Note: Descriptions are shown in the official language in which they were submitted.
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AEROSOL GENERATING COMPOSITION
Technical Field
The present invention relates to aerosol-generating materials, aerosol-
generating compositions comprising an aerosol-generating material; consumables
for use within a non-combustible aerosol provision system, the consumables
comprising the aerosol-generating composition; and non-combustible aerosol
provision systems. The invention also relates to a slurry which may be used to
produce the aerosol-generating material, methods for producing aerosol-
generating
materials, and aerosol-generating materials obtainable by the methods of the
invention.
Backciround
Smoking consumables such as cigarettes, cigars and the like burn tobacco
during use to create tobacco smoke. Alternatives to these types of consumables
release an inhalable aerosol or vapour by releasing compounds from a substrate
material by heating without burning. These may be referred to as non-
combustible
smoking consumables or aerosol generating assemblies.
One example of such a product is a heating device which releases
compounds by heating, but not burning, a solid aerosol-generating material.
This
solid aerosol-generating material may, in some cases, contain a botanical
material.
The heating volatilises at least one component of the material, typically
forming an
inhalable aerosol. These products may be referred to as heat-not-burn devices,
tobacco heating devices or tobacco heating products. Various different
arrangements
for volatilising at least one component of the solid aerosol-generating
material are
known.
As another example, there are hybrid devices. These contain a liquid source
(which may or may not contain nicotine) which is vaporised by heating to
produce an
inhalable vapour or aerosol. The device additionally contains a solid aerosol-
generating material (which may or may not contain a tobacco material) and
components of this material are entrained in the inhalable vapour or aerosol
to
produce the inhaled medium.
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Summary
According to a first aspect of the present invention, there is provided an
aerosol-generating material comprising:
- aerosol-
generating agent in an amount of from about 7 to about 13 wt%
of the aerosol-generating material on a dry weight basis;
- binder;
- flavour in an amount of from about 35 to about 50 wt% of the aerosol-
generating material on a dry weight basis; and
- filler.
In a second aspect, there is provided an aerosol-generating composition
comprising the aerosol-generating material of the first aspect.
According to a further aspect of the present invention, there is provided a
consumable for use within a non-combustible aerosol provision system, the
consumable comprising the aerosol-generating composition as defined herein.
According to a further aspect of the present invention, there is provided a
non-
combustible aerosol provision system comprising the consumable as defined
herein
and a non-combustible aerosol provision device, the non-combustible aerosol
provision device comprising an aerosol-generation device configured to (or
arranged
to) generate aerosol from the consumable when the consumable is used with the
non-combustible aerosol provision device.
According to a further aspect of the invention, there is provided the use of
an
aerosol-generating composition as defined herein in a consumable for use in a
non-
combustible aerosol provision device, the non-combustible aerosol provision
device
comprising an aerosol-generation device arranged to generate aerosol from the
consumable when the consumable is used with the non-combustible aerosol
provision device.
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According to a further aspect of the invention, there is provided the use of
an
aerosol-generating material or an aerosol-generating composition as defined
herein
for generating an aerosol.
According to a further aspect of the present invention, there is provided a
method of making an aerosol-generating material or an aerosol-generating
composition as described herein.
According to a further aspect, the invention provides an aerosol-generating
material obtainable by, or obtained by, a method of the invention.
According to a further aspect of the present invention, there is provided a
method of generating an aerosol using a non-combustible aerosol provision
system
as described herein, the method comprising heating the aerosol-generating
material.
In some embodiments, the method comprises heating the aerosol-generating
material to a temperature of less than or equal to 350 C. In some
embodiments, the
method comprises heating the aerosol-generating material to a temperature of
from
about 220 C to about 280 C.
Further features and advantages of the invention will become apparent from
the following description of preferred embodiments of the invention, given by
way of
example only, which is made with reference to the accompanying drawings.
Brief Description of the Drawinqs
Figure 1 shows a section view of an example of an aerosol-generating article.
Figure 2 shows a perspective view of the article of Figure 1.
Figure 3 shows a sectional elevation of an example of an aerosol-generating
article.
Figure 4 shows a perspective view of the article of Figure 3.
Figure 5 shows a perspective view of an example of an aerosol generating
assembly.
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Figure 6 shows a section view of an example of an aerosol generating assembly.
Figure 7 shows a perspective view of an example of an aerosol generating
assembly.
Figure 8 shows an exploded diagram of an example consumable.
Figure 9 shows an example of a consumable comprising a plurality of discrete
portions of aerosol-generating material.
Detailed Description
The aerosol-generating materials/compositions described herein are
materials/compositions that are capable of generating aerosol, for example
when
heated, irradiated or energized in any other way. The aerosol-generating
composition
may, for example, be in the form of a solid, liquid or gel which may or may
not contain
nicotine. The aerosol-generating composition comprises an aerosol-generating
material. The aerosol-generating material may be an "amorphous solid". In some
embodiments, the amorphous solid is a "monolithic solid". The aerosol-
generating
material may be non-fibrous or fibrous. In some embodiments, the aerosol-
generating material may be a dried gel. The aerosol-generating material may be
a
solid material that may retain some fluid, such as liquid, within it. In some
embodiments, the aerosol-generating composition may for example comprise from
about 50wV/0, 60wtcY0 or 70wt% of aerosol-generating material, to about
90wt`Yo,
95wtcY0 or 100wtcY0 of aerosol-generating material. In some cases, the aerosol-
generating composition consists of aerosol-generating material.
As described hereinabove, the invention provides an aerosol-generating
material
corn prisi ng:
- aerosol-generating agent in an amount of from about 7 to about 13 wt%
of the aerosol-generating material on a dry weight basis;
- binder;
- flavour in an amount of from about 35 to about 50 wt% of the aerosol-
generating material on a dry weight basis; and
- filler.
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In some cases, the aerosol-generating material comprises:
- aerosol-generating agent in an amount of from about 7 to about 13 wt%
of the aerosol-generating material;
- binder in an amount of from about 1 to about 57 wt% of the aerosol-
5 generating material;
- flavour in an amount of from about 35 to about 50 wt% of the aerosol-
generating material; and
- filler in an amount of from about 1 to about 50 wt% of the aerosol-
generating material;
wherein these amounts are calculated on a dry weight basis.
The inventors have established that flavour loss during the production of
aerosol-generating materials can be reduced by controlling the amount of
aerosol-
generating agent (such as glycerol) and flavour (such as menthol) within the
claimed
ranges. The aerosol-generating material disclosed herein comprises a
relatively low
amount of aerosol-generating agent (such as glycerol). Without wishing to be
bound
by theory, it is believed that flavour (such as menthol) and aerosol-
generating agent
(such as glycerol) may compete for emulsification sites in aerosol-generating
materials, and so reducing the amount of aerosol-generating agent may result
in
increased retention of flavour. Reducing flavour loss during the production of
aerosol-
generating materials reduces waste and is more cost effective.
Moreover, the amount of flavour (such as menthol) retained in the materials
of the present invention may be less variable. This is advantageous for the
consumer
since the material constitution (and therefore the aerosol produced) may be
more
consistent between different batches of aerosol-generating material.
The aerosol-generating material may comprise about 7 wt%, 8wt%, 9wt%,
10wt%, or 10.3wt% to about 13wt%, 12wt%, or 11wt% of aerosol-generating agent
(all calculated on a dry weight basis). In exemplary embodiments, the aerosol-
generating material comprises 8-13 wt%, 9-12wt%, 10-12wt%, more than 10wt% to
less than 12wt%, or 10.3-11.9wt% of aerosol-generating agent (all calculated
on a
dry weight basis). These amounts represent the total amount of aerosol-
generating
agent(s) in the aerosol-generating material.
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In some embodiments, the aerosol-generating agent may comprise one or
more of 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. In some cases, the aerosol-generating agent comprises, consists
essentially of or consists of glycerol.
The aerosol-generating material may comprise an amount of about 1wt%,
5wt%, 10wt%, 12wt%, 15wt%, 17wt%, 19wt% or 20wt% to about 25wt%, 27 wt%,
30wt%, 40wt%, 45wt%, 50wt /0 or 57wt 70 of binder (all calculated on a dry
weight
basis). For example, the aerosol-generating material may comprise an amount of
1-57 wt%, 5-50 wt%, 15-35wt%, 20-30wt% or 20-25wt% of binder (dry weight
basis).
These amounts represent the total amount of binder(s) in the aerosol-
generating
material.
The binder may include a cellulosic binder and/or a non-cellulosic binder.
Examples of cellulosic binders which may be used include, but are not limited
to,
hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose,
carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl
cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate
(CAB),
and cellulose acetate propionate (CAP). Examples of non-cellulosic binders
which
may be used include alginates, pectins, starches (and derivatives), gums,
silica or
silicones compounds, clays, polyvinyl alcohol and combinations thereof.
In some embodiments, the binder is selected from the group consisting of
alginates, pectins, pullulan, xanthan gum, guar gum, carrageenan, agarose,
acacia
guru, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
In some embodiments, the binder comprises alginate and/or pectin.
In some embodiments, the binder comprises, consists essentially of, or
consists of alginate and pectin.
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In some embodiments, the binder includes cellulosic binder and non-
cellulosic binder. The use of cellulosic binder (e.g. CMC) in combination with
non-
cellulosic binder may increase the temperature at which flavour (such as
menthol) is
released. The lists of suitable cellulosic and non-cellulosic binders above
apply
equally to this embodiment. In some embodiments, the cellulosic binder
comprises,
or consists or, CMC and/or the non-cellulosic binder comprises, or consists
or,
alginate and/or guar gum. In particular embodiments, the binder comprises,
consists
essentially of, or consists of CMC, alginate and guar gum.
In some embodiments, the aerosol-generating material comprises a
crosslinking agent. In some cases, the crosslinking agent comprises calcium
ions. In
some embodiments, the crosslinking agent comprises calcium lactate and/or
calcium
acetate. In some embodiments, the crosslinking agent comprises calcium
lactate. In
some cases, the aerosol-generating material may comprise a calcium-crosslinked
alginate. The crosslinking agent may also be described as a setting agent.
The aerosol-generating material may comprise about 0.5wt%, 1w0/0, 3wt% or
5wt% to about 10wt%, 9wV/0, 8 wt% or 7wt% of crosslinking agent (all
calculated on
a dry weight basis). For example, the aerosol-generating material may comprise
1-10 wt%, 3-8 wt% or 5-7 wt% of crosslinking agent (dry weight basis). These
amounts represent the total amount of crosslinking agent(s) in the aerosol-
generating
material.
In some embodiments, the aerosol-generating material does not comprise a
crosslinking agent.
The aerosol-generating material may be substantially free of cellulosic
binder.
