Note: Descriptions are shown in the official language in which they were submitted.
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Aerosol-generating material
Technical Field
The present invention relates to an aerosol-generating material, an article
comprising
an aerosol generating material, a pack of articles, a consumable for use in an
aerosol
provision system, a non-combustible aerosol provision system, and a method for
producing an aerosol-generating material.
Background
Certain tobacco industry products produce an aerosol during use, which is
inhaled by a
user. For example, tobacco heating devices heat an aerosol generating
substrate such as
tobacco to form an aerosol by heating, but not burning, the substrate. Such
tobacco
industry products can include mouthpieces through which the aerosol passes to
reach
the user's mouth.
Summary
In accordance with some embodiments described herein, in a first aspect there
is
provided an aerosol-generating material comprising a plurality of strands
and/or strips
of a tobacco material and a plurality of strips of amorphous solid material,
wherein the
plurality of strands and/or strips of tobacco material and the plurality of
strips of
amorphous solid material each have a length of at least about 5 mm.
In accordance with some embodiments described herein, in a second aspect there
is
provided an article comprising an aerosol-generating material according to the
first
aspect.
In accordance with some embodiments described herein, in a third aspect there
is
provided a pack comprising a plurality of articles, each article according to
the second
aspect above, wherein the number of the plurality of strips of amorphous solid
material
varies by less than 40% between the articles in the pack, or less than 30%
between the
articles in the pack, or less than 20% between the articles in the pack.
In accordance with some embodiments described herein, in a fourth aspect there
is
provided a pack comprising a plurality of articles, each article according to
the second
aspect above, wherein the plurality of strips of amorphous solid material
comprise a
flavourant, optionally menthol, and wherein the delivery of the flavourant
from each of
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the plurality of articles, in use, varies by less than 50% between the
articles in the pack,
or varies by less than 20% between the articles in the pack.
In accordance with some embodiments described herein, in a fifth aspect there
is
provided pack comprising a plurality of articles, each article according to
the second
aspect above, wherein the plurality of strips of amorphous solid material
comprise a
flavourant, optionally menthol, and wherein the total content of said
flavourant in each
of the plurality of articles, in use, has a standard deviation of less than
30% of the mean
content of said flavourant in said articles, or has a standard deviation of
less than 20%
/0 of the mean content of said flavourant in said articles, and wherein at
least 20% of the
mean flavourant is provided in said strips of amorphous solid material.
In accordance with some embodiments described herein, in a sixth aspect there
is
provided pack comprising a plurality of articles, each article according to
the second
aspect above, wherein the plurality of strips of amorphous solid material
comprise a
flavourant, optionally menthol, and the total amount of flavourant is between
5 mg per
article and 30 mg per article, or between 16 mg per article and 22 mg per
article, or
between 5 mg per article and 10 mg per article, or between 17 mg per article
and 30 mg
per article.
In accordance with some embodiments described herein, in a seventh aspect
there is
provided pack comprising a plurality of articles, each article according to
the second
aspect aboveõ wherein the plurality of strips of amorphous solid material
comprise a
flavourant, optionally menthol, and the standard deviation in the total amount
of
flavourant between the articles in the pack is less than 30% or 20% of the
mean total
amount of flavourant by wt%, and wherein the amorphous solid comprises at
least 50%
of the mean total amount of flavourant in each article.
In accordance with some embodiments described herein, in an eighth aspect
there is
so provided pack comprising a plurality of articles, each article according
to the second
aspect above, wherein the article is provided with ventilation, and wherein
the standard
deviation in the ventilation level between articles in the pack is less than
15%, or less
than 10%, or less than 9%.
In accordance with some embodiments described herein, in a ninth aspect there
is
provided pack comprising a plurality of articles, each article according to
the second
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aspect above, wherein the plurality of strips of amorphous solid material
comprise an
aerosol-former, optionally glycerol, and wherein the total content of said
aerosol-
former in each of the plurality of articles, in use, has a standard deviation
of less than
30% of the mean content of said aerosol-former in said articles, or has a
standard
deviation of less than 25% of the mean content of said aerosol-former in said
articles,
and wherein at least 20% of the mean aerosol-former is provided in said strips
of
amorphous solid material.
io In accordance with some embodiments described herein, in a tenth aspect
there is
provided a consumable for use in an aerosol provision system, wherein the
consumable
comprises an article according to the second aspect.
In accordance with some embodiments described herein, in an eleventh aspect
there is
provided a non-combustible aerosol provision sys Lem comprising a non-
combustible
aerosol provision device and a consumable according to the fifth aspect,
wherein the
device is arranged to heat the aerosol-generating material of the consumable.
In accordance with some embodiments described herein, in a twelfth aspect
there is
provided a method for producing an aerosol-generating material according the
first
aspect, comprising cutting a sheet of amorphous solid material to form a
plurality of
strips of amorphous solid material having a cut length of at least about 5 mm.
In accordance with some embodiments described herein, in a thirteenth aspect
there is
provided a method for producing an aerosol-generating material the method
comprising feeding a single thickness sheet of an amorphous solid material to
a cutting
apparatus and cutting the single thickness sheet.
In accordance with some embodiments described herein, in a fourteenth aspect
there is
so provided a method for producing an aerosol-generating material, the
method
comprising cutting a first portion of amorphous solid material to form a first
component comprising a plurality of strips of amorphous solid material having
a first
length and cutting a second portion of amorphous solid material to form a
second
component comprising a plurality of strips of amorphous solid material having
a
second length different to the first length.
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In accordance with some embodiments described herein, in a fifteenth aspect
there is
provided method for producing an aerosol-generating material, comprising
cutting a
sheet of amorphous solid material to form a plurality of strips of the
amorphous
solid material, and mixing the plurality of strips of amorphous solid material
with a
tobacco material, wherein the cutting step and the mixing step are performed
within 12
hours of each other, or within 6 hours of each other, or within 2 hours of
each other, or
within 30 minutes of each other.
Brief Description of the Drawings
io Embodiments of the invention will now be described, by way of example
only, with
reference to accompanying drawings, in which:
Figure 1 is a side-on cross sectional view of an article for use with a non-
combustible
aerosol provision device, the article including a mouthpiece;
Figure 2a is a side-on cross sectional view of a further article for use with
a non-
combustible aerosol provision device, in this example the article including a
capsule-
containing mouthpiece;
Figure 2b is a cross sectional view of the capsule-containing mouthpiece shown
in
Figure 2a;
Figure 3 is a perspective illustration of a non-combustible aerosol provision
device for
generating aerosol from the aerosol-generating material of the articles of
Figures 1, 2a
and 2b;
Figure 4 illustrates the device of Figure 3 with the outer cover removed and
without an
article present;
Figure 5 is a side view of the device of Figure 3 in partial cross-section;
Figure 6 is an exploded view of the device of Figure 3, with the outer cover
omitted;
Figure 7A is a cross sectional view of a portion of the device of Figure 3;
Figure 7B is a close-up illustration of a region of the device of Figure 7A;
Figure 8 is a flow diagram illustrating a first method of manufacturing an
aerosol-generating material; and
so Figure 9 is a flow diagram illustrating a second method of manufacturing
an
aerosol-generating material.
Detailed Description
As used herein, the term "delivery system" is intended to encompass systems
that
deliver at least one substance to a user, and includes:
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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 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 heating products, and hybrid systems to
generate
aerosol using a combination of aerosol-generating materials; 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, wherein
the at
least one substance may or may not comprise nicotine.
According to the present disclosure, a "combustible" aerosol provision system
is one
where a constituent aerosol-generating material of the aerosol provision
system (or
component thereof) is combusted or burned during use in order to facilitate
delivery of
at least one substance to a user.
In some embodiments, the delivery system is a combustible aerosol provision
system,
such as a system selected from the group consisting of a cigarette, a
cigarillo and a
cigar.
In some embodiments, the disclosure relates to a component for use in a
combustible
aerosol provision system, such as a filter, a filter rod, a filter segment, a
tobacco rod, a
spill, an aerosol-modifying agent release component such as a capsule, a
thread, or a
bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
According to the present disclosure, a "non-combustible" aerosol provision
system is
so one where a constituent aerosol-generating material of the aerosol
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
3,5 system, such as a powered non-combustible aerosol provision system.
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In some embodiments, the non-combustible aerosol provision system is an
electronic
cigarette, also known as a vaping device or electronic nicotine delivery
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
aerosol-
generating material heating system, also known as a heat-not-burn system. An
example of such a system is a tobacco heating system.
io In some embodiments, the non-combustible aerosol provision
system is a hybrid
system to generate aerosol using a combination of aerosol-generating
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
maLerial and a solid aerosol-generaling maLerial. The solid aerosol-generaling
maLerial
may comprise, for example, 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
so exothermic power source. In some embodiments, the exothermic
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 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 component, an
aerosol
generator, an aerosol generation area, a housing, a wrapper, a filter, a
mouthpiece,
and/or an aerosol-modifying agent.
In some embodiments, the substance to be delivered may be an aerosol-
generating
material or a material that is not intended to be aerosolised. As appropriate,
either
material may comprise one or more active constituents, one or more flavours,
one or
more aerosol-former materials, and/or one or more other functional materials.
In some embodiments, the substance to be delivered comprises an active
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 nutraceuticals, nootropics, psychoactives.
The active
substance may be naturally occurring or synthetically obtained. The active
substance
may comprise for example nicotine, caffeine, taurine, theine, vitamins such as
B6 or
B12 or C, melatonin, cannabinoids, or constituents, derivatives, or
combinations
thereof. The active substance may comprise one or more constituents,
derivatives or
extracts of tobacco, cannabis or another botanical.
In some embodiments, the active substance comprises nicotine. In some
embodiments,
the active substance comprises caffeine, melatonin or vitamin B12.
so As noted herein, the active substance may comprise or be derived from
one or more
botanicals or constituents, derivatives or extracts thereof. As used herein,
the term
"botanical" includes any material derived from plants including, but not
limited to,
extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen,
husk, shells or
the like. Alternatively, the material may comprise an active compound
naturally
3,5 existing in a botanical, obtained synthetically. The material may be in
the form of
liquid, gas, solid, powder, dust, crushed particles, granules, pellets,
shreds, strips,
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sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise,
hemp, cocoa,
cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger,
ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate,
orange skin,
papaya, rose, sage, tea such as green tea or black tea, thyme, clove,
cinnamon, coffee,
aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg,
oregano,
paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower,
vanilla,
wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,
bergamot,
orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,
olive,
lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry,
ginseng,
theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab
or
any combination thereof. The mint may be chosen from the following mint
varieties:
Mentha 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
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 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
is selected
from rooibos and fennel.
In some embodiments, the substance to be delivered comprises a flavour.
so As used herein, the terms "flavour" and "flavourant" refer to materials
which, where
local regulations permit, may be used to create a desired taste, aroma or
other
somatosensorial sensation in a product for adult consumers. They may include
naturally occurring flavour materials, botanicals, extracts of botanicals,
synthetically
obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice
(liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,
fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise),
cinnamon,
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turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red
berry,
cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical
fruit, papaya,
rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus
fruits,
Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint,
lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood,
bergamot,
geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla,
lemon oil,
orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine,
ylang-
ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint
oil from any
species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass,
rooibos, flax,
io ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea
such as green tea or
black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano,
paprika,
rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro,
myrtle, cassis,
valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil,
chive,
carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers,
bitterness
receptor siLe blockers, sensorial recepLor 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
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 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.
so In some embodiments, the flavour may comprise a sensate, which is
intended to
achieve a somatosensorial sensation which are usually chemically induced and
perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in
addition to
or in place of aroma or taste nerves, and these may include agents providing
heating,
cooling, tingling, numbing effect. A suitable heat effect agent may be, but is
not limited
to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited
to
eucolyptol, WS-3.
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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 examples, the amorphous solid comprises:
- 1-60 wt% of a gelling agent;
- 0.1-50 wt% of an aerosol-former agent; and
- o.1-8o wt% of a flavour;
wherein these weighLs are calculated on a dry weight. basis.
In some further embodiments, the amorphous solid comprises:
- 1-50 wt% of a gelling agent;
- 0.1-50 wt% of an aerosol-former agent; and
- 30-60 wt% of a flavour;
wherein these weights are calculated on a dry weight basis.
The amorphous solid material may be provided in sheet form.
In some further embodiments, the amorphous solid comprises:
- aerosol-former material in an amount of from about 40 to 8owt% of the
amorphous solid;
- gelling agent and optional filler (i.e. in some examples filler is
present in the
amorphous solid, in other examples filler is not present in the amorphous
solid),
so wherein the amount of gelling agent and filler taken together is from
about io to 6owt%
of the amorphous solid (i.e. the gelling agent and filler taken together
account for about
lo to 6owt% of the amorphous solid); and
- optionally, active substance and/or flavourant in an amount of up to
about 20wt% of the amorphous solid (i.e. the amorphous solid comprises
.20wt% active substance).
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The amorphous solid material can be formed from a dried gel. The inventors
have
found that using these component proportions means as the gel sets, flavour
compounds are stabilised within the gel matrix allowing a higher flavour
loading to be
achieved than in non-gel compositions. The flavouring (e.g. menthol) is
stabilised at
high concentrations and the products have a good shelf life.
Suitably, the amorphous solid may comprise from about iwt%, 5wt%, lowt%,
15wt%,
20wt%, 25wt%, 30vvt% or 35vvt% to about 6ovvt%, 55wt%, 50vvt%, 45wt%, 40vvt%
OF
35wt% of a gelling agent (all calculated on a dry weight basis). For example,
the
w amorphous solid may comprise 1-6owt%, 5-60vvt%, 20-60vvt%, 25-55vvt%, 30-
50wt%,
35-45vvt%, 1-50wt%, 5-45vvt%, lo-40vvt% or 20-35wt% of a gelling agent. In
some
embodiments, the gelling agent comprises a hydrocolloid. In some embodiments,
the
gelling agent comprises one or more compounds selected from the group
comprising
alginates, pectins, starches (and derivatives), celluloses (and derivatives),
gums, silica
or silicones compounds, clays, polyvinyl alcohol and combinations [hereof. For
example, in some embodiments, the gelling agent comprises one or more of
alginates,
pectins, hydroxyethyl cellulose, hydroxypropyl cellulose,
carboxymethylcellulose,
pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed
silica,
PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the
gelling agent
comprises alginate and/or pectin, and may be combined with a setting agent
(such as a
calcium source) during formation of the amorphous solid. In some cases, the
amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-
crosslinked pectin.
