Note: Descriptions are shown in the official language in which they were submitted.
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Aerosol generating compositions
Technical Field
The present invention relates to aerosol generation for delivery of
constituents,
derivatives or extracts of cannabis.
Background
Smoking articles such as cigarettes, cigars and the like burn tobacco during
use to
create tobacco smoke. Alternatives to these types of articles release an
inhalable
zo aerosol or vapour by releasing compounds from a substrate material by
heating without
burning. These may be referred to as non-combustible smoking articles, aerosol
generating assemblies or non-combustible aerosol provision systems.
One example of such a product is a heating device which release compounds by
heating,
but not burning, a solid aerosolisable material. This solid aerosolisable
material may,
in some cases, contain a tobacco material. The heating volatilises at least
one
component of the material, typically forming an inhalable aerosol. These
products may
be referred to as heat-not-burn devices, tobacco heating devices or tobacco
heating
products (THP). Various different arrangements for volatilising at least one
component
of the solid aerosolisable material are known.
As another example, there are e-cigarette / tobacco heating product hybrid
devices, also
known as electronic tobacco hybrid devices. These hybrid devices contain a
liquid
source (which may or may not contain nicotine) which is vaporised by heating
to
produce an inhalable vapour or aerosol. The device additionally contains a
solid
aerosolisable material (which may or may not contain a tobacco material) and
components of this material are entrained in the inhalable vapour or aerosol
to produce
the inhaled medium.
Summary
According to a first aspect of the present invention, there is provided an
aerosol-
generating composition comprising a first aerosol-generating material
comprising an
active substance which is a constituent, derivative or extract of cannabis and
a gelling
agent, and a second aerosol-generating material comprising a different active
substance
and a gelling agent.
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In some embodiments, the composition comprises a third or further aerosol-
generating
materials comprising an active substance and a gelling agent.
In some embodiments, the first, second and/or further aerosol-generating
materials
comprise:
from about 15 to about 70 wt% of an active substance;
from about io to about 50 wt% aerosol-former material;
from about 15 to about 6o wt% gelling agent; and
optionally filler;
io wherein the wt% values are calculated on a dry weight basis.
In some embodiments, the composition comprises from about 5 to about 6o wt% of
an
active substance.
In some embodiments, the composition comprises from about 15 to about 45 wt%
aerosol-former material.
In some embodiments, the composition comprises from about 25 to about 50 wt%
gelling agent.
In some embodiments, the gelling agent comprises or is one or more compounds
selected from polysaccharide gelling agents, such as alginate, pectin, starch
or a
derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan,
agar and
agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica
or
silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin;
and
polyvinyl alcohol.
In some embodiments, the polysaccharide gelling agent is selected from the
group
consisting of alginate and a cellulose derivative, and/or wherein the
cellulose derivative
3o is selected from 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).
In some embodiments, the gelling agent is not crosslinked.
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In some embodiments, the gelling agent is CMC.
In some embodiments, the aerosol-former material comprises (or is) 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 embodiments, the aerosol-former material comprises or is glycerol or a
io combination of glycerol and propylene glycol.
In some embodiments, the constituent, derivative or extract of cannabis is a
cannabinoid.
In some embodiments, the cannabinoid is selected from cannabigerol (CBG),
cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC),
cannabinol
(CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV),
tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin
(CBCV),
cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic
acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV),
cannabitriol
(CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid
(THCV
A).
In some embodiments, the cannabinoid is cannabidiol.
In some embodiments, the second and any further aerosol-generating material
comprises one or more active substance selected from the group consisting of:
nutraceuticals; nootropics; psychoactives; and constituents, derivatives or
extracts of
tobacco or another botanical, such as nicotine, caffeine, taurine, theine,
vitamins such
as B6 or B12 or C, melatonin, and constituents or derivatives thereof.
In some embodiments, the first and second aerosol-generating materials have
different
compositions in addition to the different active substances.
In some embodiments, the first and second aerosol-generating materials are in
the
form of sheets.
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In some embodiments, the first and second aerosol-generating materials are
sheets
having different thicknesses.
In some embodiments, the first and second aerosol-generating materials release
their
respective active substances at different temperatures.
In some embodiments, the composition comprises one or more of a shredded sheet
of
the first aerosol-generating material, a shredded sheet of the second aerosol-
generating
io material and a shredded sheet of any further aerosol-generating
material.
In some embodiments, the composition comprises from about 50-100 wt% (WWB) of
the aerosol-generating materials.
According to a second aspect of the invention there is provided a consumable
for use in
a non-combustible aerosol provision device, the consumable comprising the
aerosol-
generating composition according to the first aspect.
According to a third aspect of the invention there is provided a non-
combustible
aerosol provision system comprising a consumable according to the second
aspect and
a non-combustible aerosol provision device.
According to a fourth aspect of the invention there is provided a method for
preparing
an aerosol-generating composition according to the first aspect, wherein the
first or
second aerosol-generating material is formed by casting a slurry into a sheet.