"Substantially free" means that material comprises less than 1wt%, such as
less than
0.5wt% of the relevant component (dry weight basis). In some embodiments, the
aerosol-generating material does not comprise a cellulosic binder.
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The aerosol-generating material may be substantially free of
carboxymethylcellulose (CMC). In some embodiments, the aerosol-generating
material does not comprise CMC.
In some embodiments, the binder comprises alginate, and the alginate is
present in the aerosol-generating material in an amount of 5-50wt%, 8-40wt%,
10-30wt%, or 15-25% of the aerosol-generating material (calculated on a dry
weight
basis). In some embodiments, alginate is the only binder present in the
aerosol-
generating material. In other embodiments, the binder comprises alginate and
at least
one further non-cellulosic binder, such as pectin.
In some embodiments, the binder comprises pectin, and the pectin is present
in the aerosol-generating material in an amount of 1-10wt%, 2-8%, or 3-7% of
the
aerosol-generating material (calculated on a dry weight basis).
In some embodiments, the binder comprises alginate and pectin, and the
alginate is present in the aerosol-generating material in an amount of 5-
50wt%,
8-40wt%, 10-30wt%, or 15-25% of the aerosol-generating material, and the
pectin is
present in the aerosol-generating material in an amount of 1-10wt%, 2-8%, or 3-
7%
of the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, the binder comprises alginate and pectin, and the
alginate is present in the aerosol-generating material in an amount of 8-40wt%
and
the pectin is present in the aerosol-generating material in an amount of 1-
10wt% of
the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, the binder comprises alginate and pectin, and the
alginate is present in the aerosol-generating material in an amount of 10-
30wt% and
the pectin is present in the aerosol-generating material in an amount of 2-
8wt% of
the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, the binder comprises alginate and pectin, and the
alginate is present in the aerosol-generating material in an amount of 15-
25wt% and
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the pectin is present in the aerosol-generating material in an amount of 3-
7wt% of
the aerosol-generating material (calculated on a dry weight basis).
The aerosol-generating material may comprise about 35wt%, 36 wt% or
37wt% to about 50wt%, 45wt% or 43wt% of flavour (all calculated on a dry
weight
basis). For example, the aerosol-generating material may comprise 35-45wt%, 36-
45wt%, or 37-43wt% of flavour. These amounts represent the total amount of
flavour(s) in the aerosol-generating material.
As used herein, the terms "flavour" and "flavourant" refer to materials which,
where local regulations permit, may be used to create a desired taste, aroma,
or other
somatosensorial sensation in a product for adult consumers. They may include
naturally occurring flavour materials, botanicals, extracts of botanicals,
synthetically
obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice
(liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,
fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise),
cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry,
berry, red
berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime,
tropical fruit,
papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry,
citrus
fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,
peppermint,
lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood,
bergamot,
geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla,
lemon
oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac,
jasmine,
ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a
mint oil
from any species of the genus Mentha, eucalyptus, star anise, cocoa,
lemongrass,
rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin,
rose, tea such
as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves,
cumin,
oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant,
curcuma,
cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive,
lemon
balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol,
camphene),
flavour enhancers, bitterness receptor site blockers, sensorial receptor site
activators
or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame
potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose,
fructose,
sorbitol, or mannitol), and other additives such as charcoal, chlorophyll,
minerals,
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botanicals, or breath freshening agents. They may be imitation, synthetic or
natural
ingredients or blends thereof. They may be in any suitable form, for example,
liquid
such as an oil, solid such as a powder, or gas.
5 In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint. In some embodiments, the flavour comprises, consists essentially
of or
consists of menthol.
In some embodiments, the aerosol-generating material comprises from about
10 1wt%, 5wtcYo, 10wtcY0, 18wtcY0 or 20we/0 to about 50wtcY0, 45wt%, 40wt%,
35wtcYo or
30wtc/0 of filler (all calculated on a dry weight basis). For example, the
aerosol-
generating material may comprise 5-45wtc/o, 10-40wW0, 18-35wtc/o or 20-30wtc/o
of
filler (all calculated on a dry weight basis). These amounts represent the
total amount
of filler(s) in the aerosol-generating material.
The filler 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,
aerosol-
generating material comprises no calcium carbonate such as chalk.
In particular embodiments the filler is fibrous. For example, the filler may
be
a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or
cellulose
derivatives, such as microcrystalline cellulose (MCC) and/or nanocrystalline
cellulose. Without wishing to be bound by theory, it is believed that
including fibrous
filler in an aerosol-generating material may increase the tensile strength of
the
material. This may be particularly advantageous in examples wherein the
aerosol-
generating material is provided as a sheet, such as when an aerosol-generating
material sheet circumscribes a rod of aerosol-generating composition.
In some cases, the filler comprises (or is) wood pulp.
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In some cases, the filler comprises maltodextrin or microcrystalline cellulose
(MCC). As would be well understood by the skilled person, microcrystalline
cellulose
may be formed by depolymerising cellulose by a chemical process (e.g. using an
acid
or enzyme). One example method for forming microcrystalline cellulose involves
acid
hydrolysis of cellulose, using an acid such as HCI. The cellulose produced
after this
treatment is crystalline (i.e. no amorphous regions remain). Suitable methods
and
conditions for forming microcrystalline cellulose are well-known in the art.
In some cases, the filler has a density of less than about 2 g/cm3, such as
less
than about 0.5 g/cm3 or less than about 0.3 g/cm3.
The aerosol-generating material may have any suitable water content, such
as from 1wt % to 15wt%. Suitably, the water content of the aerosol-generating
material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt%
(wet weight basis) (WWB). The water content of the aerosol-generating material
may,
for example, be determined by Karl-Fischer-titration or Gas Chromatography
with
Thermal Conductivity Detector (GC-TCD).
Amounts of constituents of the aerosol-generating material, such as aerosol-
generating agent (e.g. glycerol) and flavourant (e,g, menthol), can be
determined by
gas chromatography. One example of a suitable gas chromatography protocol is
set
out in the Examples section below.
The aerosol-generating material may comprise a colourant. The addition of a
colourant may alter the visual appearance of the aerosol-generating material.
The
presence of colourant in the aerosol-generating material may enhance the
visual
appearance of the aerosol-generating material and the aerosol-generating
composition. By adding a colourant to the aerosol-generating material, the
aerosol-
generating material may be colour-matched to other components of the aerosol-
generating composition or to other components of an article comprising the
aerosol-
generating material.
A variety of colourants may be used depending on the desired colour of the
aerosol-generating material. The colour of aerosol-generating material may be,
for
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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 aerosol-generating
material with a brown appearance. In such embodiments, the colour of the
aerosol-
generating material may be similar to the colour of other components (such as
tobacco material) in an aerosol-generating composition comprising the aerosol-
generating material. In some embodiments, the addition of a colourant to the
aerosol-
generating material renders it visually indistinguishable from other
components in the
aerosol-generating composition.
The colourant may be incorporated during the formation of the aerosol-
generating material (e.g. when forming a slurry comprising the materials that
form the
aerosol-generating material) or it may be applied to the aerosol-generating
material
after its formation (e.g. by spraying it onto the aerosol-generating
material).
In some embodiments, the aerosol-generating composition additionally
comprises an active substance. For example, in some cases, the aerosol-
generating
composition additionally comprises a tobacco material and/or nicotine. In some
cases, the aerosol-generating composition may comprise 5-60wt% (calculated on
a
dry weight basis) of a tobacco material and/or nicotine. In some cases, the
aerosol-
generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%,
20wt% or 25wt /0 to about 70wt%, 60wr/o, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt%
(calculated on a dry weight basis) of an active substance. In some cases, the
aerosol-
generating composition may comprise from about 1wt%, 5wt%, 10wt%, 15wt%,
20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt(%, 40wt%, 35wffo, or 30wrk
(calculated on a dry weight basis) of a tobacco material. For example, the
aerosol-
generating composition may comprise 10-50wtc/o, 15-40wt% or 20-35wt% of a
tobacco material. In some cases, the aerosol-generating composition may
comprise
from about 1wt%, 2wt%, 3wtcY0 or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt%
(calculated on a dry weight basis) of nicotine. For example, the aerosol-
generating
composition may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
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In some cases, the aerosol-generating composition comprises an active
substance such as tobacco extract. In some cases, the aerosol-generating
composition may comprise 5-60wt% (calculated on a dry weight basis) of tobacco
extract. In some cases, the aerosol-generating composition may comprise from
about
5wt%, lOwt%, 15wV/0, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%,
35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For
example,
the aerosol-generating composition may comprise 10-50wrio, 15-40wt% or 20-
35wt% of tobacco extract. The tobacco extract may contain nicotine at a
concentration such that the aerosol-generating composition comprises 1wt%
1.5wtcY0,
2wt% or 2.5wt(3/0 to about lOwt%, 8wtcY0, 6wt%, 5wt%, 4. 5wt% or 4wt%
(calculated on
a dry weight basis) of nicotine. In some embodiments, the aerosol-generating
composition may comprise 1-10 wt%, 2.5-8 wt% or 2-6wt% nicotine. In some
cases,
there may be no nicotine in the aerosol-generating composition other than that
which
results from the tobacco extract.
In some embodiments, the aerosol-generating composition comprises no
tobacco material but does comprise nicotine. In some such cases, the aerosol-
generating composition may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to
about 20wt%, 18wt%, 15wt% or 12wt 70 (calculated on a dry weight basis) of
nicotine.
For example, the aerosol-generating composition may comprise 1-20wt%, 2-18wt%
or 3-12wt% of nicotine.
The aerosol-generating composition may comprise an acid. The acid may be
an organic acid. In some of these embodiments, the acid may be at least one of
a
monoprotic acid, a diprotic acid and a triprotic acid. In some such
embodiments, the
acid may contain at least one carboxyl functional group. In some such
embodiments,
the acid may be at least one of an alpha-hydroxy acid, carboxylic acid,
dicarboxylic
acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may
be
an alpha-keto acid.
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.
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Suitably the acid is lactic acid. In other embodiments, the acid is benzoic
acid.
In other embodiments the acid may be an inorganic acid. In some of these
embodiments the acid may be a mineral acid. In some such embodiments, the acid
may be at least one of sulphuric acid, hydrochloric acid, boric acid and
phosphoric
acid. In some embodiments, the acid is levulinic acid.
Inclusion of an acid is particularly preferred in embodiments in which the
aerosol-generating composition comprises nicotine. The presence of the acid
may
reduce or substantially prevent evaporation of nicotine during drying of the
slurry,
thereby reducing loss of nicotine during manufacturing. The presence of the
acid may
also improve the flavour of the aerosol when nicotine is present. For example,
the
perceived harshness of the nicotine may be reduced by the presence of the
acid.