In some embodiments, the gelling agent comprises alginate, and the alginate is
present
in the amorphous solid in an amount of from 5-40wt%, for example lo-30wt% of
the
amorphous solid (calculated on a dry weight basis). In some embodiments,
alginate is
the only gelling agent present in the amorphous solid. In other embodiments,
the
gelling agent comprises alginate and at least one further gelling agent, such
as pectin.
In some examples, alginate is comprised in the gelling agent in an amount of
from
about 5 to 40wt% of the amorphous solid, or 15 to 4owt%. That is, the
amorphous solid
comprises alginate in an amount of about 5 to 40wt% by dry weight of the
amorphous
solid, or 15 to 40wt%. In some examples, the amorphous solid comprises
alginate in an
amount of from about 20 to 40wt%, or about 15wt% to 35wt% of the amorphous
solid.
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In some examples, pectin is comprised in the gelling agent in an amount of
from about
3 to 15wt% of the amorphous solid. That is, the amorphous solid comprises
pectin in an
amount of from about 3 to 15vvt% by dry weight of the amorphous solid. In some
examples, the amorphous solid comprises pectin in an amount of from about 5 to
iowt% of the amorphous solid.
In some examples, guar gum is comprised in the gelling agent in an amount of
from
about 3 to 40wt% of the amorphous solid. That is, the amorphous solid
comprises guar
gum in an amount of from about 3 to 40wt% by dry weight of the amorphous
solid. In
io some examples, the amorphous solid comprises guar gum in an amount of
from about 5
to lowt% of the amorphous solid. In some examples, the amorphous solid
comprises
guar gum in an amount of from about 15 to 40wt% of the amorphous solid, or
from
about 20 to 40vvt%, or from about 15 to 35w1%.
In some examples, the alginate is present. in an amount of at least about
5owl% of the
gelling agent. In examples, the amorphous solid comprises alginate and pectin,
and the
ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the
alginate to the
pectin is typically >1:1, i.e. the alginate is present in an amount greater
than the amount
of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to
8:1, or about
3:1 to 6:t, or is approximately 4:1.
In some embodiments the amorphous solid may include gelling agent comprising
carrageenan.
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,
so carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC),
methyl
cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate
(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 (HPMC),
carboxymethylcellulose, guar gum, or acacia gum.
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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
agar.
Suitably, the amorphous solid may comprise from about 0.iwt%, 0.5wt%, iwt%,
3wt%,
5vvt%, 7wt% or 10% to about 8owt%, 50wt%, 45vvt%, 40vvt%, 35vvt%, 30vvt% or
25vvt%
of an aerosol-former material (all calculated on a dry weight basis). For
example, the
w amorphous solid may comprise about 40-80vvt%, 40-75vvt%, 50-70vvt%, or 55-
65vvt%
aerosol-former material. The aerosol-former material may act as a plasticiser.
For
example, the amorphous solid may comprise 0.5-40wt%, 3-35w1% or lo-25w1:% of
an
aerosol-former material. In some cases, the aerosol-former material comprises
one or
more compound selected from erythritol, propylene glycol, glycerol, triacetin,
sorbitol
and xylitol. In some cases, the aerosol-former material comprises, consists
essentially
of or consists of glycerol.
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 tri acetate; and/or
aliphatic esters of
mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and
dimethyl
tetradecanedioate.
The amorphous solid may comprise a flavour. Suitably, the amorphous solid may
comprise up to about 8ovvt%, 70vvt%, 60vvt%, 55vvt%, 50w1% or 45vvt% of a
flavour.
In some cases, the amorphous solid may comprise at least about o.iwt%, iwt%,
iowt%,
20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight
basis).
so For example, the amorphous solid may comprise 1-8owt%, lo-8owt%, 20-
70wt%, 30-
6owt%, 35-55wt% or 30-45wt% of a flavour. In some cases, the flavour
comprises,
consists essentially of or consists of menthol.
In some cases, the amorphous solid may additionally comprise an emulsifying
agent,
which emulsified molten flavour during manufacture. For example, the amorphous
solid may comprise from about 5wt% to about 15wt% of an emulsifying agent
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(calculated on a dry weight basis), suitably about iowt%. The emulsifying
agent may
comprise acacia gum.
In some embodiments, the amorphous solid is a hydrogel and comprises less than
about 20 wt% of water calculated on a wet weight basis. In some cases, the
hydrogel
may comprise less than about 15wt%, 12 Wt% or 10 wt% of water calculated on a
wet
weight basis. In some cases, the hydrogel may comprise at least about iwt%,
2wt% or at
least about 5wt% of water (WWB).
io In some embodiments, the amorphous solid additionally comprises an
active
substance. For example, in some cases, the amorphous solid additionally
comprises a
tobacco material and/or nicotine. In some cases, the amorphous solid may
comprise 5-
6owt% (calculated on a dry weight basis) of a tobacco material and/or
nicotine. In
some cases, the amorphous solid may comprise from about iwt%, 5wt%, iowt%,
15wt%,
20wt% or 25wt% to about 70wt%, 6owt%, 50wt%, 45 vv 40wt%, 35wt%, 30wt%,
20wt%, 15wt%, or iowt% (calculated on a dry weight basis) of an active
substance. In
some cases, the amorphous solid may comprise from about iwt%, 5wt%, lowt%,
15wt%,
20wt% or 25vvt% to about 70vvt%, 60vvt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt%
(calculated on a dry weight basis) of a tobacco material. For example, the
amorphous
solid may comprise 10-5owt%, 15-40wt% or 20-35wt% of a tobacco material. in
some
cases, the amorphous solid may comprise from about iwt%, 2wt%, 3wt% or 4wt% to
about 20w1%, 18w[%, 15wt% or 12wt% (calculated on a dry weight basis) of
nicotine.
For example, the amorphous solid may comprise 1-20wt%, 2-18wt% or 3-12wt% of
nicotine.
In some cases, the amorphous solid comprises an active substance such as
tobacco
extract. In some cases, the amorphous solid may comprise 5-60wt% (calculated
on a
dry weight basis) of tobacco extract. In some cases, the amorphous solid may
comprise
from about 5wt%, lowt%, 15wt%, 20wt% or 25wt% to about 60vvt%, 50wt%, 45wt%,
so 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco
extract. For
example, the amorphous solid may comprise lo-50wt%, 15-40wt% or 20-35w1% of
tobacco extract. The tobacco extract may contain nicotine at a concentration
such that
the amorphous solid comprises iwt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%,
4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine.
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In some cases, there may be no nicotine in the amorphous solid other than that
which
results from the tobacco extract.
In some embodiments the amorphous solid comprises no tobacco material but does
comprise nicotine. In some such cases, the amorphous solid may comprise from
about
iwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 1.5wt% or 1.2wt% (calculated
on a
dry weight basis) of nicotine. For example, the amorphous solid may comprise 1-
20wt%, 2-18wt% or 3-12vvt% of nicotine.
io In some cases, the total content of active substance and/or flavour may
be at least about
iwt%, 5wt%, lowt%, 20wt%, 25w1% or 30wt%. In some cases, the total content
of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%,
6owt%, 50wt% or 4owt% (all calculated on a dry weight basis).
In some cases, Lhe LoLal conLent. of tobacco material, nicotine and flavour
may be at
least about o.iwt%, iwt%, 5wt%, iowt%, 20wt%, 25wt% or 30wt%. In some cases,
the
total content of active substance and/or flavour may be less than about 90wt%,
80wt%,
70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
The amorphous solid may be made from a gel, and this gel may additionally
comprise a
solvent, included at o.1-50wt%. However, the inventors have established that
the
inclusion of a solvent in which the flavour is soluble may reduce the gel
stability and the
flavour may crystallise out of the gel. As such, in some cases, the gel does
not include a
solvent in which the flavour is soluble.
The amorphous solid may comprise filler. Taken together, the amorphous solid
typically comprises gelling agent and filler (if present) in an amount of from
about 10 to
60wt% of the amorphous solid. In examples, the amorphous solid comprises
filler in an
amount of from 1 to 1.5wt% of the amorphous solid, such as 5wt% to 1.5wt%, or
8 to
so 12wt%. In examples, the amorphous solid comprises filler in an amount
greater than
iwt%, 5wt%, or 8wt% of the amorphous solid. In some embodiments, the amorphous
solid comprises less than 6owt% of a filler, such as from iwt% to 60wt%, or
5wt% to
5owt%, or 5wt% to 3owt%, or iovvt% to 2owt%.
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In other embodiments, the amorphous solid comprises less than 40wt% 20w1%,
suitably less than iowt% or less than 5wt% of a filler. In some cases, the
amorphous
solid comprises less than iwt% of a filler, and in some cases, comprises no
filler.
The filler, if present, may comprise one or more inorganic filler materials,
such as
calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica,
magnesium
oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic
sorbents,
such as molecular sieves. The filler may comprise one or more organic filler
materials
such as wood pulp, cellulose and cellulose derivatives. In particular cases,
the
io amorphous solid comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For
example, the
filler may be a fibrous organic filler material such as wood pulp, hemp fibre,
cellulose or
cellulose derivatives. Without wishing to be bound by theory, it is believed
that
including fibrous filler in an amorphous solid may increase the tensile
strength of the
material.
In some embodiments, the amorphous solid comprises one or more cannabinoid
compounds selected from the group consisting of: cannabidiol (CBD),
tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic
acid
(CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC),
cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV),
cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran
(CBT).
The amorphous solid may comprise one or more cannabinoid compounds selected
from
the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).
so The amorphous solid may comprise cannabidiol (CBD).
The amorphous solid may comprise nicotine and cannabidiol (CBD).
The amorphous solid may comprise nicotine, cannabidiol (CBD), and THC
(tetrahydrocannabinol).
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In some embodiments, the amorphous solid does not comprise tobacco fibres.
In some examples, the amorphous solid in sheet form may have a tensile
strength of
from around 150 N/m to around 3000 N/m, for instance from 150 N/m to 2500 N/m,
Or 150 N/m to 2000 N/m, or 200 N/m to 1700 N/m, or 250 N/m to 1500 N/m, or 200
N/m to 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 150
N/m to
500 N/m, or 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such
tensile strengths may be particularly suitable for embodiments wherein the
amorphous
io solid material is formed as a sheet and then shredded and incorporated
into an aerosol-
generating article.
In some examples, such as where the amorphous solid comprises a filler, the
amorphous solid may have a tensile strength of from 150 N/m to 3000 N/m, for
example 500 N/m Lo 1200 N/m, or from 600 N/In Lo 900 N/m, or from 700 N/m to
900 N/m, or around 800 N/m or greater. In some examples, the amorphous solid
may
have a tensile strength of greater than 500 N/m, greater than woo N/m or
greater than
1500 N/m. Such tensile strengths may be particularly suitable for embodiments
wherein the amorphous solid material is included in an aerosol-generating
article as a
rolled sheet, suitably in the form of a tube.
In certain embodiments, the amorphous solid comprises a gelling agent
comprising a
cellulosic gelling agent and/or a non-cellulosic gelling agent, an active
substance and an
acid.
In some cases, the amorphous solid may consist essentially of, or consist of a
gelling
agent, water, an aerosol-former material, a flavour, and optionally an active
substance.
In some cases, the amorphous solid may consist essentially of, or consist of a
gelling
so agent, water, an aerosol-former material, a flavour, and optionally a
tobacco material
and/or a nicotine source.
The amorphous solid may comprise one or more active substances and/or
flavours, one
or more aerosol-former materials, and optionally one or more other functional
material.
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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.
The amorphous solid may comprise an acid. The acid may be an organic acid. In
some
_ro of these embodiments, the acid may be at least one of a monoprotic
acid, a diprotic acid
and a triprotic acid. In some such embodiments, the acid may contain at least
one
carboxyl functional group. In some such embodiments, the acid may be at least
one of
an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid
and keto
acid. In some such embodiments, the acid maybe an alpha-keto acid.
In some such embodiments, the acid may be at least one of succinic acid,
lactic acid,
benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic
acid,
malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic
acid.
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.
The inclusion of an acid is particularly preferred in embodiments in which
amorphous
solid comprises nicotine. In such embodiments, the presence of an acid may
stabilise
dissolved species in the slurry from which the aerosol-generating material is
formed.
The presence of the acid may reduce or substantially prevent evaporation of
nicotine
so during drying of the slurry, thereby reducing loss of nicotine during
manufacturing.
The amorphous solid may comprise a colourant. The addition of a colourant may
alter
the visual appearance of the amorphous solid. The presence of colourant in the
amorphous solid may enhance the visual appearance of the amorphous solid and
the
3,5 aerosol-generating material. By adding a colourant to the amorphous
solid, the
amorphous solid may be colour-matched to other components of the aerosol-
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generating material or to other components of an article comprising 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 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-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
(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).
The one or more other functional materials may comprise one or more of pH
regulators, colouring agents, preservatives, binders, fillers, stabilizers,
and/or
antioxidants.
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-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
3o 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 material, a material heatable by electrical
conduction,
or a susceptor.
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
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material, so that penetration thereof with a varying 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 the varying magnetic field is referred to as a magnetic
field
generator, herein.
An aerosol-modifying agent is a substance, typically located downstream of the
aerosol
io generation area, that is configured to modify the aerosol generated, 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
The aerosol-modifying agent may, for example, be an additive or a sorbenl. 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 free from
filtration
material.
An aerosol generator is an apparatus configured to cause aerosol to be
generated from
the aerosol-generating material. In some embodiments, the aerosol 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 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.
Articles, for instance those in the shape of rods, are often named according
to the
product length: "regular" (typically in the range 68 ¨ 75 mm, e.g. from about
68 mm to
about 72 mm), "short" or "mini" (68 mm or less), "king-size" (typically in the
range 75 ¨
91 mm, e.g. from about 79 mm to about 88 mm), "long" or "super-king"
(typically in the
3,5 range 91 ¨ 105 mm, e.g. from about 94 mm to about 101 mm) and "ultra-
long"
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(typically in the range from about no mm to about 121 mm).
They are also named according to the product circumference: "regular" (about
23 ¨ 25
mm), "wide" (greater than 25 mm), "slim" (about 22 - 23 mm), "demi-slim"
(about 19
¨ 22 mm), "super-slim" (about 16 ¨ 19 mm), and "micro-slim" (less than about
16 mm).
Accordingly, an article in a king-size, super-slim format will, for example,
have a length
of about 83 mm and a circumference of about 17 mm.
io Each format may be produced with mouthpieces of different lengths. The
mouthpiece
length will be from about 30 mm to 50 mm. A tipping paper connects the
mouthpiece
to the aerosol-generating material and will usually have a greater length than
the
mouthpiece, for example from 3 to 10 mm longer, such that the tipping paper
covers
the mouthpiece and overlaps the aerosol-generating material, for instance in
the form
of a rod of substraLe maLerial, lo connect the mouthpiece lo [he rod.