In some embodiments, the active substance is dissolved in a solvent in the
slurry.
According to a fifth aspect of the invention there is provided a method for
preparing an
aerosol-generating composition according to the first aspect, wherein the
first or
second aerosol-generating material is formed by extrusion.
Brief Description of the Drawings
Embodiments of the invention will now be described, by way of example only,
with
reference to accompanying drawings, in which:
Figure 1 shows a section view of an example of a consumable.
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Figure 2 shows a perspective view of the consumable of Figure 1.
Figure 3 shows a sectional elevation of an example of a consumable.
Figure 4 shows a perspective view of the consumable of Figure 3.
Figure 5 shows a perspective view of an example of a non-combustible aerosol
provision system.
Figure 6 shows a section view of an example of a non-combustible aerosol
provision
system.
Figure 7 shows a perspective view of an example of a non-combustible aerosol
provision
system.
io 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
An aerosol-generating composition is a composition that is capable of
generating
aerosol, for example when heated, irradiated or energized in any other way.
An aerosol-generating composition is provided comprising two or more different
aerosol generating materials. The first aerosol-generating material comprises
an active
substance which is a constituent, derivative or extract of cannabis and a
gelling agent,
and the second aerosol-generating material comprises a different active
substance and
a gelling agent.
According to the disclosure, different actives or different combinations of
actives are
provided in separate aerosol-generating materials. These can then be combined,
optionally with further aerosol-generating materials, to form an aerosol-
generating
composition.
This separate provision of the different actives within the aerosol-generating
composition can have a number of important benefits.
The actives incorporated in different aerosol-generating materials are kept
separated
and this is beneficial where the actives are incompatible with one another,
for example
because they interact with one another.
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The actives incorporated in different aerosol-generating materials is
beneficial where
one or more of the actives are incompatible with other components of the
aerosol-
generating material or where one active performs better in an aerosol-
generating
material including certain components whilst the other active performs better
in an
aerosol-generating material including different components. For example, the
combination of an active with one or more other component of the aerosol-
generating
material, such as certain gelling agents, aerosol former materials, flavours,
solvents or
fillers, etc., may be undesirable or less desirable.
io The actives may have different inherent chemical properties which affect
their
volatilisation and release from the aerosol-generating material into the
aerosol formed
on heating, etc. Provision of the actives in different aerosol-generating
materials
enables the aerosol-generating materials to be formulated to release the
actives at the
desired time, temperature or rate, to provide the aerosol-generating
composition with
Is the desired release profile and an aerosol with the desired properties.
For example, the release of an active from an aerosol-generating material may
be
influenced by a number of properties of the material, including the thickness
(i.e., the
surface area to volume ratio), the density of the material, the presence and
amount of
20 components within the aerosol-generating material that influence the
heating and
temperature distribution within the material, the type and amount of the
aerosol-
former, the type and amount of the gelling agent. These properties of the
first and
second aerosol-generating materials may be different to control the release of
the
respective actives.
Provision of the actives in different aerosol-generating materials enables the
aerosol-
generating materials to be arranged within the aerosol-generating composition
and/or
in a non-combustible aerosol provision system or consumable to release the
actives at
the desired time, temperature or rate, to provide the aerosol-generating
composition
with the desired release profile and an aerosol with the desired properties.
For example, different parts of the consumable or aerosol-generating
composition may
be heated to different temperatures and/or at different times, and the
arrangement
and/or heating of different aerosol-generating materials may allow the release
of the
different actives to be controlled to provide an aerosol with the desired
properties and
the desired user experience.
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The different aerosol-generating materials may be heated at different times,
for
example by having the aerosol-generating composition or consumable comprising
sections including different materials that are independently heated. For
example,
such sections may be arranged in different parts or areas of the consumable,
with
different heaters associated with the different sections, or heater(s) being
moved to
different sections. Alternatively, the heat may spread through the aerosol-
generating
composition and different sections of different aerosol-generating material
may then be
heated at different times and/or heated to different temperatures.
Thus, the provision of the actives in different aerosol-generating materials
makes it
possible to use the makeup of the materials, their form and arrangement to
tailor the
release of actives and other aerosol components to provide an aerosol with
desired
properties. The properties of the aerosol may be consistent throughout the use
of the
consumable or they may change from puff to puff or otherwise over the course
of use of
the consumable. The system may also allow the user to choose the properties of
the
aerosol from a given consumable or aerosol-generating composition. For
example,
operating the non-combustible aerosol-generating system at one temperature or
at a
particular setting may produce an aerosol with a first set of properties,
whilst a
different temperature or different setting produces an aerosol with different
properties.
The aerosol-generating compositions may also make it possible to control the
dose and
delivery of the actives with greater accuracy. This may offer the consumer a
more
consistent, more predictable and/or safer experience.
In some embodiments, at least the first aerosol-generating material contains a
high
concentration of constituent, derivative or extract of cannabis meaning high
delivery
levels of CBD can be achieved. The high concentration of constituent,
derivative or
extract of cannabis also improves the ability to deliver a sufficient quantity
of active to
the user without increasing the volume of the substrate.