In some embodiments, the aerosol-generating material is substantially free
from tobacco. By "substantially free from" it is meant that the material
comprises less
than 1wrio, such as less than 0.5wtcY0 tobacco (dry weight basis). In some
embodiments, the aerosol-generating material is free from tobacco. In some
embodiments, the aerosol-generating material does not comprise tobacco fibres.
In
particular embodiments, the aerosol-generating material does not comprise
fibrous
material.
In some embodiments, the aerosol-generating composition does not
comprise tobacco fibres. In particular embodiments, the aerosol-generating
composition does not comprise fibrous material.
In some embodiments, the aerosol-generating article does not comprise
tobacco fibres. In particular embodiments, the aerosol-generating article does
not
comprise fibrous material.
The aerosolisable or aerosol-generating material may be present on or in a
support to form a substrate. The support functions as a support on which the
aerosol-
generating material layer forms, easing manufacture. The support may provide
rigidity to the aerosol-generating material layer, easing handling.
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The support may be any suitable material which can be used to support an
aerosol-generating material. In some cases, the support may be formed from
materials selected from metal foil, paper, carbon paper, greaseproof paper,
ceramic,
carbon allotropes such as graphite and graphene, plastic, cardboard, wood or
5 combinations thereof. In some cases, the support may comprise or consist
of a
tobacco material, such as a sheet of reconstituted tobacco. In some cases, the
support may be formed from materials selected from metal foil, paper,
cardboard,
wood or combinations thereof. In some cases, the support comprises paper. In
some
cases, the support itself may be a laminate structure comprising layers of
materials
10 selected from the preceding lists. In some cases, the support may also
function as a
flavour support. For example, the support may be impregnated with a flavourant
or
with tobacco extract.
Suitably, the thickness of the support layer may be in the range of about
15 10pm, 15pm, 17pm, 20pm, 23pm, 25pm, 50pm, 75pm or 0.1mm to about 2.5mm,
2.0mm, 1.5mm, 1.0mm or 0.5mm. The support may comprise more than one layer,
and the thickness described herein refers to the aggregate thickness of those
layers.
In some cases, the support may be magnetic. This functionality may be used
to fasten the support to the assembly in use, or may be used to generate
particular
aerosol-generating material shapes. In some cases, the aerosol-generating
substrate
may comprise one or more magnets which can be used to fasten the substrate to
an
induction heater in use.
In some cases, the support may be substantially or wholly impermeable to
gas and/or aerosol. This prevents aerosol or gas passage through the support
layer,
thereby controlling the flow and ensuring it is delivered to the user. This
can also be
used to prevent condensation or other deposition of the gas/aerosol in use on,
for
example, the surface of a heater provided in an aerosol generating assembly.
Thus,
consumption efficiency and hygiene can be improved in some cases.
In some cases, the surface of the support that abuts the aerosol-generating
material may be porous. For example, in one case, the support comprises paper.
A
porous support such as paper is particularly suitable for the present
invention; the
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porous (e.g. paper) layer abuts the aerosol-generating layer and forms a
strong bond.
The aerosol-generating material is formed by drying a gel and, without being
limited
by theory, it is thought that the slurry from which the gel is formed
partially
impregnates the porous support (e.g. paper) so that when the gel sets and
forms
cross-links, the support is partially bound into the gel. This provides a
strong binding
between the gel and the support (and between the dried gel and the support).
Additionally, surface roughness may contribute to the strength of bond
between the aerosol-generating material and the support. The paper roughness
(for
the surface abutting the support) may suitably be in the range of 50-1000 Bekk
seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured
over
an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an
instrument used to determine the smoothness of a paper surface, in which air
at a
specified pressure is leaked between a smooth glass surface and a paper
sample,
and the time (in seconds) for a fixed volume of air to seep between these
surfaces is
the "Bekk smoothness")
Conversely, the surface of the support facing away from the aerosol-
generating material may be arranged in contact with the heater, and a smoother
surface may provide more efficient heat transfer. Thus, in some cases, the
support
is disposed so as to have a rougher side abutting the aerosol-generating
material
and a smoother side facing away from the aerosol-generating material.
In one particular case, the support may be a paper-backed foil; the paper
layer
abuts the aerosol-generating material layer and the properties discussed in
the
previous paragraphs are afforded by this abutment. The foil backing is
substantially
impermeable, providing control of the aerosol flow path. A metal foil backing
may also
serve to conduct heat to the aerosol-generating material.
In another case, the foil layer of the paper-backed foil abuts the aerosol-
generating material. The foil is substantially impermeable, thereby preventing
water
provided in the aerosol-generating material to be absorbed into the paper
which could
weaken its structural integrity.
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In some cases, the support is formed from or comprises metal foil, such as
aluminium foil. A metallic support may allow for better conduction of thermal
energy
to the aerosol-generating material. Additionally, or alternatively, a metal
foil may
function as a susceptor in an induction heating system. In particular
embodiments,
the support comprises a metal foil layer and a support layer, such as
cardboard. In
these embodiments, the metal foil layer may have a thickness of less than
20pm,
such as from about 1pm to about lOpm, suitably about 5prn_
In some cases, the support may have a thickness of between about 0.017mm
and about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm,
1.0mm, or 0.5mm.
The aerosol-generating material may be made from a gel, and this gel may
additionally comprise a solvent, included at 0.1-50wt%. However, 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.
An aspect of the present invention relates to an article (also referred to
herein
as a consumable). A consumable is an article, part or all of which is intended
to be
consumed during use by a user. A consumable may comprise or consist of aerosol-
generating composition. A consumable may comprise one or more other elements,
such as a filter or an aerosol modifying substance. A consumable may comprise
a
heating element that emits heat to cause the aerosol-generating composition to
generate aerosol in use. The heating element may, for example, comprise
combustible material, or may comprise a susceptor that is heatable by
penetration
with a varying magnetic field.
Articles of the present invention may be provided in any suitable shape. In
some examples, the article is provided as a rod (e.g. substantially
cylindrical). An
article provided as a rod may include the aerosol-generating composition as a
shredded sheet, optionally blended with cut tobacco. Alternatively, or
additionally, the
article provided as a rod may include the aerosol-generating composition as a
sheet,
such as a sheet circumscribing a rod of aerosol-generating material (e.g.
tobacco, or
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a combination of tobacco and an aerosol-generating material such as that
described
herein). In some embodiments, the article comprises a layer portion of aerosol-
generating composition disposed on a carrier. In examples, the article may
have at
least one substantially planar (flat) surface.
The aerosol-generating material may comprise or be in the form of an
aerosol-generating film_ The aerosol-generating film may be substantially free
from
botanical material. In particular, in some embodiments, the aerosol-generating
film
is substantially tobacco free.
The aerosol-generating film may have a thickness of about 0.015 mm to
about 1 mm. For example, the thickness may be in the range of about 0.05 mm,
0.1
mm or 0.15 mm to about 0.5 mm or 0.3 mm.
The aerosol-generating film may be continuous. For example, the film may
comprise or be a continuous sheet of material. The sheet may be in the form of
a
wrapper, it may be gathered to form a gathered sheet or it may be shredded to
form
a shredded sheet. The shredded sheet may comprise one or more strands or
strips
of aerosol-generating material.
In one case, the aerosol-generating film is shredded and blended with
another shredded aerosol-generating film.
In one case, there is provided a consumable for use in a non-combustible
aerosol-provision system comprising a planar support with complete coverage of
the aerosol-generating material (e.g. a continuous aerosol-generating film).
Figure 8
provides a schematic illustration of such a consumable, which includes a
support
layer 4 and an aerosol-generating material layer 2.
The aerosol-generating film may be discontinuous. For example, the
aerosol-generating film may comprise one or more discrete portions or regions
of
aerosol-generating material, such as dots, stripes or lines, which may be
supported
on a support. In such embodiments, the support may be planar or non-planar.
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In some cases, the discrete portions of aerosol-generating material are
substantially round, cylindrical or hemispherical. In some cases, there is a
grid-
shaped distribution of the substantially round, cylindrical or hemispherical
aerosol-
generating material.
In some cases, there is provided a consumable for use in a non-combustible
aerosol-provision system comprising a planar support with a discontinuous
aerosol-
generating film (which comprises a plurality of discrete portions of aerosol-
generating material) deposited on it.
Figure 9 provides an example of a consumable (401) wherein a
discontinuous aerosol-generating film (which comprises a discrete portion of
aerosol-generating material (403)) are provided on the consumable.
A susceptor is material that is heatable by penetration with a varying
magnetic
field, such as an alternating magnetic field. The heating material may be an
electrically-conductive 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 heating material may
be
both electrically-conductive and magnetic, so that the heating material is
heatable by
both heating mechanisms.
Induction heating is a process in which an electrically-conductive object is
heated by penetrating the object with a varying magnetic field. The process is
described by Faraday's law of induction and Ohm's law. An induction heater may
comprise an electromagnet and a device for passing a varying electrical
current, such
as an alternating current, through the electromagnet. When the electromagnet
and
the object to be heated are suitably relatively positioned so that the
resultant varying
magnetic field produced by the electromagnet penetrates the object, one or
more
eddy currents are generated inside the object. The object has a resistance to
the flow
of electrical currents. Therefore, when such eddy currents are generated in
the
object, their flow against the electrical resistance of the object causes the
object to
be heated. This process is called Joule, ohmic, or resistive heating.
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In some embodiments, the susceptor is in the form of a closed circuit. It has
been found that, when the susceptor is in the form of a closed circuit,
magnetic
coupling between the susceptor and the electromagnet in use is enhanced, which
5 results in greater or improved Joule heating.
Magnetic hysteresis heating is a process in which an object made of a
magnetic material is heated by penetrating the object with a varying magnetic
field.
A magnetic material can be considered to comprise many atomic-scale magnets,
or
10 magnetic dipoles. When a magnetic field penetrates such material, the
magnetic
dipoles align with the magnetic field. Therefore, when a varying magnetic
field, such
as an alternating magnetic field, for example as produced by an electromagnet,
penetrates the magnetic material, the orientation of the magnetic dipoles
changes
with the varying applied magnetic field. Such magnetic dipole reorientation
causes
15 heat to be generated in the magnetic material.
When an object is both electrically-conductive and magnetic, penetrating the
object with a varying magnetic field can cause both Joule heating and magnetic
hysteresis heating in the object. Moreover, the use of magnetic material can
20 strengthen the magnetic field, which can intensify the Joule heating.
In each of the above processes, as heat is generated inside the object itself,
rather than by an external heat source by heat conduction, a rapid temperature
rise
in the object and more uniform heat distribution can be achieved, particularly
through
selection of suitable object material and geometry, and suitable varying
magnetic
field magnitude and orientation relative to the object. Moreover, as induction
heating
and magnetic hysteresis heating do not require a physical connection to be
provided
between the source of the varying magnetic field and the object, design
freedom and
control over the heating profile may be greater, and cost may be lower.