Articles and their aerosol-generating materials and mouthpieces described
herein can
be made in, but are not limited to, any of the above formats.
The terms 'upstream' and 'downstream' used herein are relative terms defined
in
relation to the direction of mainstream aerosol drawn though an article or
device in
use.
The filamentary tow material described herein can comprise cellulose acetate
fibre tow.
The filamentary tow can also be formed using other materials used to form
fibres, such
as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL),
poly(1-4
butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT),
starch
based materials, cotton, aliphatic polyester materials and polysaccharide
polymers or a
combination thereof. The filamentary tow may be plasticised with a suitable
plasticiser
so for the tow, such as triacetin where the material is cellulose acetate
tow, or the tow may
be non-plasticised. The tow can have any suitable specification, such as
fibres having a
'Y' shaped or other cross section such as 'X' shaped, filamentary denier
values between
2.5 and 15 denier per filament, for example between 8.o and 11.0 denier per
filament
and total denier values of 5,000 to 50,000, for example between 10,000 and
40,000.
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As used herein, the term "tobacco material" refers to any material comprising
tobacco
or derivatives or substitutes thereof. The term "tobacco material" may include
one or
more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco
or
tobacco substitutes. The tobacco material may comprise one or more of ground
tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco
lamina,
reconstituted tobacco and/or tobacco extract.
In the tobacco material described herein, the tobacco material may contain a
filler
component. The filler component is generally a non-tobacco component, that is,
a
io component that does not include ingredients originating from tobacco.
The filler
component may be a non-tobacco fibre such as wood fibre or pulp or wheat
fibre. The
filler component may also be an inorganic material such as chalk, perlite,
vermiculite,
diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate,
magnesium carbonate. The filler component may also be a non-tobacco cast
material or
a non-tobacco exisuded maLerial. The filler component. may be present. in an
amount of
o to 20% by weight of the tobacco material, or in an amount of from 1 to 10%
by weight
of an overall composition, for instance the aerosol-generating material
described
herein. In some embodiments, the filler component is absent.
In the tobacco material described herein, the tobacco material contains an
aerosol-
former material.
In some embodiments, the aerosol-former material of the tobacco material may
be
glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.
Glycerol may
be present in an amount of from 10 to 20 % by weight of the tobacco material,
for
example 13 to 16 % by weight of the composition, i.e. the overall aerosol-
generating
material described herein, or about 14% or 15% by weight of the composition.
Propylene glycol, if present, may be present in an amount of from 0.1 to 0.3%
by weight
of the composition.
The aerosol-former material may be included in any component, for example any
tobacco component, of the tobacco material, and/or in the filler component, if
present.
Alternatively or additionally the aerosol-former material may be added to the
tobacco
material separately. In either case, the total amount of the aerosol-former
material in
the tobacco material can be as defined herein.
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The tobacco material can contain between 10% and 90% by weight tobacco leaf,
for
instance tobacco lamina. An aerosol-former material can be provided in the
tobacco
material, in addition to any aerosol-former material provided via the
amorphous solid
material. For instance, aerosol-former material as described herein can be
provided in
the tobacco material in an amount of between 2% and 20%, for instance between
about
5% and about 15% by weight of the tobacco material. Where tobacco leaf is
used, the
aerosol-former can comprise up to about 10% by weight of the leaf tobacco. To
achieve
an overall level of aerosol-former material between 10% and 20% by weight of
the
tobacco material, it has been advantageously found that this can be added in
higher
io weight percentages to the another component of the tobacco material,
such as
reconstituted tobacco material. In some examples, the tobacco material
consists
essentially of leaf tobacco, for instance lamina tobacco.
The tobacco material described herein contains nicotine. The nicotine content
is from
0.5 to 1.75% by weighl of the tobacco material, and may be, for example, from
0.8 to
1.5% by weight of the tobacco material. Additionally or alternatively, the
tobacco
material contains between 10% and 90% by weight tobacco leaf having a nicotine
content of greater than 1.5% by weight of the tobacco leaf. It has been
advantageously
found that using a tobacco leaf with nicotine content higher than 1.5% in
combination
with a lower nicotine base material, such as paper reconstituted tobacco,
provides a
tobacco material with an appropriate nicotine level but better sensory
performance
than the use of paper reconstituted tobacco alone. The tobacco leaf, for
instance cut
rag tobacco, can, for instance, have a nicotine content of between 1.5% and 5%
by
weight of the tobacco leaf.
The tobacco material described herein can contain an aerosol modifying agent,
such as
any of the flavours described herein. In one embodiment, the tobacco material
contains menthol, forming a mentholated article. The tobacco material can
comprise
from 3mg to 20mg of menthol, preferably between 5mg and 18mg and more
preferably
so between 8mg and 16mg of menthol. In the present example, the tobacco
material
comprises 16mg of menthol. The tobacco material can contain between 2% and 8%
by
weight of menthol, preferably between 3% and 7% by weight of menthol and more
preferably between 4% and 5.5% by weight of menthol. In one embodiment, the
tobacco material includes 4.7% by weight of menthol. Such high levels of
menthol
loading can be achieved using a high percentage of reconstituted tobacco
material, for
instance greater than 50% of the tobacco material by weight. Alternatively or
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additionally, the use of a high volume of aerosol-generating material, for
instance
tobacco material, can increase the level of menthol loading that can be
achieved, for
instance where greater than about 500 mm3 or suitably more than about woo mm3
of
aerosol-generating material, such as tobacco material, are used.
In the compositions or aerosol-generating materials described herein, where
amounts
are given in % by weight, for the avoidance of doubt this refers to a dry
weight basis,
unless specifically indicated to the contrary. Thus, any water that may be
present in the
tobacco material, or in any component thereof, is entirely disregarded for the
purposes
io of the determination of the weight %. The water content of the
tobacco material
described herein may vary and may be, for example, from 5 to 15% by weight.
The water
content of the tobacco material described herein may vary according to, for
example,
the temperature, pressure and humidity conditions at which the compositions
are
maintained. The water content can be determined by Karl-Fisher analysis, as
known to
those skilled in the art. On We other hand, for the avoidance of doubt, even
when We
aerosol-former material is a component that is in liquid phase, such as
glycerol or
propylene glycol, any component other than water is included in the weight of
the
tobacco material. However, when the aerosol-former material is provided in the
tobacco component of the tobacco material, or in the filler component (if
present) of
the tobacco material, instead of or in addition to being added separately to
the tobacco
material, the aerosol-former material is not included in the weight of the
tobacco
component or filler component, but is included in the weight of the "aerosol-
former
material" in the weight % as defined herein. All other ingredients present in
the tobacco
component are included in the weight of the tobacco component, even if of non-
tobacco
origin (for example non-tobacco fibres in the case of paper reconstituted
tobacco).
In an embodiment, the tobacco material comprises the tobacco component as
defined
herein and the aerosol-former material as defined herein. In an embodiment,
the
tobacco material consists essentially of the tobacco component as defined
herein and
so the aerosol-former material as defined herein. In an embodiment,
the tobacco material
consists of the tobacco component as defined herein and the aerosol-former
material as
defined herein.
Paper reconstituted tobacco may be present in the tobacco component of the
tobacco
material described herein in an amount of from 10% to l00% by weight of the
tobacco
component. In embodiments, the paper reconstituted tobacco is present in an
amount
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of from 10% to 80% by weight, or 20% to 70% by weight, of the tobacco
component. In
a further embodiment, the tobacco component consists essentially of, or
consists of,
paper reconstituted tobacco. In preferred embodiments, leaf or lamina tobacco
is
present in the tobacco component of the tobacco material in an amount of from
at least
10% by weight of the tobacco component. For instance, leaf tobacco can be
present in
an amount of at least 10% by weight of the tobacco component, while the
remainder of
the tobacco component comprises paper reconstituted tobacco, bandcast
reconstituted
tobacco, or a combination of bandcast reconstituted tobacco and another form
of
tobacco such as tobacco granules. Suitably, leaf tobacco can be present in an
amount up
io to 40 % or 6o% of the tobacco material, while the remainder of the
tobacco component
comprises paper reconstituted tobacco, bandcast reconstituted tobacco, or a
combination of bandcast reconstituted tobacco and another form of tobacco such
as
tobacco granules.
Paper reconsLiLuLed Lobacco refers to Lobacco material formed by a process in
which
tobacco feedstock is extracted with a solvent to afford an extract of solubles
and a
residue comprising fibrous material, and then the extract (usually after
concentration,
and optionally after further processing) is recombined with fibrous material
from the
residue (usually after refining of the fibrous material, and optionally with
the addition
of a portion of non-tobacco fibres) by deposition of the extract onto the
fibrous
material. The process of recombination resembles the process for making paper.
The paper reconstituted tobacco may be any type of paper reconstituted tobacco
that is
known in the art. In a particular embodiment, the paper reconstituted tobacco
is made
from a feedstock comprising one or more of tobacco strips, tobacco stems, and
whole
leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made
from a
feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco
stems.
However, in other embodiments, scraps, fines and winnowings can alternatively
or
additionally be employed in the feedstock.
The paper reconstituted tobacco for use in the tobacco material described
herein may
be prepared by methods which are known to those skilled in the art for
preparing paper
reconstituted tobacco.
In the figures described herein, like reference numerals are used to
illustrate equivalent
features, articles or components.
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Figure 1 is a side-on cross sectional view of an article 1 for use in an
aerosol delivery
system.
The article 1 comprises a mouthpiece 2, and a cylindrical rod of aerosol-
generating
material 3, connected to the mouthpiece 2. In exemplary embodiments of the
invention
the aerosol-generating material comprises a blend of at least two distinct
components.
In some embodiments the aerosol-generating material comprises a plurality of
strands
and/or strips of a tobacco material and a plurality of strips of amorphous
solid
_ho material, wherein the plurality of strands and/or strips of tobacco
material and the
plurality of strips of amorphous solid material each have a length of at least
about 5
mm. In some embodiments, the material properties and/or dimensions of the at
least
two components may be suitably selected in other ways, to ensure a relatively
uniform
mix of the components is possible, and to reduce separation or un-mixing of
the
components during or after manufacture of the rod of aerosol-generating
material.
Although described above in rod form, the aerosol-generating material can be
provided
in other forms, for instance a plug, pouch, or packet of material within an
article. The
article can comprise a consumable for an aerosol delivery or provision system
such as a
non-combustible aerosol delivery or provision system as described herein.
In the present example a first component is a tobacco material, and a second
component is an amorphous solid material.
In the some examples, the tobacco material comprises a paper reconstituted
tobacco
material. The tobacco material can alternatively or additionally comprise any
of the
forms described herein. Preferably, the tobacco material contains between 10%
and
90% by weight tobacco leaf, wherein aerosol-former material is provided in an
amount
of up to about 10% by weight of the leaf tobacco. Such aerosol-former can be
provided
so in addition to aerosol-former provided in the amorphous solid material.
For instance,
between 3% and 8% aerosol-former by weight of the tobacco material can be
used, or
between 4% and 7%, or between 5% and 7%. The remainder of the tobacco material
can
comprise paper reconstituted tobacco. In other examples, the tobacco material
comprises up to l00% tobacco leaf, for instance up to 100% tobacco lamina,
which can
be in the form of cut rag tobacco. It can be advantageous to adjust the
aerosol former
and/or water content of the tobacco lamina material to avoid a material which
is too
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dry and may become too fragile. For instance, the tobacco lamina can include
between
5% and 8% aerosol-former such as glycerol and/or between 9% and 12% water.
In the present example the amorphous solid material is a dried gel comprising
menthol.
In alternative embodiments, the amorphous solid may have any composition as
described herein.
The inventors have advantageously found that an improved article may be
produced
comprising aerosol-generating material comprising a first component comprising
tobacco material and a second component comprising amorphous solid, wherein
the
_/.9 material properties (e.g. density) and specification (e.g. thickness,
length, and cut
width) fall within the ranges set out herein.
In some cases, the amorphous solid may have a thickness of about 0.015 mm to
about
1.5 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm
or 0.15
mm to about 0.5 mm, 0.3 mm, or i mm. The inventors have found that a material
having a thickness of about 0.2 mm can be used. The amorphous solid may
comprise
more than one layer, and the thickness described herein refers to the
aggregate
thickness of those layers.
The thickness of the amorphous solid material may be measured using a calliper
or a
microscope such as a scanning electron microscope (SEM), as known to those
skilled in
the art, or any other suitable technique known to those skilled in the art.
The inventors have established that if the amorphous solid is too thick, then
heating
efficiency can be compromised. This can adversely affect power consumption in
use, for
instance the power consumption for release of flavour from the amorphous
solid.
Conversely, if the aerosol-forming amorphous solid is too thin, it can be
difficult to
manufacture and handle; a very thin material can be harder to cast and may be
fragile,
compromising aerosol formation in use. The inventors have established that the
so amorphous solid thicknesses stipulated herein optimise the material
properties in view
of these competing considerations.
In some cases, an individual strip or piece of the amorphous solid has a
minimum
thickness over its area of about 0.015 mm. In some cases, an individual strip
or piece of
the amorphous solid has a minimum thickness over its area of about 0.05 mm or
about
0.1 mm. In some cases, an individual strip or piece of the amorphous solid has
a
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maximum thickness over its area of about tomm. In some cases, an individual
strip or
piece of the amorphous solid has a maximum thickness over its area of about
0.5 mm or
about 0.3 mm.
The inventors have found that providing amorphous solid material and tobacco
material having area density values that differ from each other by less than a
given
percentage results in less separation in a mixture of these materials. In some
examples,
the area density of the amorphous solid material may be between 50% and 150%
of the
area density of the tobacco material. For instance, the area density of the
amorphous
io solid material may be between 6o% and 140% of the density of the tobacco
material, or
between 70% and no% of the area density of the tobacco material, or between
8o% and
120% of the area density of the tobacco material.
For the avoidance of doubt, where reference is made herein to area density,
this refers
to an average area density calculated for a given strip, piece or sheet of
amorphous solid
material, the area density calculated by measuring the surface area and weight
of the
given strip, piece or sheet of amorphous solid material.
In some cases, the amorphous solid thickness may vary by no more than 25%,
20%,
151% 10%, 5% or 1% across its area.
In embodiments described herein, the amorphous solid material may be
incorporated
into the article in sheet form. The amorphous solid material in sheet form may
be
shredded and then incorporated into the article, suitably mixed into an
aerosolisable
material such as a tobacco material (as described further hereinbelow).