Without wishing to be bound by theory, it is believed that the high
concentration of
constituents, derivatives or extracts of cannabis (e.g. cannabinoids) relative
to the
gelling agent unexpectedly lowers the propensity for the constituents,
derivatives or
extracts of cannabis (e.g. cannabinoids) to change colour which may occur due
to
oxidation of the cannabinoid.
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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 retained fluid
may be
water (such as water absorbed from the surroundings of the aerosol-generating
material) or the retained fluid may be solvent (such as when the aerosol-
generating
io material is formed from a slurry). In some embodiments, the solvent may
be water.
In some embodiments, the aerosol-generating composition may for example
comprise
from about 50 wt%, 60 wt% or 70 wt% of aerosol-generating material, to about
90 wt%,
95 wt% or wo wt% of aerosol-generating material, based on the weight of the
aerosol-
generating composition. These wt% values are calculated on a wet weight basis
(WVVB), i.e. including any water or other solvent present in the aerosol-
generating
composition or the aerosol-generating material.
In some embodiments, the aerosol-generating material consists essentially of,
or
consists of, gelling agent; solvent; aerosol-former material; an active
substance; and
optionally a flavour and/or optionally an additional active substance and/or
optionally
a filler.
In some embodiments, the first aerosol-generating material consists
essentially of, or
consists of, gelling agent; solvent; aerosol-former material; and constituent,
derivative
or extract of cannabis.
In some embodiments, the first aerosol-generating material consists
essentially of, or
consists of, gelling agent; solvent; aerosol-former material; cannabinoid; and
optionally
a flavour and/or optionally an additional active substance and/or optionally a
filler.
In some cases, the first aerosol-generating material consists essentially of,
or consists
of, gelling agent; solvent; aerosol-former material; and cannabinoid.
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In some embodiments, the first aerosol-generating material consists
essentially of, or
consists of, gelling agent; solvent; aerosol-former material; and constituent,
derivative
or extract of cannabis.
In some embodiments, the second or further aerosol-generating material
consists
essentially of, or consists of, gelling agent; solvent; aerosol-former
material; an active
substance; and optionally a flavour and/or optionally an additional active
substance
and/or optionally a filler.
io In some embodiments, the aerosol-generating material is a hydrogel and
comprises less
than about 20 wt% of water calculated on a wet weight basis. In some cases,
the
hydrogel may comprise less than about 15 wt%, 12 wt% or 10 wt% of water
calculated
on a wet weight basis (WWB). In some cases, the hydrogel may comprise at least
about
1 wt%, 2 wt% or at least about 5 wt% of water (WINS).
In some embodiments, the aerosol-generating material may contain less than
about 20
wt%, such as less than about 15 wt%, 12 wt% or 10 wt% of water calculated on a
wet
weight basis (WINE). For example, the aerosol-generating material may contain
about
1 to 15 wt% of water, such as 3 to 12 wt% of water (WWB). In some embodiments
the
aerosol-generating material may contain about 1 to 5 wt% of water (WWB).
In some embodiments, the aerosol-generating materials comprises:
from about 15 to about 50 wt% of an active substance;
from about 10 to about 50 wt% aerosol-former material;
from about 15 to about 60 wt% gelling agent; and
optionally filler;
wherein the wt% values are calculated on a dry weight basis.
Constituent, derivative or extract of cannabis
The first aerosol-generating material comprises an active substance which is a
constituent, derivative or extract of cannabis.
In addition, the second aerosol-generating material comprising a different
active
substance may also comprise an active substance which is a constituent,
derivative or
extract of cannabis.
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As used herein, any compound or mixture of compounds which may be obtained
from
cannabis may be a constituent, derivative or extract thereof, including
synthetic
versions of such compound(s) or such compound(s) derived from other natural
sources.
In some embodiments the constituent, derivative or extract of cannabis
comprises, or
is, one or more compounds selected from: cannabinoids (such as
phytocannabinoids
that may optionally be THC and/or CBD); terpenes (such as triterpenes);
alkaloids; and
flavonoids.
In some embodiments the constituent, derivative or extract of cannabis
comprises one
or more compounds selected from: cannabinoids (such as phytocannabinoids) and
terpenes (such as triterpenes).
In some embodiments the constituent, derivative or extract of cannabis
comprises one
or more cannabinoids, such as phytocannabinoids.
Cannabinoids are a class of natural or synthetic chemical compounds which act
on
cannabinoid receptors (i.e., CBI. and CB2) in cells that repress
neurotransmitter release
in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) from
plants such as cannabis, from animals (endocannabinoids), or artificially
manufactured
(synthetic cannabinoids). Cannabis species express at least 85 different
phytocannabinoids, and are divided into subclasses, including cannabigerols,
cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and
cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis
include,
without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol
(CBD),
tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL),
cannabicyclol
(CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin
(CBDV),
cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl
ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol
propyl
variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and
tetrahydrocannabivarinic acid (THCV A).
