consumable for use with the non-combustible
aerosol provision device may comprise aerosol-generating material, an aerosol-
generating material storage area, an aerosol-generating material transfer
10 component, an aerosol generator, an aerosol generation area, a housing,
a wrapper,
a filter, a mouthpiece, and/or an aerosol-modifying agent.
Active Substance
In some embodiments, the substance to be delivered comprises an active
15 substance.
The active substance as used herein may be a physiologically active
material, which is a material intended to achieve or enhance a physiological
response. The active substance may for example be selected from
nutraceutica1s,
20 nootropics, psychoactives. The active substance may be naturally
occurring or
synthetically obtained. The active substance may comprise for example
nicotine,
caffeine, taurine, theine, vitamins such as B6 or 812 or C, melatonin,
cannabinoids,
or constituents, derivatives, or combinations thereof The active substance may
comprise one or more constituents, derivatives or extracts of tobacco,
cannabis or
25 another botanical.
In some embodiments, the active substance comprises nicotine. In some
embodiments, the active substance comprises caffeine, melatonin or vitamin
B12.
30 In some embodiments, the active substance comprises one or more
cannabinoid
compounds selected from the group consisting of: cannabidiol (CBD),
tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic
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acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC),
cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV),
cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin
(CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE),
5 cannabicitran (CBT).
The active substance may comprise one or more cannabinoid compounds selected
from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol)
10 The active substance may comprise cannabidiol (CBD).
The active substance may comprise nicotine and cannabidiol (CBD).
The active substance may comprise nicotine, cannabidiol (CBD), and THC
15 (tetrahydrocannabinol),
Botanicals
As noted herein, the active substance may comprise or be derived from one
or more botanicals or constituents, derivatives or extracts thereof As used
herein,
20 the term "botanical" includes any material derived from plants
including, but not
limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers,
fruits, pollen,
husk, shells or the like. Alternatively, the material may comprise an active
compound naturally existing in a botanical, obtained synthetically. The
material
may be in the form of liquid, gas, solid, powder, dust, crushed particles,
granules,
25 pellets, shreds, strips, sheets, or the like. Example botanicals are
tobacco,
eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint,
spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus,
laurel,
licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such
as green
tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay
leaves,
30 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,
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cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon
basil,
chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine,
theacrine,
maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination
thereof. The mint may be chosen from the following mint varieties: Mentha
5
Arventis, Mentha c.v.,Mentha niliaca, Mentha
piperita, Mentha piperita citrata
c.v.,Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha
longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v.
and Mentha suaveolens
10
In some embodiments, the active substance comprises
or is derived from
one or more botanicals or constituents, derivatives or extracts thereof and
the
botanical is tobacco.
In some embodiments, the active substance comprises or derived from one
15
or more botanicals or constituents, derivatives or
extracts thereof and the botanical
is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one
or more botanicals or constituents, derivatives or extracts thereof and the
botanical
20 is selected from rooibos and fennel.
Flavours
In some embodiments, the substance to be delivered comprises a flavour.
25
As used herein, the terms "flavour" and "flavourant"
refer to materials
which, where local regulations permit, may be used to create a desired taste,
aroma
or other somatosensorial sensation in a product for adult consumers. They may
include naturally occurring flavour materials, botanicals, extracts of
botanicals,
synthetically obtained materials, or combinations thereof (e.g., tobacco,
cannabis,
30
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,
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berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon,
lime,
tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber,
blueberry,
mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila,
rum,
spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla,
nutmeg,
5
sandalwood, bergamot, geranium, khat, naswar, betel,
shisha, pine, honey essence,
rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom,
cassia,
caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger,
coriander, coffee, hemp, a mint oil from any species of the genus Mentha,
eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba,
hazel,
10
hibiscus, laurel, mate, orange skin, rose, tea such
as green tea or black tea, thyme,
juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,
saffron,
lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis,
valerian,
pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi,
verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness
15
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 charcoal, chlorophyll, minerals, botanicals, or
breath
freshening agents. They may be imitation, synthetic or natural ingredients or
blends
20
thereof. They may be in any suitable form, for
example, liquid such as an oil, solid
such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint. In some embodiments, the flavour comprises flavour components of
25
cucumber, blueberry, citrus fruits and/or redberry.
In some embodiments, the
flavour comprises eugenol. In some embodiments, the flavour comprises flavour
components extracted from tobacco. In some embodiments, the flavour comprises
flavour components extracted from cannabis.