In further embodiments the amorphous solid sheet may additionally be
incorporated as
a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a
rolled sheet
(i.e. in the form of a tube). In some such cases, the amorphous solid of these
so embodiments may be included in an aerosol-generating article as a sheet,
such as a
sheet circumscribing a rod of aerosolisable material (e.g. tobacco). For
example, the
amorphous solid sheet may be formed on a wrapping paper which circumscribes an
aerosolisable material such as tobacco.
The amorphous solid in sheet form may have any suitable area density, such as
from
about 30 g/m2 to about 150 g/m2. In some cases, the sheet may have a mass per
unit
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area of about 55 g/m2 to about 135 g/m2, or about 8o to about 120 g/m2, or
from about
70 to about no g/m2, or from about 100 g/m2 to about 125 g/m2, or particularly
from
about 90 to about no g/m2, or suitably about loo g/m2, 120 g/m2 or no g/m2.
These
ranges can provide a density which is similar to the density of cut rag
tobacco and as a
result a mixture of these substances can be provided which will not readily
separate.
Such area densities may be particularly suitable where the amorphous solid
material is
included in an aerosol-generating article as a shredded sheet (described
further
hereinbelow). In some cases, the sheet may have a mass per unit area of about
30 to 70
g/m2, 40 to 60 g/m2, or 25 to 60 g/m2 and may be used to wrap an aerosolisable
io material such as tobacco.
The density of the tobacco material has an impact on the speed at which heat
conducts
through the material, with lower densities, for instance those below 700
mg/cc,
conducting heat more slowly through the material, and therefore enabling a
more
susLained release of aerosol.
The tobacco material can comprise reconstituted tobacco material having a
density of
less than about 700 mg/cc, for instance paper reconstituted tobacco material.
For
instance, the aerosol-generating material 3 comprises reconstituted tobacco
material
having a density of less than about 600 mg/cc. Alternatively or in addition,
the aerosol-
generating material 3 can comprise reconstituted tobacco material having a
density of
at least 350 mg/cc.
The tobacco material may be provided in the form of cut rag tobacco. The cut
rag
tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per
cm,
equivalent to a cut width of about 1.7mm). Preferably, the cut rag tobacco has
a cut
width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a cut
width of
about 1.4mm), more preferably at least 20 cuts per inch (about 7.9 cuts per
cm,
equivalent to a cut width of about 1.27mm). In one example, the cut rag
tobacco has a
3o cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a
cut width of about
1.15mm). Preferably, the cut rag tobacco has a cut width at or below 40 cuts
per inch
(about 15.7 cuts per cm, equivalent to a cut width of about 0.64mm). Cut
widths
between 0.5 mm and 2.0 mm, for instance between o.6 and 1.7mm or between o.6
mm
and 1.5 mm, have been found to result in tobacco material which is preferably
in terms
of surface area to volume ratio, particularly when heated, and the overall
density and
pressure drop of the rod of aerosol-generating material 3. The cut rag tobacco
can be
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formed from a mixture of forms of tobacco material, for instance a mixture of
one or
more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and
bandcast
tobacco. Preferably the tobacco material comprises paper reconstituted tobacco
or a
mixture of paper reconstituted tobacco and leaf tobacco.
The tobacco material may have any suitable thickness. The tobacco material may
have a
thickness of at least about 0.145 mm, for instance at least about 0.15 mm, or
at least
about 0.16 mm. The tobacco material may have a maximum thickness of about 0.25
mm, for instance the thickness of the tobacco material may be less than about
0.22
mm, or less than about 0.2 mm. In some embodiments, the tobacco material may
have
an average thickness in the range 0.175 mm to 0.195 mm. Such thicknesses may
be
particularly suitable where the tobacco material is a reconstituted tobacco
material.
It can be desirable to provide an aerosol-generating material comprising a
blend of at
least two componenLs, such as a first. component comprising Lobacco material
and a
second component comprising amorphous solid material as described herein. Such
aerosol-generating material can provide an aerosol, in use, with a desirable
flavour
profile, since additional flavour may be introduced to the aerosol-generating
material
by inclusion in the amorphous solid material component. Flavour provided in
the
amorphous solid material may be more stably retained within the amorphous
solid
material compared to flavour added directly to the tobacco material, resulting
in a more
consistent flavour profile between articles produced according to this
invention.
As described above, tobacco material having a density of at least 350 mg/cc
and less
than about 700 mg/cc has been advantageously found to result in a more
sustained
release of aerosol. To provide an aerosol having a consistent flavour profile
the
amorphous solid material component of the aerosol-generating material should
be
evenly distributed throughout the rod. The inventors have advantageously found
that
this can be achieved by casting the amorphous solid material to have a
thickness as
so described herein, to provide an amorphous solid material having
an area density which
is similar to the area density of the tobacco material, and processing the
amorphous
solid material as described hereinbelow to ensure an even distribution
throughout the
aerosol-generating material.
The inventors have advantageously found that sufficiently even mixing of the
tobacco
material component and the amorphous solid material component can be achieved
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when the amorphous solid material in sheet form is shredded. Preferably the
cut width
of the shredded amorphous solid material is between 0.75 mm and 2 mm, for
instance
between 1 mm and 1.5 mm. The strands of amorphous solid material formed by
shredding may be cut width-wise, for example in a cross-cut type shredding
process, to
define a cut length for the shredded amorphous solid material, in addition to
a cut
width. The cut length of the shredded amorphous solid material is preferably
at least 5
mm, for instance at least 10 mm, or at least 20 mm. The cut length of the
shredded
amorphous solid material can be less than 6o mm, less than 50 mm, or less than
40
mm. The inventors have advantageously found that to achieve even mixing of the
io shredded amorphous solid material with cut rag tobacco, the cut length
of the shredded
amorphous solid material is preferably non-uniform. For example, the
distribution of
cut lengths may be a multi-modal distribution, such as a bimodal distribution.
In some
examples, a first portion of amorphous solid material may be cut to a first
length, and a
second portion of amorphous solid material may be cut to a second length, and
the cut
maLerial mixed together to form a plurality of strands or strips of amorphous
solid
material having a bimodal distribution of lengths. In some examples, the first
cut
length may be from 30 mm to 50 mm, or 35 mm for 45 mm, or about 40 mm, and the
second cut length may be from 10 mm to 30 mm, or from 15 mm to 25 mm, or about
20
mm. The number of cut lengths may be selected to match the number of modes in
the
distribution of lengths of a shredded tobacco material. The strands of
amorphous
material having different cut lengths may be mixed together in a ratio
selected to match
the distribution of lengths of the shredded tobacco material. The inventors
have found
that matching the distribution of lengths of the strands and/or strips of
amorphous
solid material to the distribution of lengths of the strands of tobacco
material can result
in a more even mixing of the amorphous solid with the tobacco material.
Although referred to as cut length, the length of the shreds or strips of
amorphous solid
material can alternatively or additionally be dictated by a dimension of the
material
determined during its manufacture, for instance the width of a sheet of the
material as
so manufactured.
In some embodiments, a plurality of strips of amorphous solid is provided and
at least
one of the plurality of strips of amorphous solid material has a length
greater than
about 10 mm. At least one of the plurality of strips of amorphous solid
material can
3,5 alternatively or in addition have a length between about 10 mm and
about 6o mm, or
between about 20 mm and about 50 mm. Each of the plurality of strips of
amorphous
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solid material can have a length between about lo mm and about 60 mm, or
between
about 20 mm and about 50 mm.
Preferably, the rod of aerosol generating material comprises a first component
comprising a tobacco material in an amount from 50 % to 98 %, for instance
from 80%
to 95%, wherein the tobacco material is for instance provided as a cut rag
tobacco, and
a second component comprising shredded amorphous solid material in an amount
from 2 % to 50 %, for instance from 5% to 20%.
io The inventors have found that it can be advantageous for manufacturing
to form the
rod of aerosol generating material from a relatively low amount, within the
ranges set
out herein, of shredded amorphous solid material comprising a relatively high
level of
aerosol-former, within the ranges set out herein, such that for a given
aerosol-former
content in the aerosol generating material, a lower number of the plurality of
strips of
amorphous solid material are required. This can be beneficial for manufacture
because
relatively more tobacco material comes into contact with components of the
manufacturing machinery compared to the amorphous solid material, which can
reduce the likelihood of material clumping on the machinery and/or blockages
forming
during manufacture. For instance, the amount of aerosol-former, such as
glycerol, in
the amorphous solid material can comprise between 20% and 70%, for instance
between 25% and 55%, between 30% and 40% or between 45% and 55% by weight of
the amorphous solid material.
The inventors have advantageously found that aerosol-generating material
according to
the present disclosure can have a more uniform distribution of the shredded
amorphous solid material throughout the aerosol-generating material. For
instance, the
standard deviation (expressed as a percentage of the mean) in the percentage
weight
inclusion level of the strips of amorphous solid material in the aerosol-
generating
material between consumables made using the aerosol generating material as
described
so herein can be less than 35%, or less than 30% by weight of the aerosol-
generating
material, based on a measurement of io consumables in the present case each
containing about 650mg of the aerosol-generating material. Table la shows the
%
inclusion achieved for three aerosol-generating materials, namely material A
with a
mean of 4.6307% amorphous solid content, material B with a mean of 10.625%
amorphous solid content and material C with a mean of 19.722% amorphous solid
content. It has been found, for instance, that for a mean amorphous solid
inclusion
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rate of greater than 10%, a standard deviation of less than 30% as a
percentage of the
mean can be achieved. The measurement is performed by carefully opening the
aerosol-generating material rod of the consumables and manually separating the
amorphous solid material from tobacco material.
Mean [wt%] Mean Amorphous Solid
Inclusion [% of
total aerosol-generating material]
Aerosol-generating material A 4.6307
SD 1.5435 (33.33% of mean)
Aerosol-generating material B 10.625
SD 2.7372 (25.76% of mean)
Aerosol-generating material C 19.722
SD 4.1161(20.87% of mean)
Table la: Total amorphous solid content by percentage weight in aerosol-
generating
material according to the present disclosure.
Exemplary aerosol-generating materials were produced according to the present
disclosure, and chemical analysis, as known to those skilled in the art, was
carried out
on samples of each exemplary aerosol-generating material to determine the
total
nicotine, glycerol and water content of the material. Ten samples of 10 g were
taken
from a batch of aerosol-generating material for chemical analysis, and the
process
repeated ten times to obtain the mean nicotine, glycerol and water content and
standard deviations thereof within a batch of aerosol-generating material
manufactured according to the methods described herein.
Each of the exemplary aerosol-generating materials 1-3 comprised i00% leaf
tobacco as
the tobacco material component, and each was produced to a different
specification in
terms of the inclusion level of the amorphous solid material component, and
the
composition of the amorphous solid material. The tobacco material included
4.5%
glycerol by weight of the tobacco material. Table 113 shows that in aerosol-
generating
materials produced according to the present disclosure, the standard deviation
in the
total glycerol content within a given batch of material was less than 35% of
the mean in
all cases, or less than 30% or less than 25%.
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Mean twt%l Nicotine Glycerol [%] Water
[%]
[%]
Aerosol-generating material 1 1.88 16.74 9.24
(51.54% VG gel at 15%
inclusion in tobacco blend A)
SD 0.07 2.20 (13% of mean) 0.28
Aerosol-generating material 2 2.07 17.19 8.81
(51.54% VG gel at 20%
inclusion in tobacco blend A)
SD 0.09 1.18 (7% of mean) 0.22
Aerosol-generating material 3 1.98 13.21 8.41
(35.19% VG gel at 20%
inclusion in tobacco blend A)
SD 0.34 2.72 (21% of mean) 0.12
Table lb: Total nicotine, glycerol and water content by percentage weight in
aerosol-
generating material according to the present disclosure.
Where the amorphous solid material comprises a flavourant, the total
flavourant in the
article may comprise the flavourant provided in the amorphous solid material,
and
optionally further flavourant applied to the tobacco material or present in a
component
of the article other than the aerosol-generating material 3. The total
flavourant content
of the article may be determined by deconstructing the article into its
component parts
and performing chemical analysis as known to those skilled in the art to
determine the
flavourant content of each component, and thereby the total flavourant
content. In
examples where the amorphous solid comprises a flavourant, the total
flavourant
content of the article may be between 5 mg and 30 mg per article, for instance
between
16 mg and 22 mg per article, or between 5 mg and 10 mg per article or between
17 mg
and 30 mg per article. The amorphous solid may comprise at least 20% of the
total
flavourant content.
Articles comprising aerosol-generating material according to the present
disclosure
were produced, where the aerosol-generating material included 5wt%, 12wt% or
20wt%
amorphous solid comprising 35wt% menthol as a flavourant. Table 2 shows the
menthol content in mg per article of articles comprising the aerosol-
generating
material. Standard deviations in the menthol content were determined by
analysing ten
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articles produced from each batch of aerosol-generating material. As shown,
the total
menthol inclusion in each article can vary between articles by a standard
deviation of
less than 20% of the mean menthol inclusion in mg.
Amorphous solid inclusion in aerosol-generating 12 Wt%, 5Wt%, 20
Wt%,
material and menthol content of amorphous solid 35% 35%
35%
by percent weight menthol menthol
menthol
Menthol per article [mg] 17.34 7.95
25.59
SD 0.81 L21
1.77
SD as % of mean 4.7% 15.2%
6.9%
Table 2: Total menthol content per article for articles including aerosol-
generating
material comprising amorphous solid material comprising 35% menthol by
percentage weight of the amorphous solid, in varying weight percentages of the
aerosol-generating material.
io The aerosol-generating material can be provided in the form of a
rod having a first end
and a second end. The portion of the rod between the first end of the rod and
a
longitudinal position half-way between the first and second ends can include
from 20%
to 8o% of the amorphous solid material in the rod.
15 The mouthpiece 2, in the present example, includes a body of
material 6 upstream of
the hollow tubular element 4, in this example adjacent to and in an abutting
relationship with the hollow tubular element 4. The body of material 6 and
hollow
tubular element 4 each define a substantially cylindrical overall outer shape
and share a
common longitudinal axis. The body of material 6 is wrapped in a first plug
wrap 7.
20 Preferably, the first plug wrap 7 has a basis weight of less
than 50 gsm, more preferably
between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a
thickness of
between 30 pm and 6o pm, more preferably between 35 pm and 45 pm. Preferably,
the
first plug wrap 7 is a non-porous plug wrap, for instance having a
permeability of less
than 100 Coresta units, for instance less than 50 Coresta units. However, in
other
25 embodiments, the first plug wrap 7 can be a porous plug wrap,
for instance having a
permeability of greater than 200 Coresta Units.
Preferably, the length of the body of material 6 is less than about 15 mm.