In some embodiments, the cannabinoids are phytocannabinoids.
In some embodiments, the terpenes are triterpenes.
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In particular embodiments, the constituent, derivative or extract of cannabis
comprises, or is, tetrahydrocannabinol (THC) and/or cannabidiol (CBD).
In some embodiments, the constituent, derivative or extract of cannabis
comprises, or
is, THC.
In particular embodiments, the constituent, derivative or extract of cannabis
comprises, or is, CBD.
In some embodiments, the total amount of the one or more constituent,
derivative or
extract of cannabis present is from about 0.1 to about 6o% by weight, based on
the total
weight of the composition. In some embodiments, the total amount of the one or
more
constituent, derivative or extract of cannabis present is from about 5 to
about 6o% by
weight, based on the total weight of the composition. In some embodiments, the
total
amount of the one or more constituent, derivative or extract of cannabis
present in the
composition is at least about 0.1%, at least about 0.2%, at least about 0.3%,
at least
about 0.4%, at least about 0.5%, at least about 0.6%, at least about 0.7%, at
least about
o.8%, at least about 0.9%, at least about 1%, at least about 2%, at least
about 3%, at
least about 4%, at least about 5%, at least about 7%, at least about 10%, at
least about
12% or at least about 15% by weight, based on the total weight of the
composition. In
some embodiments, the total amount of the one or more constituent, derivative
or
extract of cannabis present in the composition is about no more than about
6o%, no
more than about 55%, no more than about 50%, no more than about 45%, no more
than about 40%, no more than about 35%, no more than about 30%, or no more
than
about 25% by weight, based on the total weight of the composition.
Other active substances
The aerosol-generating material may further comprise other active ingredients.
In some embodiments, the first aerosol-generating material comprises a
different active
substance in addition to the constituent, derivative or extract of cannabis.
In some
cases, the aerosol-generating material may comprise from about 1 wt%, 5 wt%,
10 wt%,
15 wtO, 20 wt% or 25 wtcYo to about 6o wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or
30
wt% (calculated on a dry weight basis) of another active substance in addition
to
constituent(s), derivative(s) or extract(s) of cannabis.
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Also, the second or further aerosol-generating material comprises a different
active
substance to the constituent, derivative or extract of cannabis.
In some embodiments, the different active substance is not a constituent,
derivative or
extract of cannabis.
The additional active substance as used herein may be a physiologically active
material,
which is a material intended to achieve or enhance a physiological response.
The
io additional active substance may for example be selected from
nutraceuticals,
nootropics and psychoactives. The additional active substance may be naturally
occurring or synthetically obtained. The additional active substance may
comprise for
example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C,
melatonin,
or constituents, derivatives, or combinations thereof. The additional active
substance
may comprise one or more constituents, derivatives or extracts of tobacco or
another
botanical.
In some embodiments, the additional active substance comprises nicotine.
In some embodiments, the additional active substance comprises caffeine,
melatonin or
vitamin B12.
As noted herein, the additional active substance may comprise or be derived
from one
or more botanicals or constituents, derivatives or extracts thereof. As used
herein, the
term "botanical" includes any material derived from plants including, but not
limited
to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits,
pollen, husk, shells
or the like. Alternatively, the material may comprise an active compound
naturally
existing in a botanical, obtained synthetically. The material may be in the
form of
liquid, gas, solid, powder, dust, crushed particles, granules, pellets,
shreds, strips,
sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise,
hemp, cocoa,
coffee, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger,
ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate,
orange skin,
papaya, rose, sage, tea such as green tea or black tea, thyme, clove,
cinnamon, coffee,
aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg,
oregano,
paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower,
vanilla,
wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,
bergamot,
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orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,
olive,
lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry,
ginseng,
theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab
or
any combination thereof. The mint may be chosen from the following mint
varieties:
Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita
citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia,
Mentha
longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v.
and
Mentha suaveolens.
io In some embodiments, the additional active substance comprises or is
derived from one
or more botanicals or constituents, derivatives or extracts thereof and the
botanical is
tobacco.
In some embodiments, the additional active substance comprises or derived from
one
or more botanicals or constituents, derivatives or extracts thereof and the
botanical is
selected from eucalyptus, star anise, cocoa and hemp. In some embodiments the
additional active substance comprises (or is) a botanical selected from
eucalyptus, star
anise, cocoa and hemp.
In some embodiments, the additional active substance comprises or derived from
one
or more botanicals or constituents, derivatives or extracts thereof and the
botanical is
selected from rooibos and fennel. In some embodiments, the additional active
substance comprises (or is) a botanical selected from rooibos and fennel.
For example, in some cases, the aerosol-generating material additionally
comprises a
tobacco material and/or nicotine. In some cases, the aerosol-generating
material may
comprise 5 to 6o wt% (calculated on a dry weight basis) of a tobacco material
and/or
nicotine.