The thickness values stipulated herein are mean values for the thickness in
question. In some cases, the thickness may vary by no more than 25%, 20%, 15%,
10%, 5% or 1%.
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The "thickness" of the aerosol-generating material describes the shortest
distance between a first surface and a second surface. In embodiments where
the
aerosol-generating material is in the form of a sheet, the thickness of the
aerosol-
generating material is the shortest distance between a first planar surface of
the sheet
and a second planar surface of the sheet which opposes the first planar
surface of
the sheet. In some cases, the aerosol-generating composition may have a
thickness
of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range
of
about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. The aerosol-generating
material may comprise more than one layer, and the thickness described herein
refers to the aggregate thickness of those layers.
In some cases, the aerosol-generating material may have a thickness of
about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of
about
0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. The aerosol-generating
material may comprise more than one layer, and the thickness described herein
refers to the aggregate thickness of those layers.
The aerosol-generating composition corn prising the
aerosol-generating
material may have any suitable area density, such as from 30 g/m2 to 120 g/m2.
In
some embodiments, aerosol-generating composition may have an area density of
from about 30 to 70 g/m2, or about 40 to 60 g/m2. In some embodiments, the
aerosol-
generating composition may have an area density of from about 80 to 120 g/m2,
or
from about 70 to 110 g/m2, or particularly from about 90 to 110 g/m2. Such
area
densities may be particularly suitable where the aerosol-generating
composition is
included in an aerosol-generating article/assembly in sheet form, or as a
shredded
sheet (described further hereinbelow).
An aspect of the invention provides non-combustible aerosol provision
system comprising an article according as described herein and non-combustible
aerosol provision device comprising a heater which is configured to heat not
burn the
aerosol-generating article. A non-combustible aerosol provision system may
also be
referred to as an aerosol generating assembly. A non-combustible aerosol
provision
device may be referred to as an aerosol generating apparatus.
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In some cases, in use, the heater may heat, without burning, the aerosol-
generating material to a temperature equal to or less than 350 C, such as
between
120 C and 350 C. In some cases, the heater may heat, without burning, the
aerosol-
generating composition to between 140 C and 250 C in use, or between 220 C
and 280 C. In some cases in use, substantially all of the aerosol-generating
material
is less than about 4mm, 3mm, 2mm or 1mm from the heater. In some cases, the
material is disposed between about 0.010mm and 2.0mm from the heater, suitably
between about 0.02mm and 1.0mm, suitably 0.1mm to 0.5mm. These minimum
distances may, in some cases, reflect the thickness of a support that supports
the
aerosol-generating material. In some cases, a surface of the aerosol-
generating
material may directly abut the heater.
The heater is configured to heat not burn the aerosol-generating article, and
thus the aerosol-generating composition. The heater may be, in some cases, a
thin
film, electrically resistive heater. In other cases, the heater may comprise
an induction
heater or the like. The heater may be a combustible heat source or a chemical
heat
source which undergoes an exothermic reaction to product heat in use. The
aerosol
generating assembly may comprise a plurality of heaters. The heater(s) may be
powered by a battery.
The aerosol-generating article may additionally comprise a cooling element
and/or a filter. The cooling element, if present, may act or function to cool
gaseous
or aerosol components. In some cases, it may act to cool gaseous components
such
that they condense to form an aerosol. It may also act to space the very hot
parts of
the non-combustible aerosol provision device from the user. The filter, if
present, may
comprise any suitable filter known in the art such as a cellulose acetate
plug.
In some cases, the aerosol generating assembly may be a heat-not-burn
device. That is, it may contain a solid aerosol-generating material (and no
liquid
aerosol-generating material). In some cases, the aerosol-generating material
may
comprise the tobacco material. A heat-not-burn device is disclosed in WO
2015/062983 A2, which is incorporated by reference in its entirety.
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In some cases, the aerosol generating assembly may be an electronic
tobacco hybrid device. That is, it may contain a solid aerosol-generating
composition
and a liquid aerosol-generating material. In some cases, the aerosol-
generating
material may comprise nicotine. In some cases, the aerosol-generating material
may
comprise a tobacco material. In some cases, the aerosol-generating material
may
comprise a tobacco material and a separate nicotine source. The separate
aerosol-
generating compositions may be heated by separate heaters, the same heater or,
in
one case, a downstream aerosol-generating material may be heated by a hot
aerosol
which is generated from the upstream aerosol-generating composition. An
electronic
tobacco hybrid device is disclosed in VVO 2016/135331 Al, which is
incorporated by
reference in its entirety.
The aerosol-generating article (which may be referred to herein as an article,
a cartridge or a consumable) may be adapted for use in a THP, an electronic
tobacco
hybrid device or another aerosol generating device. In some cases, the article
may
additionally comprise a filter and/or cooling element (which have been
described
above). In some cases, the aerosol-generating article may be circumscribed by
a
wrapping material such as paper.
The aerosol-generating article may additionally comprise ventilation
apertures. These may be provided in the sidewall of the article. In some
cases, the
ventilation apertures may be provided in the filter and/or cooling element.
These
apertures may allow cool air to be drawn into the article during use, which
can mix
with the heated volatilised components thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised
components from the article when it is heated in use. The heated volatilised
components are made visible by the process of cooling the heated volatilised
components such that supersaturation of the heated volatilised components
occurs.
The heated volatilised components then undergo droplet formation, otherwise
known
as nucleation, and eventually the size of the aerosol particles of the heated
volatilised
components increases by further condensation of the heated volatilised
components
and by coagulation of newly formed droplets from the heated volatilised
components.
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In some cases, the ratio of the cool air to the sum of the heated volatilised
components and the cool air, known as the ventilation ratio, is at least 15%.
A
ventilation ratio of 15% enables the heated volatilised components to be made
visible
by the method described above. The visibility of the heated volatilised
components
enables the user to identify that the volatilised components have been
generated and
adds to the sensory experience of the smoking experience.
In another example, the ventilation ratio is between 50% and 85% to provide
additional cooling to the heated volatilised components. In some cases, the
ventilation ratio may be at least 60% or 65%.
In some cases, the aerosol-generating composition may be included in the
article/assembly in sheet form. In some cases, the aerosol-generating
composition
may be included as a planar sheet. In some cases, the aerosol-generating
composition may be included as a planar sheet, as a bunched or gathered sheet,
as
a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some
such cases,
the aerosol-generating material of these embodiments may be included in an
aerosol-
generating article/assembly as a sheet, such as a sheet circumscribing a rod
of
aerosol-generating material (e.g. tobacco). In some other cases, the aerosol-
generating composition may be formed as a sheet and then shredded and
incorporated into the article. In some cases, the shredded sheet may be mixed
with
cut rag tobacco and incorporated into the article.
In some examples, the aerosol-generating material in sheet form may have a
tensile strength of from around 200 N/m to around 900 N/m. In some examples,
the
aerosol-generating material may have a tensile strength of from 200 N/m to 400
N/m,
or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be
particularly
suitable for embodiments wherein the aerosol-generating composition is formed
as
a sheet and then shredded and incorporated into an aerosol-generating article.
In
some examples the aerosol-generating material may have a tensile strength of
from
600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such
tensile
strengths may be particularly suitable for embodiments wherein the aerosol-
generating composition is included in an aerosol-generating article/assembly
as a
rolled sheet, suitably in the form of a tube.
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In some embodiments, the aerosol-generating material is formed as a film on
a support. The aerosol-generating film may be a continuous film or a
discontinuous
film, such as an arrangement of discrete portions of film on a support.
5
Referring to Figures 1 and 2, there are shown a partially cut-away section
view and a perspective view of an example of an aerosol-generating article
101. The
article 101 is adapted for use with a device having a power source and a
heater. The
article 101 of this embodiment is particularly suitable for use with the
device 1 shown
10 in Figures 5 to 7, described below. In use, the article 101
may be removably inserted
into the device shown in Figure 5 at an insertion point 20 of the device 1.
The article 101 of one example is in the form of a substantially cylindrical
rod
that includes a body of aerosol-generating composition 103 and a filter
assembly 105
15 in the form of a rod. The aerosol-generating composition
comprises the aerosol-
generating material described herein. In some embodiments, it may be included
in
sheet form. In some embodiments it may be included in the form of a shredded
sheet.
In some embodiments, the aerosol-generating composition described herein may
be
incorporated in sheet form and in shredded form.
The filter assembly 105 includes three segments, a cooling segment 107, a
filter segment 109 and a mouth end segment 111. The article 101 has a first
end 113,
also known as a mouth end or a proximal end and a second end 115, also known
as
a distal end. The body of aerosol-generating composition 103 is located
towards the
distal end 115 of the article 101. In one example, the cooling segment 107 is
located
adjacent the body of aerosol-generating composition 103 between the body of
aerosol-generating composition 103 and the filter segment 109, such that the
cooling
segment 107 is in an abutting relationship with the aerosol-generating
composition
103 and the filter segment 103. In other examples, there may be a separation
between the body of aerosol-generating composition 103 and the cooling segment
107 and between the body of aerosol-generating composition 103 and the filter
segment 109. The filter segment 109 is located in between the cooling segment
107
and the mouth end segment 111. The mouth end segment 111 is located towards
the proximal end 113 of the article 101, adjacent the filter segment 109. In
one
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example, the filter segment 109 is in an abutting relationship with the mouth
end
segment 111. In one embodiment, the total length of the filter assembly 105 is
between 37mm and 45mm, more preferably, the total length of the filter
assembly
105 is 41mm.
In one example, the rod of aerosol-generating composition 103 is between
34mm and 50mm in length, suitably between 38mm and 46mm in length, suitably
42mm in length.
In one example, the total length of the article 101 is between 71mm and
95mm, suitably between 79mm and 87mm, suitably 83mm.
An axial end of the body of aerosol-generating composition 103 is visible at
the distal end 115 of the article 101. However, in other embodiments, the
distal end
115 of the article 101 may comprise an end member (not shown) covering the
axial
end of the body of aerosol-generating composition 103.
The body of aerosol-generating composition 103 is joined to the filter
assembly 105 by annular tipping paper (not shown), which is located
substantially
around the circumference of the filter assembly 105 to surround the filter
assembly
105 and extends partially along the length of the body of aerosol-generating
composition 103. In one example, the tipping paper is made of 58GSM standard
tipping base paper. In one example the tipping paper has a length of between
42mm
and 50mm, suitably of 46mm.