More
preferably, the length of the body of material 6 is less than about 10 mm. In
addition, or
so as an alternative, the length of the body of material 6 is at
least about 5 mm.
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Preferably, the length of the body of material 6 is at least about 6 mm. In
some
preferred embodiments, the length of the body of material 6 is from about 5 mm
to
about 15 mm, more preferably from about 6 mm to about 12 mm, even more
preferably
from about 6 mm to about 12 min, most preferably about 6 mm, 7 mm, 8 mm, 9 mm
or
10 mm. In the present example, the length of the body of material 6 is 10 mm.
In the present example, the body of material 6 is formed from filamentary tow.
In the
present example, the tow used in the body of material 6 has a denier per
filament
(d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can, for
instance, have
io a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. In
the present
example, the tow comprises plasticised cellulose acetate tow. The plasticiser
used in
the tow comprises about 7% by weight of the tow. In the present example, the
plasticiser is triacetin. In other examples, different materials can be used
to form the
body of material 6. For instance, rather than tow, the body 6 can be formed
from
paper, for ins Lance in a similar way Lo paper filiers known for use in
cigareiies.
Alternatively, the body 6 can be formed from tows other than cellulose
acetate, for
instance polylactic acid (PLA), other materials described herein for
filamentary tow or
similar materials. The tow is preferably formed from cellulose acetate. The
tow,
whether formed from cellulose acetate or other materials, preferably has a
d.p.f. of at
least 5, more preferably at least 6 and still more preferably at least 7.
These values of
denier per filament provide a tow which has relatively coarse, thick fibres
with a lower
surface area which result in a lower pressure drop across the mouthpiece 2
than tows
having lower d.p.f. values. Preferably, to achieve a sufficiently uniform body
of material
6, the tow has a denier per filament of no more than 12 d.p.f., preferably no
more than
ii d.p.f. and still more preferably no more than 10 d.p.f.
The total denier of the tow forming the body of material 6 is preferably at
most 30,000,
more preferably at most 28,000 and still more preferably at most 25,000. These
values
of total denier provide a tow which takes up a reduced proportion of the cross
sectional
so area of the mouthpiece 2 which results in a lower pressure drop across
the mouthpiece
2 than tows having higher total denier values. For appropriate firmness of the
body of
material 6, the tow preferably has a total denier of at least 8,000 and more
preferably at
least 10,000. Preferably, the denier per filament is between 5 and 12 while
the total
denier is between 10,000 and 25,000. More preferably, the denier per filament
is
between 6 and 10 while the total denier is between 11,000 and 22,000.
Preferably the
cross-sectional shape of the filaments of tow are 'Y shaped, although in other
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embodiments other shapes such as 'X' shaped filaments can be used, with the
same
d.p.f. and total denier values as provided herein.
As shown in Figure 1, the mouthpiece 2 of the article 1 comprises an upstream
end 2a
adjacent to the rod of aerosol-generating material 3 and a downstream end 2b
distal
from the rod of aerosol-generating material 3. At the downstream end 2b, the
mouthpiece 2 has a hollow tubular element 4 formed from filamentary tow. This
has
advantageously been found to significantly reduce the temperature of the outer
surface
of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes
into
io contact with a consumer's mouth when the article 1 is in use. In
addition, the use of the
tubular element 4 has also been found to significantly reduce the temperature
of the
outer surface of the mouthpiece 2 even upstream of the tubular element 4.
Without
wishing to be bound by theory, it is hypothesised that this is due to the
tubular element
4 channelling aerosol closer to the centre of the mouthpiece 2, and therefore
reducing
the transfer of heat from the aerosol to the outer surface of the mouthpiece
2.
In the present example, the article 1 has an outer circumference of about 21
mm (i.e. the
article is in the demi-slim format). In other examples, the article can be
provided in
any of the formats described herein, for instance having an outer
circumference of
between 15mm and 25mm. Since the article is to be heated to release an
aerosol,
improved heating efficiency can be achieved using articles having lower outer
circumferences within this range, for instance circumferences of less than
23mm. To
achieve improved aerosol via heating, while maintaining a suitable product
length,
article circumferences of greater than 19mm have also been found to be
particularly
effective. Articles having circumferences of between 19mm and 23mm, and more
preferably between 20MM and 22MM, have been found to provide a good balance
between providing effective aerosol delivery while allowing for efficient
heating.
The outer circumference of the mouthpiece 2 is substantially the same as the
outer
so circumference of the rod of aerosol-generating material 3, such that
there is a smooth
transition between these components. In the present example, the outer
circumference
of the mouthpiece 2 is about 20.8mm. A tipping paper 5 is wrapped around the
full
length of the mouthpiece 2 and over part of the rod of aerosol-generating
material 3
and has an adhesive on its inner surface to connect the mouthpiece 2 and rod
3. In the
present example, the tipping paper 5 extends 5 mm over the rod of aerosol-
generating
material 3 but it can alternatively extend between 3 mm and 10 mm over the rod
3, or
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more preferably between 4 mm and 6 mm, to provide a secure attachment between
the
mouthpiece 2 and rod 3. The tipping paper 5 can have a basis weight which is
higher
than the basis weight of plug wraps used in the article 1, for instance a
basis weight of
40 gsm to 8o gsm, more preferably between 50 gsm and 70 gsm, and in the
present
example 58 gsm. These ranges of basis weights have been found to result in
tipping
papers having acceptable tensile strength while being flexible enough to wrap
around
the article 1 and adhere to itself along a longitudinal lap seam on the paper.
The outer
circumference of the tipping papers, once wrapped around the mouthpiece 2, is
about
21 MM.
The "wall thickness" of the hollow tubular element 4 corresponds to the
thickness of the
wall of the tube 4 in a radial direction. This may be measured, for example,
using a
calliper. The wall thickness is advantageously greater than 0.9 mm, and more
preferably tomm or greater. Preferably, the wall thickness is substantially
constant
around the entire wall of We hollow tubular element 4. However, where Llie
wall
thickness is not substantially constant, the wall thickness is preferably
greater than 0.9
mm at any point around the hollow tubular element 4, more preferably Lomm or
greater.
Preferably, the length of the hollow tubular element 4 is less than about 20
mm. More
preferably, the length of the hollow tubular element 4 is less than about 15
mm. Still
more preferably, the length of the hollow tubular element 4 is less than about
10 mm.
In addition, or as an alternative, the length of the hollow tubular element 4
is at least
about 5 mm. Preferably, the length of the hollow tubular element 4 is at least
about 6
mm. In some preferred embodiments, the length of the hollow tubular element 4
is
from about 5 mm to about 20 mm, more preferably from about 6 mm to about 10
mm,
even more preferably from about 6 mm to about 8 mm, most preferably about 6
mm, 7
mm or about 8 mm. In the present example, the length of the hollow tubular
element 4
is 6 mm.
Preferably, the density of the hollow tubular element 4 is at least about 0.25
grams per
cubic centimetre (g/cc), more preferably at least about 0.3 g/cc. Preferably,
the density
of the hollow tubular element 4 is less than about 0.75 grams per cubic
centimetre
(g/cc), more preferably less than o.6 g/cc. In some embodiments, the density
of the
hollow tubular element 4 is between 0.25 and 0.75 g/cc, more preferably
between 0.3
and o.6 g/cc, and more preferably between 0.4 g/cc and o.6 g/cc or about 0.5
g/cc.
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These densities have been found to provide a good balance between improved
firmness
afforded by denser material and the lower heat transfer properties of lower
density
material. For the purposes of the present invention, the "density" of the
hollow tubular
element 4 refers to the density of the filamentary tow forming the element
with any
plasticiser incorporated. The density may be determined by dividing the total
weight of
the hollow tubular element 4 by the total volume of the hollow tubular element
4,
wherein the total volume can be calculated using appropriate measurements of
the
hollow tubular element 4 taken, for example, using callipers. Where necessary,
the
appropriate dimensions may be measured using a microscope.
The filamentary tow forming the hollow tubular element 4 preferably has a
total denier
of less than 45,000, more preferably less than 42,000. This total denier has
been found
to allow the formation of a tubular element 4 which is not too dense.
Preferably, the
total denier is at least 20,000, more preferably at least 25,000. In preferred
embodiments, the filamentary tow forming the hollow tubular element 4 has a
total
denier between 25,000 and 45,000, more preferably between 35,000 and 45,000.
Preferably the cross-sectional shape of the filaments of tow are 'Y' shaped,
although in
other embodiments other shapes such as 'X' shaped filaments can be used.
The filamentary tow forming the hollow tubular element 4 preferably has a
denier per
filament of greater than 3. This denier per filament has been found to allow
the
formation of a tubular element 4 which is not too dense. Preferably, the
denier per
filament is at least 4, more preferably at least 5. In preferred embodiments,
the
filamentary tow forming the hollow tubular element 4 has a denier per filament
between 4 and 10, more preferably between 4 and 9. In one example, the
filamentary
tow forming the hollow tubular element 4 has an 8Y4o,000 tow formed from
cellulose
acetate and comprising 18% plasticiser, for instance triacetin.
The hollow tubular element 4 preferably has an internal diameter of greater
than
so 3.omm. Smaller diameters than this can result in increasing the velocity
of aerosol
passing though the mouthpiece 2 to the consumers mouth more than is desirable,
such
that the aerosol becomes too warm, for instance reaching temperatures greater
than
40 C or greater than 45 C. More preferably, the hollow tubular element 4 has
an
internal diameter of greater than 3.imm, and still more preferably greater
than 3.mm
or 3.6mm. In one embodiment, the internal diameter of the hollow tubular
element 4
is about 3.9mm.
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The hollow tubular element 4 preferably comprises from 15% to 22% by weight of
plasticiser. For cellulose acetate tow, the plasticiser is preferably
triacetin, although
other plasticisers such as polyethelyne glycol (PEG) can be used. More
preferably, the
tubular element 4 comprises from 16% to 20% by weight of plasticiser, for
instance
about 17%, about 18% or about 19% plasticiser.
In the present example the hollow tubular element 4 is a first hollow tubular
element 4
and the mouthpiece includes a second hollow tubular element 8, also referred
to as a
io cooling element, upstream of the first hollow tubular element 4. In the
present
example, the second hollow tubular element 8 is upstream of, adjacent to and
in an
abutting relationship with the body of material 6. The body of material 6 and
second
hollow tubular element 8 each define a substantially cylindrical overall outer
shape and
share a common longitudinal axis. The second hollow tubular element 8 is
formed
from a pluraliLy of layers of paper which are parallel wound, wiLh bulled
seams, Lo form
the tubular element 8. In the present example, first and second paper layers
are
provided in a two-ply tube, although in other examples 3, 4 or more paper
layers can be
used forming 3, 4 or more ply tubes. Other constructions can be used, such as
spirally
wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type
process, moulded or extruded plastic tubes or similar. The second hollow
tubular
element 8 can also be formed using a stiff plug wrap and/or tipping paper as
the second
plug wrap 9 and/or tipping paper 5 described herein, meaning that a separate
tubular
element is not required. The stiff plug wrap and/or tipping paper is
manufactured to
have a rigidity that is sufficient to withstand the axial compressive forces
and bending
moments that might arise during manufacture and whilst the article 1 is in
use. For
instance, the stiff plug wrap and/or tipping paper can have a basis weight
between 70
gsm and 120 gsm, more preferably between 80 gsm and 110 gsm. Additionally or
alternatively, the stiff plug wrap and/or tipping paper can have a thickness
between 8o
Lim and 200 vim, more preferably between 100 pm and 160 Ltm, or from 120 ktm
to 150
so pm. It can be desirable for both the second plug wrap 9 and tipping
paper 5 to have
values in these ranges, to achieve an acceptable overall level of rigidity for
the second
hollow tubular element 8.
The second hollow tubular element 8 preferably has a wall thickness, which can
be
measured in the same way as that of the first hollow tubular element 4, of at
least about
loo Lim and up to about 1.5mm, preferably between loo ktm and 1 mm and more
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preferably between 150 um and 500 p.m, or about 300 tm. In the present
example, the
second hollow tubular element 8 has a wall thickness of about 290 um.
Preferably, the length of the second hollow tubular element 8 is less than
about 50 mm.
More preferably, the length of the second hollow tubular element 8 is less
than about
40 mm. Still more preferably, the length of the second hollow tubular element
8 is less
than about 30 mm. In addition, or as an alternative, the length of the second
hollow
tubular element 8 is preferably at least about 10 mm. Preferably, the length
of the
second hollow tubular element 8 is at least about 15 mm. In some preferred
/o embodiments, the length of the second hollow tubular element 8 is from
about 20 rrirri
to about 30 mm, more preferably from about 22 rrirri to about 28 mm, even more
preferably from about 24 to about 26 mm, most preferably about 25 mm. In the
present
example, the length of the second hollow tubular element 8 is 25 mm.
The second hollow Lubular element. 8 is located around and defines an air gap
within
the mouthpiece 2 which acts as a cooling segment. The air gap provides a
chamber
through which heated volatilised components generated by the aerosol-
generating
material 3 flow. The second hollow tubular element 8 is hollow to provide a
chamber
for aerosol accumulation yet rigid enough to withstand axial compressive
forces and
bending moments that might arise during manufacture and whilst the article 1
is in use.
The second hollow tubular element 8 provides a physical displacement between
the
aerosol-generating material 3 and the body of material 6. The physical
displacement
provided by the second hollow tubular element 8 will provide a thermal
gradient across
the length of the second hollow tubular element 8.
Preferably, the mouthpiece 2 comprises a cavity having an internal volume
greater than
450 mm3. Providing a cavity of at least this volume has been found to enable
the
formation of an improved aerosol. Such a cavity size provides sufficient space
within
the mouthpiece 2 to allow heated volatilised components to cool, therefore
allowing the
so exposure of the aerosol-generating material 3 to higher temperatures
than would
otherwise be possible, since they may result in an aerosol which is too warm.
In the
present example, the cavity is formed by the second hollow tubular element 8,
but in
alternative arrangements it could be formed within a different part of the
mouthpiece 2.
More preferably, the mouthpiece 2 comprises a cavity, for instance formed
within the
second hollow tubular element 8, having an internal volume greater than 500
mm3, and
still more preferably greater than 550 mm3, allowing further improvement of
the
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aerosol. In some examples, the internal cavity comprises a volume of between
about
550 mm3 and about 750 mm3, for instance about 600 mm3 or 700 mm3.