In some cases, the aerosol-generating material may comprise from about 1 wt%,
5 wt%,
10 wt%, 15 wt%, 20 wt% or 25 wt% to about 6o wt%, 50 wt%, 45 wt%, 40 wt%, 35
wt%,
or 30 wt% (calculated on a dry weight basis) of a tobacco material. For
example, the
aerosol-generating material may comprise up to about 50 wt% of a tobacco
material.
For example, the aerosol-generating material may comprise about 10 to 50 wt%,
15 to
40 wt% or 20 to 35 Wt% of a tobacco material. In some cases, the aerosol-
generating
material may comprise from about 1 wt%, 2 wt%, 3 wt% or 4 wt% to about 20 Wt%,
18
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wtO, 15 wt% or 12 wt% (calculated on a dry weight basis) of nicotine. For
example, the
aerosol-generating material may comprise about 1 to 20 WtO, 2 to 18 wt% or 3
to 12
wt% of nicotine.
In some cases, the aerosol-generating material comprises an additional active
substance such as tobacco extract. In some cases, the aerosol-generating
material may
comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In
some cases,
the aerosol-generating material may comprise from about 5 wt%, 10 wt%, 15 wt%,
20
wt% or 25 wt% to about 6o wt%, 50 we/6, 45 wt%, 40 wt%, 35 wtoz/0,
or 30 wt%
io (calculated on a dry weight basis) tobacco extract. For example, the
aerosol-generating
material may comprise about 10 to 50 wt%, 15 to 40 wt% or 20 to 35 wt% of
tobacco
extract. The tobacco extract may contain nicotine at a concentration such that
the
aerosol-generating material comprises about 1 wt%, 1.5 wt%, 2 wt% or 2.5wt% to
about
6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine.
In some
cases, there may be no nicotine in the aerosol-generating material other than
that
which results from any tobacco extract.
In some embodiments the aerosol-generating material in the aerosol-generating
composition comprises no tobacco material but does comprise nicotine. In some
such
cases, the aerosol-generating material may comprise from about 1 wt%, 2 Wt%, 3
wt%
or 4 wt% to about 20 WtO, 18 WtO, 15 Wt% or 12 wt% (calculated on a dry weight
basis)
of nicotine. For example, the aerosol-generating material may comprise about 1
to 20
WtO, 2 to 18 wt% or 3 to 12 wt% of nicotine.
In some embodiments, the aerosol-generating material and the aerosol-
generating
composition do not contain any tobacco material (including tobacco extract) or
nicotine.
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 contain any
tobacco material (including tobacco extract) or nicotine. In some embodiments,
the
aerosol-generating composition does not comprise tobacco fibres. In particular
embodiments, the aerosol-generating composition does not comprise fibrous
material.
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Gelling agent
Suitably, the amorphous solid may comprise from about 15 wt% to about 6o wt%
gelling agent, for example from about 25 wt%, 30 wt%, or 35 wt% to about 40
wt%, 45
wt% or 50 wt% of a gelling agent (all calculated on a dry weight basis). For
example,
the aerosol-generating material may comprise about 25 to 50 wt%, 30 to 45 wt%
or 35
to 40 wt% of the gelling agent. In some embodiments, the gelling agent
comprises a
hydrocolloid.
io In some embodiments, the gelling agent comprises (or is) one or more
compounds
selected from polysaccharide gelling agents, such as alginate, pectin, starch
or a
derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan,
agar and
agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica
or
silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin;
and
polyvinyl alcohol.
In some embodiments the gelling agent comprises (or is) one or more
polysaccharide
gelling agents.
In some embodiments, the polysaccharide gelling agent is selected from
alginate,
pectin, starch or a derivative thereof, or cellulose or a derivative thereof.
In some
embodiments the polysaccharide gelling agent is selected from alginate and a
cellulose
derivative.
In some embodiments, the gelling agent is a polysaccharide gelling agent,
optionally
wherein the polysaccharide gelling agent is selected from alginate and a
cellulose
derivative.
In some embodiments, the alginate is sodium alginate.
In some embodiments, the polysaccharide gelling agent is a cellulose
derivative.
Without wishing to be bound by theory, the inventors believe that such gelling
agents
do not react with calcium ions to form crosslinks.
In some embodiments, the polysaccharide gelling agent is alginate.
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In some embodiments the gelling agent is not crosslinked. The absence of
crosslinks in
the gelling agent facilitates quicker delivery of the constituent, derivative
or extract of
cannabis (and any optional additional active substances and/or flavours) from
the
aerosol-generating material.
Examples of cellulosic gelling agents (also referred to herein as cellulose
derivatives)
include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl
cellulose,
hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl
methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate
(CA),
io cellulose acetate butyrate (CAB), and cellulose acetate
propionate (CAP). In some
embodiments the cellulose or derivative thereof is selected from 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). In some embodiments, the cellulose derivative is CMC.
For example, in some embodiments, the gelling agent comprises (or is) one or
more of
alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose,
carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose,
acacia
gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
In some embodiments, the gelling agent comprises (or is) one or more of
hydroxyethyl
cellulose, hydroxypropyl cellulose, carboxymethylcellulose, guar gum, acacia
gum,
alginate and/or pectin.