In one example, the cooling segment 107 is an annular tube and is located
around and defines an air gap within the cooling segment. The air gap provides
a
chamber for heated volatilised components generated from the body of aerosol-
generating composition 103 to flow. The cooling segment 107 is hollow to
provide a
chamber for aerosol accumulation yet rigid enough to withstand axial
compressive
forces and bending moments that might arise during manufacture and whilst the
article 101 is in use during insertion into the device 1. In one example, the
thickness
of the wall of the cooling segment 107 is approximately 0.29mm.
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The cooling segment 107 provides a physical displacement between the
aerosol-generating composition 103 and the filter segment 109. The physical
displacement provided by the cooling segment 107 will provide a thermal
gradient
across the length of the cooling segment 107. In one example the cooling
segment
107 is configured to provide a temperature differential of at least 40 degrees
Celsius
between a heated volatilised component entering a first end of the cooling
segment
107 and a heated volatilised component exiting a second end of the cooling
segment
107. In one example the cooling segment 107 is configured to provide a
temperature
differential of at least 60 degrees Celsius between a heated volatilised
component
entering a first end of the cooling segment 107 and a heated volatilised
component
exiting a second end of the cooling segment 107. This temperature differential
across
the length of the cooling element 107 protects the temperature sensitive
filter
segment 109 from the high temperatures of the aerosol-generating composition
103
when it is heated by the device 1. If the physical displacement was not
provided
between the filter segment 109 and the body of aerosol-generating composition
103
and the heating elements of the device 1, then the temperature sensitive
filter
segment may 109 become damaged in use, so it would not perform its required
functions as effectively.
In one example the length of the cooling segment 107 is at least 15mm. In
one example, the length of the cooling segment 107 is between 20mm and 30mm,
more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.
The cooling segment 107 is made of paper, which means that it is comprised
of a material that does not generate compounds of concern, for example, toxic
compounds when in use adjacent to the heater of the device 1. In one example,
the
cooling segment 107 is manufactured from a spirally wound paper tube which
provides a hollow internal chamber yet maintains mechanical rigidity. Spirally
wound
paper tubes are able to meet the tight dimensional accuracy requirements of
high-
speed manufacturing processes with respect to tube length, outer diameter,
roundness and straightness.
In another example, the cooling segment 107 is a recess created from stiff
plug wrap or tipping paper. The stiff plug wrap or tipping paper is
manufactured to
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have a rigidity that is sufficient to withstand the axial compressive forces
and bending
moments that might arise during manufacture and whilst the article 101 is in
use
during insertion into the device 1.
The filter segment 109 may be formed of any filter material sufficient to
remove one or more volatilised compounds from heated volatilised components
from
the aerosol-generating material. In one example the filter segment 109 is made
of a
mono-acetate material, such as cellulose acetate. The filter segment 109
provides
cooling and irritation-reduction from the heated volatilised components
without
depleting the quantity of the heated volatilised components to an
unsatisfactory level
for a user.
In some embodiments, a capsule (not illustrated) may be provided in filter
segment 109. It may be disposed substantially centrally in the filter segment
109,
both across the filter segment 109 diameter and along the filter segment 109
length.
In other cases, it may be offset in one or more dimension. The capsule may in
some
cases, where present, contain a volatile component such as a flavourant or
aerosol
generating agent.
The density of the cellulose acetate tow material of the filter segment 109
controls the pressure drop across the filter segment 109, which in turn
controls the
draw resistance of the article 101. Therefore the selection of the material of
the filter
segment 109 is important in controlling the resistance to draw of the article
101. In
addition, the filter segment performs a filtration function in the article
101.
In one example, the filter segment 109 is made of a 8Y15 grade of filter tow
material, which provides a filtration effect on the heated volatilised
material, whilst
also reducing the size of condensed aerosol droplets which result from the
heated
volatilised material.
The presence of the filter segment 109 provides an insulating effect by
providing further cooling to the heated volatilised components that exit the
cooling
segment 107. This further cooling effect reduces the contact temperature of
the
user's lips on the surface of the filter segment 109.
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In one example, the filter segment 109 is between 6mm to 10mm in length,
suitably 8mm.
The mouth end segment 111 is an annular tube and is located around and
defines an air gap within the mouth end segment 111. The air gap provides a
chamber for heated volatilised components that flow from the filter segment
109. The
mouth end segment 111 is hollow to provide a chamber for aerosol accumulation
yet
rigid enough to withstand axial compressive forces and bending moments that
might
arise during manufacture and whilst the article is in use during insertion
into the
device 1. In one example, the thickness of the wall of the mouth end segment
111 is
approximately 0.29mm. In one example, the length of the mouth end segment 111
is
between 6mm to 10mm, suitably 8mm.
The mouth end segment 111 may be manufactured from a spirally wound
paper tube which provides a hollow internal chamber yet maintains critical
mechanical rigidity. Spirally wound paper tubes are able to meet the tight
dimensional
accuracy requirements of high-speed manufacturing processes with respect to
tube
length, outer diameter, roundness and straightness.
The mouth end segment 111 provides the function of preventing any liquid
condensate that accumulates at the exit of the filter segment 109 from coming
into
direct contact with a user.
It should be appreciated that, in one example, the mouth end segment 111
and the cooling segment 107 may be formed of a single tube and the filter
segment
109 is located within that tube separating the mouth end segment 111 and the
cooling
segment 107.
Referring to Figures 3 and 4, there are shown a partially cut-away section and
perspective views of an example of an article 301. The reference signs shown
in
Figures 3 and 4 are equivalent to the reference signs shown in Figures 1 and
2, but
with an increment of 200.
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In the example of the article 301 shown in Figures 3 and 4, a ventilation
region
317 is provided in the article 301 to enable air to flow into the interior of
the article
301 from the exterior of the article 301. In one example the ventilation
region 317
takes the form of one or more ventilation holes 317 formed through the outer
layer of
5 the article 301. The ventilation holes may be located in the cooling
segment 307 to
aid with the cooling of the article 301. In one example, the ventilation
region 317
comprises one or more rows of holes, and preferably, each row of holes is
arranged
circumferentially around the article 301 in a cross-section that is
substantially
perpendicular to a longitudinal axis of the article 301.
In one example, there are between one to four rows of ventilation holes to
provide ventilation for the article 301. Each row of ventilation holes may
have
between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for
example,
be between 100 to 500pm in diameter. In one example, an axial separation
between
rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.
In one example, the ventilation holes 317 are of uniform size. In another
example, the ventilation holes 317 vary in size. The ventilation holes can be
made
using any suitable technique, for example, one or more of the following
techniques:
laser technology, mechanical perforation of the cooling segment 307 or pre-
perforation of the cooling segment 307 before it is formed into the article
301. The
ventilation holes 317 are positioned so as to provide effective cooling to the
article
301.
In one example, the rows of ventilation holes 317 are located at least 11mm
from the proximal end 313 of the article, suitably between 17mm and 20mm from
the
proximal end 313 of the article 301. The location of the ventilation holes 317
is
positioned such that user does not block the ventilation holes 317 when the
article
301 is in use.
Providing the rows of ventilation holes between 17mm and 20mm from the
proximal end 313 of the article 301 enables the ventilation holes 317 to be
located
outside of the device 1, when the article 301 is fully inserted in the device
1, as can
be seen in Figures 6 and 7. By locating the ventilation holes outside of the
device,
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non-heated air is able to enter the article 301 through the ventilation holes
from
outside the device 1 to aid with the cooling of the article 301.
The length of the cooling segment 307 is such that the cooling segment 307
will be partially inserted into the device 1, when the article 301 is fully
inserted into
the device 1. The length of the cooling segment 307 provides a first function
of
providing a physical gap between the heater arrangement of the device 1 and
the
heat sensitive filter arrangement 309, and a second function of enabling the
ventilation holes 317 to be located in the cooling segment, whilst also being
located
outside of the device 1, when the article 301 is fully inserted into the
device 1. As can
be seen from Figures 6 and 7, the majority of the cooling element 307 is
located
within the device 1. However, there is a portion of the cooling element 307
that
extends out of the device 1. It is in this portion of the cooling element 307
that extends
out of the device 1 in which the ventilation holes 317 are located.
Referring now to Figures 5 to 7 in more detail, there is shown an example of
a device 1 arranged to heat aerosol-generating composition to volatilise at
least one
component of said aerosol-generating composition, typically to form an aerosol
which
can be inhaled. The device 1 is a heating device which releases compounds by
heating, but not burning, the aerosol-generating composition.
A first end 3 is sometimes referred to herein as the mouth or proximal end 3
of the device 1 and a second end 5 is sometimes referred to herein as the
distal end
5 of the device 1_ The device 1 has an on/off button 7 to allow the device 1
as a whole
to be switched on and off as desired by a user.
The device 1 comprises a housing 9 for locating and protecting various
internal components of the device 1. In the example shown, the housing 9
comprises
a uni-body sleeve 11 that encompasses the perimeter of the device 1, capped
with a
top panel 17 which defines generally the 'top' of the device 1 and a bottom
panel 19
which defines generally the 'bottom' of the device 1. In another example the
housing
comprises a front panel, a rear panel and a pair of opposite side panels in
addition to
the top panel 17 and the bottom panel 19.
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The top panel 17 and/or the bottom panel 19 may be removably fixed to the
uni-body sleeve 11, to permit easy access to the interior of the device 1, or
may be
"permanently" fixed to the uni-body sleeve 11, for example to deter a user
from
accessing the interior of the device 1. In an example, the panels 17 and 19
are made
of a plastics material, including for example glass-filled nylon formed by
injection
moulding, and the uni-body sleeve 11 is made of aluminium, though other
materials
and other manufacturing processes may be used
The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the
device 1 through which, in use, the article 101, 301 including the aerosol-
generating
composition may be inserted into the device 1 and removed from the device 1 by
a
user.
The housing 9 has located or fixed therein a heater arrangement 23, control
circuitry 25 and a power source 27. In this example, the heater arrangement
23, the
control circuitry 25 and the power source 27 are laterally adjacent (that is,
adjacent
when viewed from an end), with the control circuitry 25 being located
generally
between the heater arrangement 23 and the power source 27, though other
locations
are possible.
The control circuitry 25 may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the aerosol-
generating composition in the article 101, 301 as discussed further below.
The power source 27 may be for example a battery, which may be a
rechargeable battery or a non-rechargeable battery. Examples of suitable
batteries
include for example a lithium-ion battery, a nickel battery (such as a
nickel¨cadmium
battery), an alkaline battery and/ or the like. The battery 27 is electrically
coupled to
the heater arrangement 23 to supply electrical power when required and under
control of the control circuitry 25 to heat the aerosol-generating composition
in the
article (as discussed, to volatilise the aerosol-generating material without
causing the
aerosol-generating composition to burn).
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An advantage of locating the power source 27 laterally adjacent to the heater
arrangement 23 is that a physically large power source 25 may be used without
causing the device 1 as a whole to be unduly lengthy. As will be understood,
in
general a physically large power source 25 has a higher capacity (that is, the
total
electrical energy that can be supplied, often measured in Amp-hours or the
like) and
thus the battery life for the device 1 can be longer.