The second hollow tubular element 8 can be configured to provide a temperature
differential of at least 40 degrees Celsius between a heated volatilised
component
entering a first, upstream end of the second hollow tubular element 8 and a
heated
volatilised component exiting a second, downstream end of the second hollow
tubular
element 8. The second hollow tubular element 8 is preferably configured to
provide a
temperature differential of at least 60 degrees Celsius, preferably at least
80 degrees
io Celsius and more preferably at least loo degrees Celsius between a
heated volatilised
component entering a first, upstream end of the second hollow tubular element
8 and a
heated volatilised component exiting a second, downstream end of the second
hollow
tubular element 8. This temperature differential across the length of the
second hollow
tubular element 8 protects the temperature sensitive body of material 6 from
the high
temperatures of the aerosol-generating material 3 when it is heated.
In alternative articles, the second hollow tubular element 8 can be replaced
with an
alternative cooling element, for instance an element formed from a body of
material
which allows aerosol to pass through it longitudinally, and which also
performs the
function of cooling the aerosol.
In the present example, the first hollow tubular element 4, body of material 6
and
second hollow tubular element 8 are combined using a second plug wrap 9 which
is
wrapped around all three sections. Preferably, the second plug wrap 9 has a
basis
weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm.
Preferably, the second plug wrap 9 has a thickness of between 30 tint and 6o
tun, more
preferably between 35 ttm and 45 p.m. The second plug wrap 9 is preferably a
non-
porous plug wrap having a permeability of less than 100 Coresta Units, for
instance less
than 50 Coresta Units. However, in alternative embodiments, the second plug
wrap 9
so can be a porous plug wrap, for instance having a permeability of greater
than 200
Coresta Units.
In the present example, the aerosol-generating material 3 is wrapped in a
wrapper to.
The wrapper 10 can, for instance, be a paper or paper-backed foil wrapper. In
the
present example, the wrapper 10 is substantially impermeable to air. In
alternative
embodiments, the wrapper lo preferably has a permeability of less than ioo
Coresta
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Units, more preferably less than 60 Coresta Units. It has been found that low
permeability wrappers, for instance having a permeability of less than loo
Coresta
Units, more preferably less than 60 Coresta Units, result in an improvement in
the
aerosol formation in the aerosol-generating material 3. Without wishing to be
bound
by theory, it is hypothesised that this is due to reduced loss of aerosol
compounds
through the wrapper 10. The permeability of the wrapper io can be measured in
accordance with ISO 2965:2009 concerning the determination of air permeability
for
materials used as cigarette papers, filter plug wrap and filter joining paper.
io In the present embodiment, the wrapper 10 comprises aluminium foil.
Aluminium foil
has been found to be particularly effective at enhancing the formation of
aerosol within
the aerosol-generating material 3. In the present example, the aluminium foil
has a
metal layer having a thickness of about 6 larn. In the present example, the
aluminium
foil has a paper backing. However, in alternative arrangements, the aluminium
foil can
be other thicknesses, for instance between 4 pin and 16 p.m in thickness. The
aluminium foil also need not have a paper backing, but could have a backing
formed
from other materials, for instance to help provide an appropriate tensile
strength to the
foil, or it could have no backing material. Metallic layers or foils other
than aluminium
can also be used. The total thickness of the wrapper is preferably between 20
vim and
6o pm, more preferably between 30 pm and 50 pm, which can provide a wrapper
having appropriate structural integrity and heat transfer characteristics. The
tensile
force which can be applied to the wrapper before it breaks can be greater than
3,000
grams force, for instance between 3,000 and 10,000 grams force or between
3,000 and
4,500 grams force.
The article has a ventilation level of about 75% of the aerosol drawn through
the article.
In alternative embodiments, the article can have a ventilation level of
between 50% and
80% of aerosol drawn through the article, for instance between 65% and 75%. In
some
examples, the standard deviation in the level of ventilation in a batch of
articles
so produced according to the present disclosure is less than 5%, or less
than 4% or less
than 3%. For the purposes of determining the standard deviation in the
ventilation
level, a batch refers to at least io articles produced to the same
specification. For
instance, those articles provided in a pack of articles can be used as basis
for the
measurements. Such standard deviations can be achieved due to the improved
blending
of the tobacco material and amorphous solid material in aerosol-generating
material
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produced according to the present invention, since the improved blend can
result in a
more consistent packing of the aerosol-generating material in the articles.
Ventilation at these levels helps to slow down the flow of aerosol drawn
through the
mouthpiece 2 and thereby enable the aerosol to cool sufficiently before it
reaches the
downstream end 2b of the mouthpiece 2. The ventilation is provided directly
into the
mouthpiece 2 of the article 1. In the present example, the ventilation is
provided into
the second hollow tubular element 8, which has been found to be particularly
beneficial
in assisting with the aerosol generation process. The ventilation is provided
via first
io and second parallel rows of perforations 12, in the present case formed
as laser
perforations, at positions 17.925 mm and 18.625 mm respectively from the
downstream, mouth-end 2b of the mouthpiece 2. These perforations pass though
the
tipping paper 5, second plug wrap 9 and second hollow tubular element 8. In
alternative embodiments, the ventilation can be provided into the mouthpiece
at other
locations, for instance into the body of material 6 or first tubular element
4.
Preferably the aerosol-generating material 3 is provided as a cylindrical rod
of aerosol-
generating material. Irrespective of the form of the aerosol-generating
material, it
preferably has a length of about 10 mm to loo mm. In some embodiments, the
length
of the aerosol-generating material is preferably in the range about 25 mm to
50 mm,
more preferably in the range about 30 mm to 45 mm, and still more preferably
about
mm to 40 mm.
The volume of aerosol-generating material 3 provided can vary from about 200
MM3tO
25 about 4300 mm3, preferably from about 500 mm3 to 1500 mm3, more
preferably from
about l000 mm3 to about 1300 mm3. The provision of these volumes of aerosol-
generating material, for instance from about 1000 mm3 to about 1300 mm3, has
been
advantageously shown to achieve a superior aerosol, having a greater
visibility and
sensory performance compared to that achieved with volumes selected from the
lower
so end of the range.
The mass of aerosol-generating material 3 provided can be greater than 200 mg,
for
instance from about 200 mg to 400 mg, preferably from about 230 mg to 360 mg,
more
preferably from about 250 mg to 360 mg. It has been advantageously found that
providing a higher mass of aerosol-generating material results in improved
sensory
performance compared to aerosol generated from a lower mass of tobacco
material.
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Figure 2a is a side-on cross sectional view of a further article 1' including
a capsule-
containing mouthpiece 2'. Figure 2b is a cross sectional view of the capsule-
containing
mouthpiece shown in Figure 2a through the line A-A' thereof. Article 1' and
capsule-
containing mouthpiece 2' are the same as the article 1 and mouthpiece 2
illustrated in
Figure 1, except that an aerosol modifying agent is provided within the body
of material
6, in the present example in the form of a capsule 11, and that an oil-
resistant first plug
wrap 7' surrounds the body of material 6. In other examples, the aerosol
modifying
agent can be provided in other forms, such as material injected into the body
of
io material 6 or provided on a thread, for instance the thread carrying a
flavourant or
other aerosol modifying agent, which may also be disposed within the body of
material
6.
The capsule 11 can comprise a breakable capsule, for instance a capsule which
has a
solid, frangible shell surrounding a liquid payload. In the present example, a
single
capsule 11 is used. The capsule 11 is entirely embedded within the body of
material 6.
In other words, the capsule 11 is completely surrounded by the material
forming the
body 6. In other examples, a plurality of breakable capsules may be disposed
within the
body of material 6, for instance 2, 3 or more breakable capsules. The length
of the body
of material 6 can be increased to accommodate the number of capsules required.
In
examples where a plurality of capsules is used, the individual capsules may be
the same
as each other, or may differ from one another in terms of size and/or capsule
payload.
In other examples, multiple bodies of material 6 may be provided, with each
body
containing one or more capsules.
The capsule 11 has a core-shell structure. In other words, the capsule n
comprises a
shell encapsulating a liquid agent, for instance a flavourant or other agent,
which can be
any one of the flavourants or aerosol modifying agents described herein. The
shell of
the capsule can be ruptured by a user to release the flavourant or other agent
into the
so body of material 6. The first plug wrap 7' can comprise a barrier
coating to make the
material of the plug wrap substantially impermeable to the liquid payload of
the
capsule 11. Alternatively or in addition, the second plug wrap 9 and/or
tipping paper 5
can comprise a barrier coating to make the material of that plug wrap and/or
tipping
paper substantially impermeable to the liquid payload of the capsule 11.
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In the present example, the capsule 11 is spherical and has a diameter of
about 3 mm.
In other examples, other shapes and sizes of capsule can be used. The total
weight of
the capsule 11 may be in the range about 10 mg to about 50 mg.
In the present example, the capsule 11 is located at a longitudinally central
position
within the body of material 6. That is, the capsule 11 is positioned so that
its centre is 4
mm from each end of the body of material 6. In other examples, the capsule 11
can be
located at a position other than a longitudinally central position in the body
of material
6, i.e. closer to the downstream end of the body of material 6 than the
upstream end, or
io closer to the upstream end of the body of material 6 than the downstream
end.
Preferably, the mouthpiece 2' is configured so that the capsule 11 and the
ventilation
holes 12 are longitudinally offset from each other in the mouthpiece 2'.
A cross section of the mouthpiece 2' is shown in Figure 2b, this being taken
through
line A-A' of Figure 2a. Figure 2b shows [he capsule 11, [he body of maLerial
6, lhe first.
and second plug wraps 7', 9 and the tipping paper 5. In the present example,
the
capsule 11 is centred on the longitudinal axis (not shown) of the mouthpiece
2'. The
first and second plug wraps 7', 9 and tipping 5 are arranged concentrically
around the
body of material 6.
The breakable capsule n has a core-shell structure. That is, the encapsulating
material
or barrier material creates a shell around a core that comprises the aerosol
modifying
agent. The shell structure hinders migration of the aerosol modifying agent
during
storage of the article 1' but allows controlled release of the aerosol
modifying agent, also
referred to as an aerosol modifier, during use.
In some cases, the barrier material (also referred to herein as the
encapsulating
material) is frangible. The capsule is crushed or otherwise fractured or
broken by the
user to release the encapsulated aerosol modifier. Typically, the capsule is
broken
so immediately prior to heating being initiated but the user can select
when to release the
aerosol modifier. The term "breakable capsule" refers to a capsule, wherein
the shell
can be broken by means of a pressure to release the core; more specifically
the shell can
be ruptured under the pressure imposed by the user's fingers when the user
wants to
release the core of the capsule.
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In some cases, the barrier material is heat resistant. That is to say, in some
cases, the
barrier will not rupture, melt or otherwise fail at the temperature reached at
the capsule
site during operation of the aerosol provision device. Illustratively, a
capsule located in
a mouthpiece may be exposed to temperatures in the range of 30 C to loo C for
example, and the barrier material may continue to retain the liquid core up to
at least
about 50 C to 120 C.
In other cases, the capsule releases the core composition on heating, for
example by
melting of the barrier material or by capsule swelling leading to rupture of
the barrier
io material.
The total weight of a capsule may be in the range of about 1 mg to about 100
mg,
suitably about 5 mg to about 6o mg, about 8 mg to about 50 mg, about 10 mg to
about
20 mg, or about 12 mg to about 18 mg.
The total weight of the core formulation may be in the range of about 2 mg to
about 90
mg, suitably about 3 mg to about 70 mg, about 5 mg to about 25 mg, about 8 mg
to
about 20 mg, or about 10 mg to about 15 mg.
The capsule according to the invention comprises a core as described above,
and a shell.
The capsules may present a crush strength from about 4.5 N to about 40 N, more
preferably from about 5 N to about 30 N or to about 28 N (for instance about
9.8 N to
about 24.5 N). The capsule burst strength can be measured when the capsule is
removed from the body of material 6 and using a force gauge to measure the
force at
which the capsule bursts when pressed between two flat metal plates. A
suitable
measurement device is the Sauter FK 50 force gauge with a flat headed
attachment,
which can be used to crush the capsule against a flat, hard surface having a
surface
similar to the attachment.
so The capsules may be substantially spherical and have a diameter of at
least about 0.4
mm, o.6 mm, o.8 mm, 1.0 mm, 2.0 111111, 2.5 min, 2.8 mm or 3.0 mm. The
diameter of
the capsules may be less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm,
5.0
mm, 4.5 mm, 4.0 mm, 3.5 mm or 3.2 mm. Illustratively, the capsule diameter may
be in
the range of about 0.4 mm to about 10.0 mm, about 0.8 mm to about 6.0 mm,
about
2.5 mm to about 5.5 mm or about 2.8 mm to about 3.2 mm. In some cases, the
capsule
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may have a diameter of about 3.0 mm. These sizes are particularly suitable for
incorporation of the capsule into an article as described herein.
The cross-sectional area of the capsule 11 at its largest cross sectional area
is in some
embodiments less than 28% of the cross sectional area of the portion of the
mouthpiece
2' in which the capsule 11 is provided, more preferably less than 27% and
still more
preferably less than 25%. For instance, for the spherical capsule having a
diameter of
3.0 mm, the largest cross sectional area of the capsule is 7.07 mm2. For the
mouthpiece
2' having a circumference of 21 mm as described herein, the body of material 6
has an
io outer circumference of 20.8 mm, and the radius of this component will be
3.31 mm,
corresponding to a cross sectional area of 34.43 mm2. The capsule cross
sectional area
is, in this example, 20.5% of the cross-sectional area of the mouthpiece 2'.
As another
example, if the capsule had a diameter of 3.2mm, its largest cross sectional
area would
be 8.04 mm2. In this case, the cross sectional area of the capsule would be
23.4% of the
cross sectional area of the body of maerial 6. A capsule with a largest cross
sectional
area less than 28% of the cross sectional area of the portion of the
mouthpiece 2' in
which the capsule 11 is provided has the advantage that the pressure drop
across the
mouthpiece 2' is reduced as compared to capsules with larger cross sectional
areas and
adequate space remains around the capsule for aerosol to pass without the body
of
material 6 removing significant amounts of the aerosol mass as it passes
through the
mouthpiece 2'.
Preferably the pressure drop or difference (also referred to a resistance to
draw) across
the article, measured as the open pressure drop (i.e. with the ventilation
openings
open), reduces by less than 8 mmH20 when the capsule is broken. More
preferably, the
open pressure drop reduces by less than 6 mmI-120 and more preferably less
than 5
mmH20. These values are measured as the average achieved by at least 80
articles
made to the same design. Such small changes in pressure drop mean that other
aspects
of the product design, such as setting the correct ventilation level for a
given product
so pressure drop, can be achieved irrespective of whether or not the
consumer chooses to
break the capsule.
The barrier material may comprise one or more of a gelling agent, a bulking
agent, a
buffer, a colouring agent and a plasticiser.