In some cases, the gelling agent comprises (or is) alginate and/or pectin, and
may be
combined with a setting agent (such as a calcium source) during formation of
the
aerosol-generating material. In some cases, the aerosol-generating material
may
comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises (or is) alginate, optionally
wherein
the alginate is present in the aerosol-generating material in an amount of
from about 15
to 40 wt%, for example about 15 to 25 wt%, of the aerosol-generating material
(calculated on a dry weight basis).
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In some embodiments, the gelling agent comprises (or is) alginate, optionally
wherein
the alginate is present in the aerosol-generating material in an amount of
from about 15
to 40 wt%, for example about 30 to 40 wt%, of the aerosol-generating material
(calculated on a dry weight basis).
In some embodiments, alginate is the only gelling agent present in the aerosol-
generating material.
In other embodiments, the gelling agent comprises alginate and at least one
further
gelling agent, such as pectin.
In particular embodiments, the gelling agent is carboxymethylcellulose,
optionally
wherein the carboxymethylcellulose (CMC) is present in an amount of about 15
to 50
wt%, for example about 20 to 40 wt% or about 30 wt%. In some embodiments, CMC
is
the only gelling agent present in the aerosol-generating material.
Cannabinoids have good stability in gels comprising cellulosic gelling agents
such as
CMC. Without wishing to be bound by theory, it is believed that the cellulosic
gelling
agents such as CMC do not promote oxidation of cannabinoids. It has therefore
been
found that undesirable colour change of the cannabinoid can be reduced or
avoided
when using cellulosic gelling agents such as CMC.
In some embodiments, the weight ratio of the total amount of gelling agent to
the total
amount of constituents, derivatives or extracts of cannabis is from about 2:1
to 1:2, such
as about 1.5:1 to 1:1.5 or 1.2:1 to 1:1.2.
Aerosol-former material
The aerosol-former material may comprise one or more constituents capable of
forming
an aerosol.
Suitably, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%,
3
wt%, 5 wtO, 7 wt% or to wt% to about 50 wt%, 45 wtO, 40 wtO, 35 wtO, 30 wt% or
25
wt% of an aerosol-former material (all calculated on a dry weight basis). For
example,
the amorphous solid may comprise 0.5 to 40 wt%, 3 to 35 wt% or to to 25 wt% of
an
aerosol-former material.
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In some embodiments, the aerosol-former material 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 embodiments, the aerosol-former material may comprise one or more of
erythritol, propylene glycol, glycerol, and triacetin. In some cases, the
aerosol-former
material comprises, consists essentially of or consists of glycerol, or a
mixture of
io glycerol and propylene glycol.
In some embodiments, the aerosol-former material comprises a mixture of
glycerol and
propylene glycol in a weight ratio of glycerol to propylene glycol of about
3:1 to 1:3,
about 2:1 to 1:2, about 1.5:1 to 1:1.5, about 55:45 to 45:55, or about 45:55.
The aerosol-former material may act as a plasticiser. If the content of the
plasticiser is
too high, the aerosol-generating material may absorb water resulting in a
material that
does not create an appropriate consumption experience in use. If the
plasticiser
content is too low, the aerosol-generating material may be brittle and easily
broken.
20 The plasticiser content specified herein provides an aerosol-generating
material
flexibility which allows a sheet of the aerosol-generating material or aerosol-
generating
composition to be wound onto a bobbin, which is useful in manufacture of
aerosol
generating articles (consumables).
25 Filler
The aerosol-generating composition may further comprise a filler. Use of a
filler may
help to reduce tackiness of the aerosol-generating material, for example if
high levels of
aerosol-former material are present.
30 In some embodiments, the aerosol-generating material may comprise less
than about
50 wt% of a filler, such as from about 1 wt% to 50 wt%, or 5 wt% to 40 wt%, or
5 wt% to
30 wt%, or 10 wt% to 20 wt%.
In other embodiments, the aerosol-generating material comprises less than 20
WtO,
35 suitably less than 10 wt% or less than 5 wt% of a filler. In some cases,
the aerosol-
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generating material comprises less than 1 wt% of a filler, and in some cases
the aerosol-
generating material comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials,
such as
calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica,
magnesium
oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic
sorbents,
such as molecular sieves. The filler may comprise one or more organic filler
materials
such as wood pulp; tobacco pulp; hemp fibre; starch and starch derivatives,
such as
maltodextrin; chitosan; and cellulose and cellulose derivatives, such as
microcrystalline
io cellulose and nanocrystalline cellulose. In particular cases, the
aerosol-generating
material comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For
example, the
filler may be a fibrous organic filler material such as wood pulp, tobacco
pulp, hemp
Is fibre, cellulose or cellulose. derivatives. In some embodiments, the
fibrous organic filler
material may be wood pulp, hemp fibre, cellulose or cellulose derivatives. In
some
embodiments, the fibrous filler is wood pulp. 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
20 wherein the aerosol-generating material is provided as a sheet, such as
when an
aerosol-generating material sheet circumscribes a rod of aerosolisable
material.