In one example, the heater arrangement 23 is generally in the form of a hollow
cylindrical tube, having a hollow interior heating chamber 29 into which the
article
101, 301 comprising the aerosol-generating material is inserted for heating in
use.
Different arrangements for the heater arrangement 23 are possible. For
example, the
heater arrangement 23 may comprise a single heating element or may be formed
of
plural heating elements aligned along the longitudinal axis of the heater
arrangement
23. The or each heating element may be annular or tubular, or at least part-
annular
or part-tubular around its circumference. In an example, the or each heating
element
may be a thin film heater. In another example, the or each heating element may
be
made of a ceramics material. Examples of suitable ceramics materials include
alumina and aluminium nitride and silicon nitride ceramics, which may be
laminated
and sintered. Other heating arrangements are possible, including for example
inductive heating, infrared heater elements, which heat by emitting infrared
radiation,
or resistive heating elements formed by for example a resistive electrical
winding.
In one particular example, the heater arrangement 23 is supported by a
stainless steel support tube and comprises a polyimide heating element. The
heater
arrangement 23 is dimensioned so that substantially the whole of the body of
aerosol-
generating composition 103, 303 of the article 101, 301 is inserted into the
heater
arrangement 23 when the article 101, 301 is inserted into the device 1.
The or each heating element may be arranged so that selected zones of the
aerosol-generating material can be independently heated, for example in turn
(over
time, as discussed above) or together (simultaneously) as desired.
The heater arrangement 23 in this example is surrounded along at least part
of its length by a thermal insulator 31. The insulator 31 helps to reduce heat
passing
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from the heater arrangement 23 to the exterior of the device 1. This helps to
keep
down the power requirements for the heater arrangement 23 as it reduces heat
losses generally. The insulator 31 also helps to keep the exterior of the
device 1 cool
during operation of the heater arrangement 23. In one example, the insulator
31 may
be a double-walled sleeve which provides a low pressure region between the two
walls of the sleeve. That is, the insulator 31 may be for example a "vacuum"
tube, i.e.
a tube that has been at least partially evacuated so as to minimise heat
transfer by
conduction and/or convection. Other arrangements for the insulator 31 are
possible,
including using heat insulating materials, including for example a suitable
foam-type
material, in addition to or instead of a double-walled sleeve.
The housing 9 may further comprises various internal support structures 37
for supporting all internal components, as well as the heating arrangement 23.
The device 1 further comprises a collar 33 which extends around and projects
from the opening 20 into the interior of the housing 9 and a generally tubular
chamber
35 which is located between the collar 33 and one end of the vacuum sleeve 31.
The
chamber 35 further comprises a cooling structure 35f, which in this example,
comprises a plurality of cooling fins 35f spaced apart along the outer surface
of the
chamber 35, and each arranged circumferentially around outer surface of the
chamber 35. There is an air gap 36 between the hollow chamber 35 and the
article
101, 301 when it is inserted in the device 1 over at least part of the length
of the
hollow chamber 35. The air gap 36 is around all of the circumference of the
article
101, 301 over at least part of the cooling segment 307.
The collar 33 comprises a plurality of ridges 60 arranged circumferentially
around the periphery of the opening 20 and which project into the opening 20.
The
ridges 60 take up space within the opening 20 such that the open span of the
opening
20 at the locations of the ridges 60 is less than the open span of the opening
20 at
the locations without the ridges 60. The ridges 60 are configured to engage
with an
article 101, 301 inserted into the device to assist in securing it within the
device 1.
Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60
and
the article 101, 301 form ventilation paths around the exterior of the article
101, 301.
These ventilation paths allow hot vapours that have escaped from the article
101,
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301 to exit the device 1 and allow cooling air to flow into the device 1
around the
article 101, 301 in the air gap 36.
In operation, the article 101, 301 is removably inserted into an insertion
point
5 20 of
the device 1, as shown in Figures 5 to 7. Referring particularly to Figure 6,
in
one example, the body of aerosol-generating composition 103, 303, which is
located
towards the distal end 115, 315 of the article 101, 301, is entirely received
within the
heater arrangement 23 of the device 1. The proximal end 113, 313 of the
article 101,
301 extends from the device 1 and acts as a mouthpiece assembly for a user.
In operation, the heater arrangement 23 will heat the article 101, 301 to
volatilise at least one component of the aerosol-generating composition from
the
body of aerosol-generating composition 103, 303.
The primary flow path for the heated volatilised components from the body of
aerosol-generating composition 103, 303 is axially through the article 101,
301,
through the chamber inside the cooling segment 107, 307, through the filter
segment
109, 309, through the mouth end segment 111,313 to the user. In one example,
the
temperature of the heated volatilised components that are generated from the
body
of aerosol-generating composition is between 60 C and 250 C, which may be
above
the acceptable inhalation temperature for a user. As the heated volatilised
component
travels through the cooling segment 107, 307, it will cool and some
volatilised
components will condense on the inner surface of the cooling segment 107, 307.
In the examples of the article 301 shown in Figures 3 and 4, cool air will be
able to enter the cooling segment 307 via the ventilation holes 317 formed in
the
cooling segment 307. This cool air will mix with the heated volatilised
components to
provide additional cooling to the heated volatilised components.
Another aspect of the invention provides a method of making an aerosol-
generating material according to the first aspect.
The method may comprise (a) forming a slurry comprising components of the
aerosol-generating material or precursors thereof and a solvent (typically
water), (b)
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forming a layer of the slurry, (c) optionally setting the slurry, and (d)
drying the slurry
to form an aerosol-generating material.
In some cases, less than or equal to about 15 wt% of the flavour added to the
slurry is lost in steps (a)-(d), such as less than or equal to about 10 wt% or
less than
or equal to 5 wt% of the flavour added to the slurry.
In some cases, the dried aerosol-generating material retains at least about 85
wt% of the flavour added to the slurry, such as at least about 90% or at least
about
95 ck of the flavour added to the slurry. The amounts of components in the
slurry can
be determined based on the weights of the components added to the slurry. The
amounts of menthol and glycerol in the dried aerosol-generating material can
be
measured by gas chromatography.
Step (a) may comprise combining aerosol-generating agent, binder, flavour,
filler, solvent (typically water) and any optional further components of the
aerosol-
generating material to form the slurry.
Step (b) of forming a layer of the slurry may comprise spraying, casting or
extruding the slurry, for example. In some cases, the slurry layer is formed
by
electrospraying the slurry. In some cases, the slurry layer is formed by
casting the
slurry.
In some cases, (b) and/or (c) and/or (d) may, at least partially, occur
simultaneously (for example, during electrospraying). In some cases, (b), (c)
and (d)
may occur sequentially.
In some cases, the slurry is applied to a support. The layer may be formed on
a support.
In examples, the slurry comprises binder, aerosol-generating agent, flavour
and filler. The slurry may comprise these components on a dry weight basis in
any of
the proportions given herein in relation to the composition of the aerosol-
generating
material. For example, the slurry may comprise:
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- aerosol-generating agent in an amount of from about 7 to about 13 wt%
of the slurry;
- binder;
- flavour in an amount of from about 35 to about 50 wt% of the slurry; and
- filler;
wherein the above amounts are calculated on a dry weight basis. The slurry
further
comprises a solvent (typically water).
In one embodiment, the slurry comprises:
- aerosol-generating agent in an amount of from about 7 to about 13 wt%;
- binder in an amount of from about 1 to about 57 wt%;
- flavour in an amount of from about 35 to about 50 wt%; and
- filler in an amount of from about 1 to about 50 wt%;
wherein the above amounts are calculated on a dry weight basis. The slurry
further
1 5 comprises a solvent (typically water).
The setting step (c) may comprise the addition of a setting agent (also
referred
to as a crosslinking agent) to the slurry. Suitable setting/crosslinking
agents and
amounts thereof are set out above. For example, the slurry may comprise
sodium,
potassium or ammonium alginate as a gel-precursor, and a setting agent or
crosslinking agent comprising a calcium source (such as calcium chloride,
calcium
acetate or calcium lactate), may be added to the slurry to form a calcium
alginate gel.
In some embodiments the setting agent is applied by spraying the slurry with
the setting agent.
The total amount of the setting agent/crosslinking agent, such as a calcium
source, may be 0.5-7wV/0 (calculated on a dry weight basis). The addition of
too little
setting agent/crosslinking agent may result in an aerosol-generating material
which
does not stabilise the aerosol-generating material components and results in
these
components dropping out of the aerosol-generating material. The addition of
too
much setting agent or crosslinking agent may result in an aerosol-generating
material
that is very tacky and consequently has poor handleability.
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Alginate salts are derivatives of alginic acid and are typically high
molecular
weight polymers (10-600 kDa). Alginic acid is a copolymer of 13-D-mannuronic
(M)
and a-L-guluronic acid (G) units (blocks) linked together with (1,4)-
glycosidic bonds
to form a polysaccharide. On addition of calcium cations, the alginate
crosslinks to
form a gel. Alginate salts with a high G monomer content more readily form a
gel on
addition of the calcium source. In some cases therefore, the gel-precursor may
comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or
70%
of the monomer units in the alginate copolymer are a-L-guluronic acid (G)
units.
Setting the gel in step (c) may not be required, for example when the only
binder present is a cellulosic binder such as CMC. When a non-cellulosic
binder
agent is present, such as alginate, the slurry may further comprise a setting
agent or
crosslinking agent and/or a setting agent or crosslinking agent may be applied
to the
slurry. In this case, the method may further comprise the step (c) of setting
the slurry.
The drying step (d) may, in some cases, remove from about 50wt%, 60wt%,
70wtck, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (VVVVB) of water in the
slurry.
The drying step (d) may, in some cases, may reduce the cast material
thickness by at least 80%, suitably 85% or 87%. For instance, the slurry may
be cast
at a thickness of 2mm, and the resulting dried aerosol-generating material may
have
a thickness of 0.2mm.
During step (d) the slurry may be heated to remove at least about 60 wt%, 70
wt%, 80 wt%, 85 wt% or 90 wt% of the solvent, which is typically water.
Following drying step (d), the aerosol-generating material may have a water
content as defined above. In particular, the aerosol-generating material may
have of
from 1wt % to 15wt% (WWB). Suitably, the water content of the aerosol-
generating
material may be from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt%
(wet weight basis) (VWVB). The water content of the aerosol-generating
material may,
for example, be determined by Karl-Fischer-titration or Gas Chromatography
with
Thermal Conductivity Detector (GC-TCD).