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Suitably, the gelling agent of the capsule may be, for example, a
polysaccharide or
cellulosic gelling agent, a gelatin, a gum, a gel, a wax or a mixture thereof.
Suitable
polysaccharides include alginates, dextrans, maltodextrins, cyclodextrins and
pectins.
Suitable alginates include, for instance, a salt of alginic acid, an
esterified alginate or
glyceryl alginate. Salts of alginic acid include ammonium alginate,
triethanolamine
alginate, and group I or II metal ion alginates like sodium, potassium,
calcium and
magnesium alginate. Esterified alginates include propylene glycol alginate and
glyceryl
alginate. In an embodiment, the barrier material is sodium alginate and/ or
calcium
alginate. Suitable cellulosic materials include methyl cellulose, ethyl
cellulose,
/o hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl
cellulose, cellulose
acetate and cellulose ethers. The gelling agent may comprise one or more
modified
starches. The gelling agent may comprise carrageenans. Suitable gums include
agar,
gellan gum, gum Arabic, pullulan gum, mannan gum, gum ghatti, gum tragacanth,
Karaya, locust bean, acacia gum, guar, quince seed and xanthan gums. Suitable
gels
include agar, agarose, carrageenans, furoidan and furcellaran. Suitable waxes
include
carnauba wax. In some cases, the gelling agent may comprise carrageenans
and/or
gellan gum; these gelling agents are particularly suitable for inclusion as
the gelling
agent as the pressure required to break the resulting capsules is particularly
suitable.
The barrier material may comprise one or more bulking agents, such as
starches,
modified starches (such as oxidised starches) and sugar alcohols such as
maltitol.
The barrier material may comprise a colouring agent which renders easier the
location
of the capsule within the aerosol generating device during the manufacturing
process of
the aerosol generating device. The colouring agent is preferably chosen among
colorants and pigments.
The barrier material may further comprise at least one buffer, such as a
citrate or
phosphate compound.
The barrier material may further comprise at least one plasticiser, which may
be
glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol
or another
polyalcohol with plasticising properties, and optionally one acid of the
monoacid, diacid
or triacid type, especially citric acid, fumaric acid, malic acid, and the
like. The amount
of plasticiser ranges from 1% to 30% by weight, preferably from 2% to 15% by
weight,
and even more preferably from 3 to 10% by weight of the total dry weight of
the shell.
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The barrier material may also comprise one or more filler materials. Suitable
filler
materials include comprising starch derivatives such as dextrin, maltodextrin,
cyclodextrin (alpha, beta or gamma), or cellulose derivatives such as
hydroxypropyl-
methylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC),
carboxy-methylcellulose (CMC), polyvinyl alcohol, polyols or mixture thereof.
Dextrin
is a preferred filler. The amount of filler in the shell is at most 98.5%,
preferably from
25 to 95% more preferably from 40 to 80% and even more preferably from 50 to
60 %
by weight on the total dry weight of the shell.
The capsule shell may additionally comprise a hydrophobic outer layer which
reduces
the susceptibility of the capsule to moisture-induced degradation. The
hydrophobic
outer layer is suitably selected from the group comprising waxes, especially
carnauba
wax, candelilla wax or beeswax, carbowax, shellac (in alcoholic or aqueous
solution),
ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyl- propylcellulose,
latex
composition, polyvinyl alcohol, or a combination thereof. More preferably, the
at least
one moisture barrier agent is ethyl cellulose or a mixture of ethyl cellulose
and shellac.
The capsule core comprises the aerosol modifier. This aerosol modifier may be
any
volatile substance which modifies at least one property of the aerosol. For
example, the
aerosol substance may modify the pH, the sensorial properties, the water
content, the
delivery characteristics or the flavour. In some cases, the aerosol modifier
may be
selected from an acid, a base, water or a flavourant. In some embodiments, the
aerosol
modifier comprises one or more flavourants.
The flavourant may suitably be licorice, rose oil, vanilla, lemon oil, orange
oil, a mint-
flavour, suitably menthol and/or a mint oil from any species of the genus
Mentha such
as peppermint oil and/or spearmint oil, or lavender, fennel or anise.
In some cases, the flavourant comprises menthol.
In some cases, the capsule may comprise at least about 25% w/w flavourant
(based on
the total weight of the capsule), suitably at least about 30% w/w flavourant,
35% w/w
flavourant, 40% w/w flavourant, 45% w/w flavourant or 50% w/w flavourant.
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In some cases, the core may comprise at least about 25% w/w flavourant (based
on the
total weight of the core), suitably at least about 30% w/w flavourant, 35% w/w
flavourant, 40% w/w flavourant, 45% w/w flavourant or 50% w/w flavourant. In
some
cases, the core may comprise less than or equal to about 75% w/w flavourant
(based on
the total weight of the core), suitably less than or equal to about 65% w/w
flavourant,
55% w/w flavourant, or 50% w/w flavourant. Illustratively, the capsule may
include an
amount of flavourant in the range of 25-75% w/w (based on the total weight of
the
core), about 35-60% w/w or about 40-55% w/w.
_/0 The capsules may include at least about 2 mg, 3 mg or 4 mg of the
aerosol modifier,
suitably at least about 4.5 mg of the aerosol modifier, 5 mg of the aerosol
modifier, 5.5
mg of the aerosol modifier or 6 mg of the aerosol modifier.
In some cases, the consumable comprises at least about 7 mg of the aerosol
modifier,
sullably at. least about 8 mg of the aerosol modifier, 10 mg of the aerosol
modifier, 12
mg of the aerosol modifier or 15 mg of the aerosol modifier. The core may also
comprise
a solvent which dissolves the aerosol modifier.
Any suitable solvent may be used.
Where the aerosol modifier comprises a flavourant, the solvent may suitably
comprise
short or medium chain fats and oils. For example, the solvent may comprise tri-
esters
of glycerol such as C2-C12 triglycerides, suitably C6-Cio triglycerides or Cs-
C12
triglycerides. For example, the solvent may comprise medium chain
triglycerides (MCT
- C8-C12), which may be derived from palm oil and/or coconut oil.
The esters may be formed with caprylic acid and/or capric acid. For example,
the
solvent may comprise medium chain triglycerides which are caprylic
triglycerides
and/or capric tryglycerides. For example, the solvent may comprise compounds
so identified in the CAS registry by numbers 73398-61-5, 65381-09-1, 85409-
09-2. Such
medium chain triglycerides are odourless and tasteless.
The hydrophilic-lipophilic balance (HLB) of the solvent may be in the range of
9 to 13,
suitably 10 to 12. Methods of making the capsules include co-extrusion,
optionally
followed by centrifugation and curing and/or drying. The contents of WO
2007/010407
A2 is incorporated by reference, in its entirety.
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In the examples described above, the mouthpieces 2, 2' each comprise a single
body of
material 6. In other examples, either the mouthpiece of Figure 1 or of Figures
2a and
2b may include multiple bodies of material. The mouthpieces 2, 2' may comprise
a
cavity between the bodies of material.
In some examples, the mouthpiece 2, 2' downstream of the aerosol generating
material
3 can comprise a wrapper, for instance the first or second plug wraps 7, 9, or
tipping
paper 5, which comprises an aerosol modifying agent as described herein or
other
io sensate material. The aerosol modifying agent may be disposed on an
inwardly or
outwardly facing surface of the mouthpiece wrapper. For instance, the aerosol
modifying agent or other sensate material may be provided on an area of the
wrapper,
such as an outwardly facing surface of the tipping paper 5, which comes into
contact
with the consumer's lips during use. By disposing the aerosol modifying agent
or other
sensate material on the outwardly facing surface of the mouthpiece wrapper,
the
aerosol modifying agent or other sensate material may be transferred to the
consumer's
lips during use. Transfer of the aerosol modifying agent or other sensate
material to the
consumer's lips during use of the article may modify the organoleptic
properties (e.g.
taste) of the aerosol generated by the aerosol generating substrate 3 or
otherwise
provide the consumer with an alternative sensory experience. For example, the
aerosol
modifying agent or other sensate material may impart flavour to the aerosol
generated
by the aerosol generating substrate 3. The aerosol modifying agent or other
sensate
material may be at least partially soluble in water such that it is
transferred to the user
via the consumer's saliva. The aerosol modifying agent or other sensate
material may
be one that volatilises by the heat generated by the aerosol provision system.
This may
facilitate transfer of the aerosol modifying agent to the aerosol generated by
the aerosol
generating substrate 3. A suitable sensate material may be a flavour as
described
herein, sucralose or a cooling agent such as menthol or similar.
so According to embodiments described herein, a pack can be provided
comprising a
plurality of articles as described herein. The number of the plurality of
strips of
amorphous solid material in each article can vary by less than 40% between the
articles
in the pack, or less than 30% between the articles in the pack, or less than
20% between
the articles in the pack. Alternatively or in addition, the plurality of
strips of
amorphous solid material in each article in a pack can comprise a flavourant,
and the
delivery of the flavourant from each of the plurality of articles, in use,
varies by less
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than 50% between the articles in the pack, or varies by less than 20% between
the
articles in the pack. For example, the standard deviation in the inclusion
level of the
flavourant by percentage weight between articles in the pack may be less than
50%, or
less than 30%, or less than 20%, for instance between 5% and 50%, or between
5% and
30%, or between 10% and 25% of the mean. The flavourant level may be
determined by
chemical analysis as known to those skilled in the art, and the standard
deviation may
be determined for a batch of at least 10 articles, for instance a pack of
articles.
Figure 3 shows an example of a non-combustible aerosol provision device 100
for
io generating aerosol from an aerosol generating medium/material such as
the aerosol
generating material 3 of the articles 1, 1' described herein. In broad
outline, the device
loo may be used to heat a replaceable article no comprising the aerosol
generating
medium, for instance the articles 1, 1' described herein, to generate an
aerosol or other
inhalable medium which is inhaled by a user of the device 100. The device loo
and
replaceable article no LogeLher form a system.
The device loo comprises a housing 102 (in the form of an outer cover) which
surrounds and houses various components of the device 100. The device 100 has
an
opening 104 in one end, through which the article no may be inserted for
heating by a
heating assembly. In use, the article no may be fully or partially inserted
into the
heating assembly where it may be heated by one or more components of the
heater
assembly.
The device 100 of this example comprises a first end member 106 which
comprises a lid
108 which is moveable relative to the first end member 106 to close the
opening 104
when no article no is in place. In Figure 3, the lid io8 is shown in an open
configuration, however the lid 108 may move into a closed configuration. For
example,
a user may cause the lid 108 to slide in the direction of arrow "B".
so The device loo may also include a user-operable control element 112,
such as a button
or switch, which operates the device loo when pressed. For example, a user may
turn
on the device loo by operating the switch 112.
The device loo may also comprise an electrical component, such as a
socket/port 114,
which can receive a cable to charge a battery of the device loo. For example,
the socket
114 may be a charging port, such as a USB charging port.
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Figure 4 depicts the device loo of Figure 3 with the outer cover 102 removed
and
without an article no present. The device 100 defines a longitudinal axis 134.
As shown in Figure 4, the first end member 106 is arranged at one end of the
device 100
and a second end member 116 is arranged at an opposite end of the device loo.
The first
and second end members 106, 116 together at least partially define end
surfaces of the
device 100. For example, the bottom surface of the second end member 116 at
least
partially defines a bottom surface of the device 100. Edges of the outer cover
102 may
io also define a portion of the end surfaces. In this example, the lid 1o8
also defines a
portion of a top surface of the device loo.
The end of the device closest to the opening 104 may be known as the proximal
end (or
mouth end) of the device loo because, in use, it is closest to the mouth of
the user. In
use, a user inserts an article 110 111LO the opening 1.04, operales the user
control 112 Lo
begin heating the aerosol generating material and draws on the aerosol
generated in the
device. This causes the aerosol to flow through the device 100 along a flow
path towards
the proximal end of the device 100.
The other end of the device furthest away from the opening 104 may be known as
the
distal end of the device wo because, in use, it is the end furthest away from
the mouth
of the user. As a user draws on the aerosol generated in the device, the
aerosol flows
away from the distal end of the device 100.
The device 100 further comprises a power source 118. The power source 118 may
be, for
example, a battery, such as a rechargeable battery or a non-rechargeable
battery.
Examples of suitable batteries include, for example, a lithium battery (such
as a
lithium-ion battery), a nickel battery (such as a nickel¨cadmium battery), and
an
alkaline battery. The battery is electrically coupled to the heating assembly
to supply
so electrical power when required and under control of a controller (not
shown) to heat
the aerosol generating material. In this example, the battery is connected to
a central
support 120 which holds the battery 118 in place.
The device further comprises at least one electronics module 122. The
electronics
module 122 may comprise, for example, a printed circuit board (PCB). The PCB
122
may support at least one controller, such as a processor, and memory. The PCB
122
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may also comprise one or more electrical tracks to electrically connect
together various
electronic components of the device lotp. For example, the battery terminals
may be
electrically connected to the PCB 122 so that power can be distributed
throughout the
device loci. The socket 114 may also be electrically coupled to the battery
via the
electrical tracks.
In the example device 10(:), the heating assembly is an inductive heating
assembly and
comprises various components to heat the aerosol generating material of the
article 110
via an inductive heating process. Induction heating is a process of heating an
_/(:) electrically conducting object (such as a susceptor) by
electromagnetic induction. An
induction heating assembly may comprise an inductive element, for example, one
or
more inductor coils, and a device for passing a varying electric current, such
as an
alternating electric current, through the inductive element. The varying
electric current
in the inductive element produces a varying magnetic field. The varying
magnetic field
penetraLes a suscepLor suiLably positioned wiLh respect. Lo [he inductive
element, and
generates eddy currents inside the susceptor. The susceptor has electrical
resistance to
the eddy currents, and hence the flow of the eddy currents against this
resistance
causes the susceptor to be heated by Joule heating. In cases where the
susceptor
comprises ferromagnetic material such as iron, nickel or cobalt, heat may also
be
generated by magnetic hysteresis losses in the susceptor, i.e. by the varying
orientation
of magnetic dipoles in the magnetic material as a result of their alignment
with the
varying magnetic field. In inductive heating, as compared to heating by
conduction for
example, heat is generated inside the susceptor, allowing for rapid heating.
Further,
there need not be any physical contact between the inductive heater and the
susceptor,
allowing for enhanced freedom in construction and application.
The induction heating assembly of the example device 100 comprises a susceptor
arrangement 132 (herein referred to as "a susceptor"), a first inductor coil
124 and a
second inductor coil 126. The first and second inductor coils 124, 126 are
made from an
so electrically conducting material. In this example, the first and second
inductor coils
124, 126 are made from Litz wire/cable which is wound in a helical fashion to
provide
helical inductor coils 124, 126. Litz wire comprises a plurality of individual
wires which
are individually insulated and are twisted together to form a single wire.