In some embodiments the gelling agent is CMC and is used together with wood
pulp as
a filler.
Flavour
The aerosol-generating material and/or the aerosol-generating composition may
optionally comprise a flavour. For example, the or each aerosol-generating
material
may comprise up to about 60 wt%, 55 wt%, 50 wt% or 45 wt% of a flavour. In
some
cases, the aerosol-generating material may comprise at least about 0.1 wt%, 1
wt%, 10
wt%, 20 WtO, 30 wt%, 35 wt% or 40 wt% of a flavour (all calculated on a dry
weight
basis). For example, the aerosol-generating material may comprise ito 6o wt%,
10 to
60 wtO, 20 to 50 wt%, or 30 to 40 wt% a flavour.
The different aerosol-generating materials in the aerosol-generating
composition may
include the same or different flavours, and/or flavours in different amounts.
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As used herein, the terms "flavour" and "flavourant" refer to materials which,
where
local regulations permit, may be used to create a desired taste, aroma or
other
somatosensorial sensation in a product for adult consumers. They may include
naturally occurring flavour materials, botanicals, extracts of botanicals,
synthetically
obtained 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,
io 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, botanicals, or breath
freshening
agents. They may be imitation, synthetic or natural ingredients or blends
thereof. They
may be in any suitable form, for example, liquid such as an oil, solid such as
a powder,
or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
blueberry, citrus fruits and/or redberry.
In some embodiments, the flavour comprises eugenol.
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In some embodiments, the flavour comprises flavour components extracted from
tobacco.
In some embodiments, the flavour comprises flavour components extracted from
cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to
achieve a somatosensorial sensation which are usually chemically induced and
io perceived by the stimulation of the fifth cranial nerve (trigeminal
nerve), in addition to
or in place of aroma or taste nerves, and these may include agents providing
heating,
cooling, tingling, numbing effect. A suitable heat effect agent may be, but is
not limited
to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited
to eucolyptol
or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).
In some cases, the aerosol-generating material may additionally comprise an
emulsifying agent, which emulsified molten flavour during manufacture. For
example,
the aerosol-generating material may comprise from about 5 wt% to about 15 wt%
of an
emulsifying agent (calculated on a dry weight basis), suitably about 10 wt%.
The
emulsifying agent may comprise acacia gum.
Solvent
The amorphous solid may be made from a gel, and this gel may additionally
comprise a
solvent, included at 0.1-50 wt%. However, it has been established that the
inclusion of
a solvent in which the flavour is soluble may reduce the gel stability and the
flavour
may crystallise out of the gel. As such, in some cases, the gel does not
include a solvent
in which the flavour is soluble.
Other functional material
In some embodiments, one or more aerosol-generating material may further
comprise
one or more other functional material(s).
In some embodiments, the aerosol-generating material may further comprise one
or
more additional active substances and/or flavours, and optionally one or more
other
functional material. The one or more other functional materials may comprise
one or
more of pH regulators, colouring agents, preservatives, stabilizers, and/or
antioxidants.
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Sheets
In some embodiments, one or more of the aerosol-generating materials are each
formed as a sheet.
In some cases, the aerosol-generating material sheet may be incorporated into
the non-
combustible aerosol provision system or consumable in sheet form. The aerosol-
generating material sheet may be incorporated as a planar sheet, as a gathered
or
bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a
tube). In
io some such cases, the aerosol-generating material of these
embodiments may be
included in the system/consumable as a sheet, such as a sheet circumscribing a
rod of
aerosolisable material (e.g. tobacco). For example, the aerosol-generating
material
sheet may be formed on a wrapping paper which circumscribes an aerosolisable
material such as tobacco. In other cases, the sheet may be shredded and then
incorporated into the assembly, optionally mixed into an aerosolisable
material such as
cut rag tobacco or a non-tobacco plant material.
Where the aerosol-generating composition comprises two or more aerosol-
generating
materials in sheet form, the sheets may be incorporated into the non-
combustible
aerosol provision system or consumable in the same manner or in different
manners.
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 material may be in the form of a sheet or layer
having a
thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in
the
range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, for
example
0.1-3 mm or 0.15-3 mm. A material having a thickness of 0.2 mm may be
particularly
suitable. The aerosol-generating material may comprise more than one layer,
and the
thickness described herein refers to the aggregate thickness of those layers.
Where the
aerosol-generating composition comprises two or more aerosol-generating
materials in
sheet form, the sheets may have the same thickness or different thicknesses.
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If the aerosol-generating material is too thick, then heating efficiency may
be
compromised. This adversely affects the power consumption in use. Conversely,
if the
aerosol-generating material is too thin, it may be difficult to manufacture
and handle; a
very thin material is harder to cast and may be fragile, compromising aerosol
formation
in use.