30
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
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nerve), in addition to or in place of aroma or taste nerves, and these may
include
agents providing heating, cooling, tingling, numbing effect. A suitable heat
effect
agent may be, but is not limited to, vanillyl ethyl ether and a suitable
cooling agent
may be, but not limited to eucolyptol, WS-3.
Aerosol-generating material
Aerosol-generating material is a material that is capable of generating
aerosol, for example when heated, irradiated or energized in any other way.
Aerosol-generating material may, for example, be in the form of a solid,
liquid or
gel which may or may not contain an active substance and/or flavourants. In
some
embodiments, the aerosol-generating material may comprise an "amorphous
solid", which may alternatively be referred to as a "monolithic solid" (i.e.
non-
fibrous). In some embodiments, the amorphous solid may be a dried gel. The
amorphous solid is a solid material that may retain some fluid, such as
liquid,
within it. In some embodiments, the aerosol-generating material may for
example
comprise from about 50wt%, 60wr/o or 70wt% of amorphous solid, to about
90wt%, 95wt% or 100wt% of amorphous solid.
The aerosol-generating material may comprise one or more active
substances andJor flavours, one or more aerosol-former materials, and
optionally
one or more other functional materials.
Aerosol-former material
The aerosol-former material may comprise one or more constituents
capable of forming an aerosol. In some embodiments, the aerosol-former
material
may comprise one or more of glycerine, glycerol, propylene glycol, diethylene
glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol,
erythritol,
meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl
citrate,
triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate,
tributyrin,
lauryl acetate, lauric acid, myristic acid, and propylene carbonate_
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In some embodiments, the aerosol former 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
5 dimethyl dodecanedioate and dimethyl tetradecanedioate.
Functional material
The one or more other functional materials may comprise one or more of
pH regulators, colouring agents, preservatives, binders, fillers, stabilizers,
and/or
10 antioxidants.
Substrate
The material may be present on or in a support, to form a substrate. The
support may, for example, be or comprise paper, card, paperboard, cardboard,
15 reconstituted material, a plastics material, a ceramic material, a
composite material,
glass, a metal, or a metal alloy. In some embodiments, the support comprises a
susceptor. In some embodiments, the susceptor is embedded within the material.
In some alternative embodiments, the susceptor is on one or either side of the
material.
Consumable
A consumable is an article comprising or consisting of aerosol-generating
material, part or all of which is intended to be consumed during use by a
user. A
consumable may comprise one or more other components, such as an aerosol-
25 generating material storage area, an aerosol-generating material
transfer
component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a
filter
and/or an aerosol-modifying agent. A consumable may also comprise an aerosol
generator, such as a heater, that emits heat to cause the aerosol-generating
material
to generate aerosol in use. The heater may, for example, comprise combustible
30 material, a material heatable by electrical conduction, or a susceptor.
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Su sceptor
A susceptor is a material that is heatable by penetration with a varying
magnetic field, such as an alternating magnetic field. The susceptor may be an
electrically-conductive material, so that penetration thereof with a varying
5 magnetic field causes induction heating of the heating material. The
heating
material may be magnetic material, so that penetration thereof with a varying
magnetic field causes magnetic hysteresis heating of the heating material. The
susceptor may be both electrically-conductive and magnetic, so that the
susceptor
is heatable by both heating mechanisms. The device that is configured to
generate
10 the varying magnetic field is referred to as a magnetic field generator,
herein.
Aerosol-modifying agent
An aerosol-modifying agent is a substance, typically located downstream
of the aerosol generation area, that is configured to modify the aerosol
generated,
15 for example by changing the taste, flavour, acidity or another
characteristic of the
aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying
agent release component, that is operable to selectively release the aerosol-
modifying agent
20 The aerosol-modifying agent may, for example, be an additive or
a sorbent.
The aerosol-modifying agent may, for example, comprise one or more of a
flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying
agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying
agent
may be in powder, thread or granule form. The aerosol-modifying agent may be
25 free from filtration material.
Aerosol generator
An aerosol generator is an apparatus configured to cause aerosol to be
generated from the aerosol-generating material. In some embodiments, the
aerosol
30 generator is a heater configured to subject the aerosol-generating
material to heat
energy, so as to release one or more volatiles from the aerosol-generating
material
to form an aerosol. In some embodiments, the aerosol generator is configured
to
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cause an aerosol to be generated from the aerosol-generating material without
heating. For example, the aerosol generator may be configured to subject the
aerosol-generating material to one or more of vibration, increased pressure,
or
electrostatic energy.
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