Litz wires are
designed to reduce the skin effect losses in a conductor. In the example
device 100, the
first and second inductor coils 124, 126 are made from copper Litz wire which
has a
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rectangular cross section. In other examples the Litz wire can have other
shape cross
sections, such as circular.
The first inductor coil 124 is configured to generate a first varying magnetic
field for
heating a first section of the susceptor 132 and the second inductor coil 126
is
configured to generate a second varying magnetic field for heating a second
section of
the susceptor 132. In this example, the first inductor coil 124 is adjacent to
the second
inductor coil 126 in a direction along the longitudinal axis 134 of the device
loo (that is,
the first and second inductor coils 124, 126 to not overlap). The susceptor
arrangement
/o 132 may comprise a single susceptor, or two or more separate susceptors.
Ends 130 of
the first and second inductor coils 124, 126 can be connected to the PCB 122.
It will be appreciated that the first and second inductor coils 124, 126, in
some
examples, may have at least one characteristic different from each other. For
example,
[lie first inducLor coil 124 may have at. leas( one characLerisLic different.
from (he second
inductor coil 126. More specifically, in one example, the first inductor coil
124 may
have a different value of inductance than the second inductor coil 126. In
Figure 4, the
first and second inductor coils 124, 126 are of different lengths such that
the first
inductor coil 124 is wound over a smaller section of the susceptor 132 than
the second
inductor coil 126. Thus, the first inductor coil 124 may comprise a different
number of
turns than the second inductor coil 126 (assuming that the spacing between
individual
turns is substantially the same). In yet another example, the first inductor
coil 124 may
be made from a different material to the second inductor coil 126. In some
examples,
the first and second inductor coils 124, 126 may be substantially identical.
In this example, the first inductor coil 124 and the second inductor coil 126
are wound
in opposite directions. This can be useful when the inductor coils are active
at different
times. For example, initially, the first inductor coil 124 may be operating to
heat a first
section/portion of the article 110, and at a later time, the second inductor
coil 126 may
so be operating to heat a second section/portion of the article 110.
Winding the coils in
opposite directions helps reduce the current induced in the inactive coil when
used in
conjunction with a particular type of control circuit. In Figure 4, the first
inductor coil
124 is a right-hand helix and the second inductor coil 126 is a left-hand
helix. However,
in another embodiment, the inductor coils 124, 126 may be wound in the same
direction, or the first inductor coil 124 may be a left-hand helix and the
second inductor
coil 126 may be a right-hand helix.
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The susceptor 132 of this example is hollow and therefore defines a receptacle
within
which aerosol generating material is received. For example, the article no can
be
inserted into the susceptor 132. In this example the susceptor 120 is tubular,
with a
circular cross section.
The susceptor 132 may be made from one or more materials. Preferably the
susceptor
132 comprises carbon steel having a coating of Nickel or Cobalt.
io In some examples, the susceptor 132 may comprise at least two materials
capable of
being heated at two different frequencies for selective aerosolization of the
at least two
materials. For example, a first section of the susceptor 132 (which is heated
by the first
inductor coil 124) may comprise a first material, and a second section of the
susceptor
132 which is heated by the second inductor coil 126 may comprise a second,
different
material. In another example, the first section may comprise first and second
materials,
where the first and second materials can be heated differently based upon
operation of
the first inductor coil 124. The first and second materials may be adjacent
along an axis
defined by the susceptor 132, or may form different layers within the
susceptor 132.
Similarly, the second section may comprise third and fourth materials, where
the third
and fourth materials can be heated differently based upon operation of the
second
inductor coil 126. The third and fourth materials may be adjacent along an
axis defined
by the susceptor 132, or may form different layers within the susceptor 132.
Third
material may the same as the first material, and the fourth material may be
the same as
the second material, for example. Alternatively, each of the materials may be
different.
The susceptor may comprise carbon steel or aluminium for example.
The device 100 of Figure 4 further comprises an insulating member 128 which
may be
generally tubular and at least partially surround the susceptor 132. The
insulating
member 128 may be constructed from any insulating material, such as plastic
for
so example. In this particular example, the insulating member is
constructed from
polyether ether ketone (PEEK). The insulating member 128 may help insulate the
various components of the device loo from the heat generated in the susceptor
132.
The insulating member 128 can also fully or partially support the first and
second
inductor coils 124, 126. For example, as shown in Figure 4, the first and
second
inductor coils 124, 126 are positioned around the insulating member 128 and
are in
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contact with a radially outward surface of the insulating member 128. In some
examples the insulating member 128 does not abut the first and second inductor
coils
124, 126. For example, a small gap may be present between the outer surface of
the
insulating member 128 and the inner surface of the first and second inductor
coils 124,
126.
In a specific example, the susceptor 132, the insulating member 128, and the
first and
second inductor coils 124, 126 are coaxial around a central longitudinal axis
of the
susceptor 132.
Figure 5 shows a side view of device 100 in partial cross-section. The outer
cover 102 is
present in this example. The rectangular cross-sectional shape of the first
and second
inductor coils 124, 126 is more clearly visible.
The device loo further comprises a support 136 which engages one end of the
susceptor
132 to hold the susceptor 132 in place. The support 136 is connected to the
second end
member 116.
The device may also comprise a second printed circuit board 138 associated
within the
control element 112.
The device ioo further comprises a second lid/cap 140 and a spring 142,
arranged
towards the distal end of the device 100. The spring 142 allows the second lid
140 to be
opened, to provide access to the susceptor 132. A user may open the second lid
140 to
clean the susceptor 132 and/or the support 136.
The device 100 further comprises an expansion chamber 144 which extends away
from
a proximal end of the susceptor 132 towards the opening 104 of the device.
Located at
least partially within the expansion chamber 144 is a retention clip 146 to
abut and hold
so the article 110 when received within the device loo. The expansion
chamber 144 is
connected to the end member 106.
Figure 6 is an exploded view of the device loo of Figure 5, with the outer
cover 102
omitted.
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Figure 7A depicts a cross section of a portion of the device loo of Figure 5.
Figure 7B
depicts a close-up of a region of Figure 7A. Figures 7A and 7B show the
article no
received within the susceptor 132, where the article no is dimensioned so that
the
outer surface of the article no abuts the inner surface of the susceptor 132.
This
ensures that the heating is most efficient. The article no of this example
comprises
aerosol generating material noa. The aerosol generating material noa is
positioned
within the susceptor 132. The article no may also comprise other components
such as a
filter, wrapping materials and/or a cooling structure.
w Figure 7B shows that the outer surface of the susceptor 132 is spaced
apart from the
inner surface of the inductor coils 124, 126 by a distance 150, measured in a
direction
perpendicular to a longitudinal axis 158 of the susceptor 132. In one
particular example,
the distance 150 is about 3mm to 4mm, about 3-3.5mm, or about 3.25mm.
Figure 7B further shows that [he ouLer surface of Lhe insulating member 128 is
spaced
apart from the inner surface of the inductor coils 124, 126 by a distance 152,
measured
in a direction perpendicular to a longitudinal axis 158 of the susceptor 132.
In one
particular example, the distance 152 is about 0.05mm. In another example, the
distance
152 is substantially omm, such that the inductor coils 124, 126 abut and touch
the
insulating member 128.
In one example, the susceptor 132 has a wall thickness 154 of about 0.025mm to
imm,
or about 0.05mm.
In one example, the susceptor 132 has a length of about 4omm to 60mm, about
4omm
to 45mm, OF about 44.5mm.
In one example, the insulating member 128 has a wall thickness 156 of about
o.25mm
to 2MM, 0.25MM to imm, or about 0.5mm.
In use, the articles 1, 1' described herein can be inserted into a non-
combustible aerosol
provision device such as the device loo described with reference to Figures 3
to 7. At
least a portion of the mouthpiece 2, 2' of the article 1, 1' protrudes from
the non-
combustible aerosol provision device loo and can be placed into a user's
mouth. An
aerosol is produced by heating the aerosol generating material 3 using the
device loo.
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The aerosol produced by the aerosol-generating material 3 passes through the
mouthpiece 2 to the user's mouth.
Figure 8 illustrates a first method of manufacturing an aerosol-generating
material, for
instance and aerosol-generating material for use in an article for use in a
non-
combustible aerosol provision system.
At step Sioi a single thickness of amorphous solid material in sheet form is
fed into a
shredding apparatus. This can be achieved, for example, by providing a bobbin
of
io amorphous solid sheet material which can be continuously fed into a
shredding
apparatus. Alternatively, a discrete portion of amorphous solid material in
sheet form,
such as a sheet known to those skilled in the art as a flag, can be fed into a
shredding
apparatus. The inventors have surprisingly found that, in contrast to the
conventional
tobacco cutting process where several sheets of lamina material are fed to a
cutting
apparatus simultaneously, Were are benefits for amorphous solid material in
sheet
form when shredded in single sheet thicknesses. Feeding multiple thicknesses
of
amorphous solid sheet material into a shredding apparatus in a single pass
tends to
result in uneven distribution of the material in the final aerosol-generating
material, as
multiple thicknesses of the sheet material potentially adhere together,
resulting in the
formation of clumps. Alternatively, multiple thicknesses of amorphous solid
sheet
material can be fed into a shredding apparatus in a single pass, for instance
where the
'tackiness' of the amorphous solid sheet is relatively low, avoiding the
formation of
clumps.
At step S102, said single thickness of amorphous solid material is shredded to
obtain
strips of amorphous solid material having a defined cut width. Optionally the
amorphous solid material may be subject to a second cutting step, such as in a
cross-cut
type shredding process, to obtain a defined cut length.
so At step S1o3, the strips of amorphous solid material obtained in step
S102 are mixed
with a tobacco material. The inventors have advantageously found that mixing
of the
shredded amorphous solid material with a tobacco material should preferably be
carried out as soon after step S102 as possible. The inventors have found that
prolonged storage of shredded amorphous solid material can result in clumps of
3,5 amorphous solid shreds forming in the shredded material, such that when
the shredded
amorphous solid material is mixed with a tobacco material, and used to form
articles as
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described herein, the clumps of amorphous solid material result in an uneven
distribution of amorphous solid material between articles, and within
individual rods of
aerosol-generating material.
In some embodiments, the shredded amorphous solid material is incorporated
into the
tobacco material fewer than 12 hours after the cutting step, for instance
fewer than 6
hours, or fewer than 4 hours, or fewer than 2 hours, or fewer than 1 hour.
Optionally,
the shredded amorphous solid material may be fed into tobacco material in an
online
process, such that the time between shredding of the amorphous solid material
and
io incorporation of the shredded material into a tobacco material to form
the final
aerosol-generating material may be less than 30 seconds, for instance less
than 20
seconds, or less than 10 seconds.
In some embodiments, a method of producing an aerosol-generating material
comprises culling a sheet of amorphous solid material to form a plurality of
strips of
amorphous solid material having a cut length of at least about 5 mm, or at
least about
10 mm, or at least about 20 mm. In some embodiments, the method comprises
cutting
a sheet of amorphous solid material to form a plurality of strips of amorphous
solid
material each having a cut length of between about 5 mm and about 6o mm, or
between
about 10 mm and about 55 mm, or between about 20 mm and about 50 mm.
The mixing step can be performed using a rotary drum blender, for instance
rotating at
an RPM of 5 to 30 RPM, for instance 10 ¨ 15RPM. The drum diameter can be
between
o.8m and 1.2M with 5 sets of 10 to 20 pins (optional) projecting from the
inner walls of
the drum towards the centre of the drum, the pins having a length of between
5% and
15% of the drum diameter, for instance about lo%, with the pins of each set
spaced
longitudinally along the length of the drum and each set spaced around the
inner
circumference. The drum angle of its central axis during the mixing operation
can be
approximately 10 to 30 degrees from horizontal (open side up). Batches of 5 ¨
20 kg
so total solids, typically 8 ¨ lokg, can be mixed in such a drum, with a
mixing time of 30
seconds to 10 minutes, for instance 30 seconds to 2 minutes.
Alternatively, the mixing step can be incorporated into the standard primary
manufacturing process for tobacco material, for instance using the add-back
line and a
flavour mixing cylinder. This method may be suited to larger quantities of
material. A
continuous rotary drum blender can be used, which is fed by two weigh
conveyors, each
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feeding one component (tobacco material or cut amorphous solid material, such
as
shredded gel) at the correct relative kg/hr rate to achieve the desired
inclusion level of
amorphous solid in the aerosol-generating material. The components are blended
in
the rotating drum blender during their passage, and collected at the exit.
Typical
dimensions and operating conditions of a continuous rotary drum blender are an
RPM
of 12 - 15 RPM, a drum diameter of 0.6 ¨ o.8m, a drum length of 2.0 - 3.0 m.
The
residence time of the materials in the drum can be between 30 ¨ 120 seconds
(typically
40 - 70 seconds).
io Figure 9 illustrates a second method of manufacturing an aerosol-
generating material,
for instance and aerosol-generating material for use in an article for use in
a non-
combustible aerosol provision system. The second method can be performed using
equipment as described in relation to the first method above, and the skilled
person
would be aware that the steps of the first and second methods can be combined
as
appropriaLe. The method includes a step (S2o1) of culling a first porLion of
amorphous
solid material to form a first component comprising a plurality of strips of
amorphous
solid material having a first length. The method also includes a step (S2o2)
of cutting a
second portion of amorphous solid material to form a second component
comprising a
plurality of strips of amorphous solid material having a second length
different to the
first length. At step S2o3, the cut strips of amorphous solid material are
mixed with a
tobacco material comprising strips and/or strands of tobacco material. Using
two or
more different lengths of amorphous solid material can enable the size of the
strips of
the amorphous solid material to more closely match the material size
distribution of the
tobacco material, resulting in better mixing of the amorphous solid and
tobacco
material.
The various embodiments described herein are presented only to assist in
understanding and teaching the claimed features. These embodiments are
provided as
a representative sample of embodiments only, and are not exhaustive and/or
exclusive.
so It is to be understood that advantages, embodiments, examples,
functions, features,
structures, and/or other aspects described herein are not to be considered
limitations
on the scope of the invention as defined by the claims or limitations on
equivalents to
the claims, and that other embodiments may be utilised and modifications may
be
made without departing from the scope of the claimed invention. Various
embodiments
of the invention may suitably comprise, consist of, or consist essentially of,
appropriate
combinations of the disclosed elements, components, features, parts, steps,
means, etc,
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other than those specifically described herein. In addition, this disclosure
may include
other inventions not presently claimed, but which may be claimed in future.
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