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The aerosol-generating material, optionally in the form of a film, may be
formed by combining the aerosol-generating agent, binder, flavour, filler, a
solvent
(typically water) and any optional further components to form a slurry and
then
heating the slurry to volatilise at least some of the solvent to form the
aerosol-
generating film. The slurry may be heated to remove at least about 60 wt%, 70
wt%, 80 wt%, 85 wt% or 90 wt% of the solvent_
The slurry itself may also form part of the invention. In some cases, the
slurry
solvent may consist essentially of or consist of water. In some cases, the
slurry may
comprise from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (VVVVB).
In cases where the solvent consists of water, the dry weight content of the
slurry may match the dry weight content of the aerosol-generating material.
Thus, the
1 5
discussion herein relating to the solid material is explicitly disclosed in
combination
with the slurry aspect of the invention. In particular, aspects and
embodiments above
defining components of the aerosol-generating material and amounts thereof
apply
mutatis mutandis to the slurry of the invention and the method of the
invention.
In a further aspect, the invention also provides an aerosol-generating
material
obtainable by, or obtained by a method of the invention. Aspects and
embodiments
above defining components of the aerosol-generating material and amounts
thereof
apply mutatis mutandis to this further aspect of the invention.
According to an aspect of the present invention there is provided a method of
generating an aerosol using a non-combustible aerosol provision system as
described herein. In some embodiments, the method comprises heating the
aerosol-
generating material to a temperature of less than or equal to 350 C. In some
embodiments, the method comprises heating the aerosol-generating material to a
temperature of from about 220 C to about 280 C. In some embodiments, the
method comprises heating at least a portion of the aerosol-generating material
to a
temperature of from about 220 00 to about 280 C over a session of use.
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"Session of use" as used herein refers to a single period of use of the non-
combustible aerosol provision system by a user. The session of use begins at
the
point at which power is first supplied to at least one heating unit present in
the heating
assembly. The device will be ready for use after a period of time has elapsed
from
5 the start of the session of use. The session of use ends at the point at
which no power
is supplied to any of the heating elements in the aerosol-generating device.
The end
of the session of use may coincide with the point at which the smoking article
is
depleted (the point at which the total particulate matter yield (mg) in each
puff would
be deemed unacceptably low by a user). The session will have a duration of a
plurality
10 of puffs. Said session may have a duration less than 7 minutes, or 6
minutes, or 5
minutes, or 4 minutes and 30 seconds, or 4 minutes, or 3 minutes and 30
seconds.
In some embodiments, the session of use may have a duration of from 2 to 5
minutes,
or from 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or suitably 4 minutes. A
session may
be initiated by the user actuating a button or switch on the device, causing
at least
15 one heating element to begin rising in temperature.
All percentages by weight described herein (denoted wt%) are calculated on
a dry weight basis (DWB), unless explicitly stated otherwise. All weight
ratios are
also calculated on a dry weight basis. A weight quoted on a dry weight basis
refers
20 to the whole of the slurry, aerosol-generating composition or aerosol-
generating
material, other than the water, and may include components which by themselves
are liquid at room temperature and pressure, such as glycerol. Conversely, a
weight percentage quoted on a wet weight basis (VVVVB) refers to all
components,
including water.
For the avoidance of doubt, where in this specification the term "comprises"
is used in defining the invention or features of the invention, embodiments
are also
disclosed in which the invention or feature can be defined using the terms
"consists
essentially of" or "consists of" in place of "comprises". Reference to a
material
"comprising" certain features means that those features are included in,
contained
in, or held within the material.
Any feature described in relation to one aspect of the invention is expressly
disclosed in combination with any other aspect described herein.
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Exemplary Embodiments
Further embodiments of the invention are as follows:
I. An aerosol-generating material comprising:
- aerosol-generating agent in an amount of from about 7 to about 13 wt%
of the aerosol-generating material on a dry weight basis;
- binder;
- flavour in an amount of from about 35 to about 50 wt% of the aerosol-
generating material on a dry weight basis; and
- filler.
2. The aerosol-generating material of Embodiment 1, wherein the flavour
comprises menthol.
3. The aerosol-generating material of Embodiment 2, wherein the flavour
consists of menthol.
4. The aerosol-generating material of any preceding Embodiment, wherein the
aerosol-generating agent comprises one or more of 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.
5. The aerosol-generating material of Embodiment 4, wherein the aerosol-
generating agent consists of one or more of 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.
6. The aerosol-generating material of any preceding Embodiment, wherein the
aerosol-generating agent comprises glycerol.
7. The aerosol-generating material of Embodiment 6, wherein the aerosol-
generating agent consists of glycerol.
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8. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises aerosol-generating agent
in an amount of 8-13 wt% (on a dry weight basis).
9. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises aerosol-generating agent
in an amount of 9-12wt% (on a dry weight basis).
10. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises aerosol-generating agent
in an amount of 10-12wt% (on a dry weight basis).
11. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises aerosol-generating agent
in an amount of more than 10wt% to less than 12 wt% (on a dry weight basis).
12. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises aerosol-generating agent
in an amount of 10.3-11.9wt% (on a dry weight basis).
13. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises flavour in an amount of
35-45 wt% (on a dry weight basis).
14. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises flavour in an amount of
36-45wt% (on a dry weight basis).
15. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises flavour in an amount of
37-43wt% (on a dry weight basis).
16. The aerosol-generating material according to any preceding Embodiment,
wherein the binder comprises alginate and/or pectin.
17. The aerosol-generating material according to any preceding Embodiment,
wherein the binder comprises alginate and pectin.
18. The aerosol-generating material according to any of Embodiments 1-16,
wherein the binder consists of alginate and/or pectin.
19. The aerosol-generating material according to any preceding Embodiment,
wherein the binder consists of alginate and pectin.
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20. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material is substantially free of cellulosic
binder.
21. The aerosol-generating material according to any preceding Embodimentõ
wherein the aerosol-generating material is substantially free of
carboxymethylcel lulose.
21a. The aerosol-generating material according to any of Embodiments 1-17,
wherein the binder comprises a cellulosic binder and a non-cellulosic binder.
21b. The aerosol-generating material according to Embodiment 21a, wherein the
cellulosic binder comprises, consists essentially of, or consists of,
carboxymethyl
cellulose.
21c. The aerosol-generating material according to Embodiment 21a or 21b,
wherein the non-cellulosic binder comprises, consists essentially of, or
consists
of, alginate and/or guar gum.
21d. The aerosol-generating material according to Embodiment 21c, wherein the
non-cellulosic binder comprises, consists essentially of, or consists of,
alginate
and guar gum.
21e. The aerosol-generating material according to any of Embodiments 21a-21d,
wherein the binder comprises, consists essentially of, or consists of CMC,
alginate and guar gum.
22. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises binder in an amount of
1-57wt% (on a dry weight basis).
23. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises binder in an amount of
5-50wt% (on a dry weight basis).
24. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises binder in an amount of
15-35wt% (on a dry weight basis).
25. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises binder in an amount of
20-30wt% (on a dry weight basis).
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26. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises binder in an amount of
20-25wt% (on a dry weight basis).
27. The aerosol-generating material according to any preceding Embodiment,
wherein the filler comprises wood pulp.
28. The aerosol-generating material according to any preceding Embodiment,
wherein the filler consists of wood pulp.
29. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises filler in an amount of
5-45wt% (on a dry weight basis).
30. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises filler in an amount of such
as 10-40wt% (on a dry weight basis).
31. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises filler in an amount of 18-
35wtcY0 (on a dry weight basis).
32. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises filler in an amount of
20-30wt% (on a dry weight basis).
33. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material further comprises a crosslinking
agent.
34. The aerosol-generating material according to Embodiment 33, wherein the
crosslinking agent comprises calcium ions
35. The aerosol-generating material according to Embodiment 34, wherein
crosslinking agent comprises calcium lactate and/or calcium acetate.
36. The aerosol-generating material according to Embodiment 35, wherein
crosslinking agent consists of calcium lactate and/or calcium acetate.
36a. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises 1-10 wt% of crosslinking
agent (dry weight basis).
36b. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises 3-8 wt% of crosslinking
agent
(dry weight basis).
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36c. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material comprises 5-7 wt% of crosslinking
agent
(dry weight basis).
37. The aerosol-generating material according to any preceding Embodiment,
5 wherein the aerosol-generating material is substantially free from
tobacco.
38. The aerosol-generating material according to any preceding Embodiment,
wherein the aerosol-generating material is in the form of a sheet_
39. The aerosol-generating material according to any preceding Embodiment,
aerosol-generating material is in the form of a film on a support.
10 40. An aerosol-generating composition comprising the aerosol-generating
material of any of Embodiments 1-39.
41. An aerosol-generating composition consisting essentially of the aerosol-
generating material of Embodiments 1-39.
42. An aerosol-generating cornposition consisting of the aerosol-generating
15 material of any of Embodiments 1-39.
43. A consumable for use with a non-combustible aerosol provision device, the
consumable comprising the aerosol-generating composition according to any
of Embodiments 40-42 or the aerosol-generating material of any of
Embodiments 1-39.
20 44. A non-combustible aerosol provision system comprising the
consumable
according to Embodiment 43 and a non-combustible aerosol provision device,
wherein the non-combustible aerosol provision device is configured to
generate aerosol from the consumable when the consumable is used with the
non-combustible aerosol provision device.
25 45. The system according to Embodiment 44 wherein the non-combustible
aerosol provision device comprises a heater configured to heat but not burn
the consumable.
46. Use of the aerosol-generating material of any of Embodiments 1-39 or an
aerosol-generating composition of any of Embodiments 41-43 for generating
30 an aerosol.
Si. A slurry comprising:
aerosol-generating agent in an amount of from about 7 to about 13
wt% of the slurry on a dry weight basis;
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- binder;
- flavour in an amount of from about 35 to about 50 wt% of the slurry on
a dry weight basis;
- filler; and
a solvent.
S2. The slurry of Embodiment Si, wherein the flavour
comprises menthol.
S3_ The slurry of Embodiment S2, wherein the flavour
consists of menthol.
S4. The slurry of any preceding Embodiment, wherein the aerosol-generating
agent comprises one or more of 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.
S5. The slurry of Embodiment S4, wherein the aerosol-generating agent
consists
of one or more of glycerol, propylene glycol, diethylene glycol, triethylene
glycol,
tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl
van illate,
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.
S6. The slurry of any preceding Embodiment, wherein the aerosol-generating
agent comprises glycerol.
S7. The slurry of Embodiment S6, wherein the aerosol-
generating agent consists
of glycerol.
S8_ The slurry according to any preceding Embodiment,
wherein the slurry
comprises aerosol-generating agent in an amount of 8-13 wt% (on a dry weight
basis).
S9. The slurry according to any preceding Embodiment, wherein the slurry
comprises aerosol-generating agent in an amount of 9-12wt% (on a dry weight
basis).
S10. The slurry according to any preceding Embodiment, wherein the slurry
comprises aerosol-generating agent in an amount of 10-12wt% (on a dry weight
basis).
S11. The slurry according to any preceding Embodiment, wherein the slurry
comprises aerosol-generating agent in an amount of more than 10wt% to less
than
12 wt% (on a dry weight basis).
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S12. The slurry according to any preceding Embodiment, wherein the slurry
comprises aerosol-generating agent in an amount of 10.3-11.9wt% (on a dry
weight
basis).
S13. The slurry according to any preceding Embodiment, wherein the slurry
comprises flavour in an amount of 35-45 wt% (on a dry weight basis).
S14. The slurry according to any preceding Embodiment, wherein the slurry
comprises flavour in an amount of 36-45wt% (on a dry weight basis).
S15. The slurry according to any preceding Embodiment, wherein the slurry
comprises flavour in an amount of 37-43wt% (on a dry weight basis).
S16. The slurry according to any preceding Embodiment, wherein the binder
comprises alginate and/or pectin.
S17. The slurry according to any preceding Embodiment, wherein the binder
comprises alginate and pectin.
S18. The slurry according to any of Embodiments S1-S16, wherein the binder
1 5 consists of alginate and/or pectin.
S19. The slurry according to any preceding Embodiment, wherein the binder
consists of alginate and pectin.
S20. The slurry according to any preceding Embodiment, wherein the slurry is
substantially free of cellulosic binder.
S21. The slurry according to any preceding Embodimentõ wherein the slurry is
substantially free of carboxymethylcellulose.
S22. The slurry according to any preceding Embodiment, wherein the slurry
comprises binder in an amount of 1-57wt% (on a dry weight basis).
S23. The slurry according to any preceding Embodiment, wherein the slurry
comprises binder in an amount of 5-50wt% (on a dry weight basis).
S24. The slurry according to any preceding Embodiment, wherein the slurry
comprises binder in an amount of 15-35wt% (on a dry weight basis).
S25. The slurry according to any preceding Embodiment, wherein the slurry
comprises binder in an amount of 20-30wt% (on a dry weight basis).
S26. The slurry according to any preceding Embodiment, wherein the slurry
comprises binder in an amount of 20-25wt% (on a dry weight basis).
S27. The slurry according to any preceding Embodiment, wherein the filler
comprises wood pulp.
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S28. The slurry according to any preceding Embodiment, wherein the filler
consists
of wood pulp.
S29. The slurry according to any preceding Embodiment, wherein the slurry
comprises filler in an amount of 5-45wt% (on a dry weight basis).
S30. The slurry according to any preceding Embodiment, wherein the slurry
comprises filler in an amount of such as 10-40wt% (on a dry weight basis).
S31. The slurry according to any preceding Embodiment, wherein the slurry
comprises filler in an amount of 18-35wt% (on a dry weight basis).
S32. The slurry according to any preceding Embodiment, wherein the slurry
comprises filler in an amount of 20-30wt% (on a dry weight basis).
S33. The slurry according to any preceding Embodiment, wherein the slurry
further
comprises a crosslinking agent.
S34. The slurry according to Embodiment S33, wherein the crosslinking agent
comprises calcium ions
S35. The slurry according to Embodiment S34, wherein crosslinking agent
comprises calcium lactate and/or calcium acetate.
S36. The slurry according to Embodiment S35, wherein crosslinking agent
consists
of calcium lactate and/or calcium acetate.
S36a. The slurry according to any preceding Embodiment, wherein the slurry
comprises 1-10 wt% of crosslinking agent (dry weight basis).
S36b. The slurry according to any preceding Embodiment, wherein the slurry
comprises 3-8 wt% of crosslinking agent (dry weight basis).
S36c. The slurry according to any preceding Embodiment, wherein the slurry
comprises 5-7 wt% of crosslinking agent (dry weight basis).
S37. The slurry according to any preceding Embodiment, wherein the slurry is
substantially free from tobacco.
S38. The slurry according to any preceding Embodiment, wherein the solvent
comprises water.
S39. The slurry according to any preceding Embodiment, wherein the solvent is
water.
Embodiment 47. A method of making an aerosol-generating
material the
method comprising:
(a) forming a slurry according to any of Embodiments S1-S39
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(b) forming a layer of the slurry;
(c) optionally setting the slurry; and
(d) drying the slurry to form the aerosol-generating material.
Embodiment 48. The method of Embodiment 47, wherein the
aerosol-
generating material is the aerosol-generating material of any of Embodiments 1-
39.
Embodiment 49. The method of Embodiment 47 or 48, wherein
less than or
equal to about 15 wt% of the flavour added to the slurry is lost in steps (a)-
(d).
Embodiment 50. The method of Embodiment 49, wherein less
than or equal to
about 10 wt% of the flavour added to the slurry is lost in steps (a)-(d).
Embodiment 51. The method of Embodiment 50, wherein less than or equal to
5 wt% of the flavour added to the slurry is lost in steps (a)-(d).
Embodiment 52. An aerosol-generating material obtainable by
the method of
any of Embodiments 47-51.
Embodiment 53. An aerosol-generating material obtained by
the method of any
of Embodiments 47-51.
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Examples
Gas chromatography measurement method
5 REAGENTS
A1.1 Solvent: Methanol - (HPLC Grade or similar)
A1.2 Internal standard (ISTD): n-Heptadecane or Anethole (purity > 99.0%)
A1.3 Reference substances: menthol - (purity >99.0%)
A1.4 Carrier gas: helium of high purity (at least 99,995%)
10 A1.5 Auxiliary gases: air for flame ionisation detector (FID), hydrogen
of high purity
(at least 99,995%) for the FID,
A1.6 Other reagents: Ultrapure water
A1.7 Extraction solution: extraction solvent (A1.1) containing the internal
standard
(A1.2)
15 A1.8.1 Extraction Solution
Weigh (2.5 0.01) g of n-heptadecane (ISTD) into a weighing vessel and add to
the
5 L volumetric flask, containing 400-500 mL of methanol. Mix thoroughly to
dissolve
the n-heptadecane overnight. When dissolved make up to the correct volume with
methanol.
20 A1.8.2 Calibration Stock Solution (SA)
Weigh accurately approximately (8.0 0.01) g menthol directly into a 200-mL
volumetric flask. Rinse the weighing vessel with extraction solution, into the
volumetric flask, after each compound has been weighed. Fill up to volume with
extraction solution and mix the flask contents by repeated inversion of the
flask.
APPARATUS
= Gas Chromatograph equipped with a splitJsplitless injection system, one
analytical column, flame ionisation (FID) detector and data analysis system.
= GC Column: Phenomenex ZB-WAXplus (or equivalent); 30 m x 0.53 mm id
x 1.00 pm
= Analytical Balance (precision 0.1 mg)
= Volumetric Glassware
= Stoppered 150 mL conical flasks
= Amber Vials with lids to store the solutions in the refrigerator (60 mL
and 40
mL)
= GC vials and caps
= Crimping Tool
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= Magnetic Stirrer
= Orbital/Horizontal flask shaker
= Glass Pipettes ¨ grade A
PROCEDURE
A calibration graph was constructed for menthol analyte by diluting
calibration
stock solution (A1.8.2) to provide a range of calibration standards and
analysing the
calibration standards by gas chromatography.
Dried aerosol-generating materials were extracted according to the following
procedure. The extracts were then analysed by gas chromatography. Peak areas
were used as a measure of analyte concentration.
= Weigh 0.25 g of the dried aerosol-generating material sample into a 150-mL
conical flask
= Add 50 mL of Extraction Solution with a calibrated dispenser.
= Stopper the flask.
= Set shaking on an Orbital/Horizontal shaker for 3 hours at 150 rpm.
= Using a plastic 5 mL syringe, filter some extract through a 0.45 pm PTFE
filter
into a 2 mL amber GC Vial.
= Crimp the vial and label.
Column Parameters
Front MNPH
Column ZB-WAXplus 30 m x 0.53 mm x
1.00 pm
Carrier Gas Helium Carrier Gas Helium
Pressure (psi) 5.1 Pressure (psi) 5.1
Inlet/Injector Parameters
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Front - NINIPH
Mode !--_HD Mess
Temperature CC) 270
Pressure (psi) 5.1
Split Ratio
Split Flow (milmin) NA
Total Flow (mLimin) 48
Injection Volume (1.1L)
Gas Saver On
Detector Parameters
Front - WINPH
Type
Temperature_) 2 7 :11
H2 Flow Ref. Flow 2.D
Air Flow (miJmin) .4L1U
Make Up. Constant
Make Up He (niLirrin) 15.0
On Off Fian-Ã.
Negative Polarity
Oven parameters
Initial Temperature
Initial. Time 4
Ramp Rate 272
Final Temperature 23(1
Final Time 2.5 min
To enable conversion of concentrations to dry weight basis, water
concentrations of the aerosol generating materials were also measured by Karl
Fischer titration.
Example 1 (reference)
Reference aerosol-generating materials were produced by forming a slurry
comprising water, menthol, glycerol, alginate, pectin, and wood pulp, casting
the
slurry, applying calcium lactate onto the cast slurry and drying the slurry.
The
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amounts of the constituents added to the slurry were as follows (all on a dry
weight
basis):
Slurry composition
Component ( % DWB)
Menthol 40
Glycerol 16
Fibre (wood pulp) 20
Pectin 4.8
Alginate 19.2
The amount of menthol in the dried aerosol-generating material was then
measured using gas chromatography according to the procedure outlined above.
Across 45 samples, the mean amount of menthol measured in the dried material
was
about 28.5 wt% (compared to 40 wt% in the initial slurry). The samples
therefore
showed significant menthol loss (about 29% loss) during the production
process.
Example 2
Aerosol-generating materials according to the invention were produced by
forming a slurry comprising water, menthol, glycerol, alginate, pectin, and
wood pulp,
casting the slurry, applying calcium lactate onto the cast slurry (in the same
amount
as in Example 1) and drying the slurry. The amounts of menthol and glycerol in
the
aerosol-generating materials were then measured using gas chromatography
according to the procedure outlined above.
The amounts of the constituents added to the slurry were as follows (all on a
dry weight basis):
Slurry composition
Component (% DWB)
Menthol 40
Glycerol 11
Fibre (wood pulp) 25
Pectin 4.8
Alginate 19.2
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The amount of menthol in the dried aerosol-generating material was then
measured for two different samples of the composition, and found to be 39.85
wt%
(sample 1) and 38.74 wt% (sample 2). The samples therefore showed less than 5%
menthol loss during the production process.
As can be seen from this Example, reducing the amount of glycerol
unexpectedly reduced menthol loss from the aerosol-generating material
compared
to reference Example 1.
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