The thickness stipulated herein is a mean thickness for the material. In some
cases, the
aerosol-generating material thickness may vary by no more than 25%, 20%, 15%,
10%,
5% or 1%.
In some examples, the aerosol-generating material in sheet form may have a
tensile
strength of from around 200 N/m to around 2000 N/m. 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, such as where the aerosol-
generating
material does not comprise a filler, the aerosol-generating material in sheet
form may
have a tensile strength of from around 200 N/m to around 400 N/m, or around
200
N/m to around 300 N/m, or about 250 N/m. Such tensile strengths may be
particularly suitable for embodiments wherein the aerosol-generating material
and/or
the aerosol-generating composition is formed as a sheet and then shredded and
incorporated into a consumable. In some examples, such as where the aerosol-
generating material comprises a filler, the aerosol-generating material may
have a
tensile strength of from around 600 N/m to around 900 N/m, or from around 700
N/m to around 900 N/m, or around 800 N/m. Such tensile strengths may be
particularly suitable for embodiments wherein the aerosol-generating material
and/or
the aerosol-generating composition is included in a consumable/non-combustible
aerosol provision system as a rolled sheet, suitably in the form of a tube.
Where the aerosol-generating composition comprises two or more aerosol-
generating
materials in sheet form, the sheets may have the same tensile strength or
different
tensile strengths.
The aerosol-generating composition comprising the aerosol-generating material
may
have any suitable area density, such as from 30 g/m2 to 120 g/m2. In some
cases, the
aerosol-generating composition may have a mass per unit area of 80-120 g/m2,
or from
about 70 to no g/m2, or particularly from about 90 to no g/m2, or suitably
about loo
g/m2 (so that it has a similar density to cut rag tobacco and a mixture of
these
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substances will not readily separate). Such area densities may be particularly
suitable
where the aerosol-generating composition is included in assembly
consumable/system
in sheet form, or as a shredded sheet (described further hereinbelow). In some
cases,
the aerosol-generating composition may have a mass per unit area of about 30
to 70
g/m2, 40 to 6o g/m2, or 25 to 6o g/m2 and may be used to wrap an aerosolisable
material such as tobacco.
Where the aerosol-generating composition comprises two or more aerosol-
generating
materials in sheet form, the sheets may have the same area density or
different area
io densities.
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. In some
cases, the
aerosol-generating film does not comprise a filler.
The aerosol-generating material for use in aerosol generation may be present
on or in a
support, to form a substrate. The support may, for example, be or comprise
paper,
card, paperboard, cardboard, reconstituted material, a plastics material, a
ceramic
material, a composite material, glass, a metal, or a metal alloy. In some
embodiments,
the support comprises a susceptor. In some embodiments, the susceptor is
embedded
within the material. In some alternative embodiments, the susceptor is on one
or either
side of the material.
Where the aerosol-generating composition comprises two or more aerosol-
generating
materials in sheet form, the sheets may be formed on the same support, may be
formed
on the same type of support, or may be formed on different supports.
The aerosol-generating composition may comprise a carrier on which the aerosol-
generating material is provided. The carrier functions as a support on which
the
aerosol-generating material layer forms, easing manufacture. The carrier may
provide
tensile strength to the aerosol-generating material layer, easing handling.
In some cases, the carrier may be formed from materials selected from metal
foil,
paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as
graphite
and graphene, plastic, cardboard, wood or combinations thereof. In some cases,
the
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carrier may comprise or consist of a tobacco material, such as a sheet of
reconstituted
tobacco. In some cases, the carrier may be formed from materials selected from
metal
foil, paper, cardboard, wood or combinations thereof. In some cases, the
carrier itself
be a laminate structure comprising layers of materials selected from the
preceding lists.
In some cases, the carrier may also function as a flavour carrier. For
example, the
carrier may be impregnated with a flavour or with tobacco extract.
In some cases, the carrier may be magnetic. This functionality may be used to
fasten
the carrier to the non-combustible aerosol provision device in use, or may be
used to
io generate particular aerosol-generating material shapes. In some cases,
the aerosol-
generating composition may comprise one or more magnets which can be used to
fasten the material to an induction heater in use.
In some cases, the carrier may be substantially or wholly impermeable to gas
and/or
aerosol. This prevents aerosol or gas passage through the carrier layer,
thereby
controlling the flow and ensuring it is delivered to the user. This can also
be used to
prevent condensation or other deposition of the gas/aerosol in use on, for
example, the
surface of a heater provided in an aerosol generating assembly. Thus,
consumption
efficiency and hygiene can be improved in some cases.
In some cases, the surface of the carrier that abuts the aerosol-generating
material may
be porous. For example, in one case, the carrier comprises paper. A porous
carrier
such as paper has been found to be particularly suitable; the porous (e.g.
paper) layer
abuts the aerosol-generating material layer and forms a strong bond. The
aerosol-
generating material may be formed by drying a gel and, without being limited
by
theory, it is thought that the slurry from which the gel is formed partially
impregnates
the porous carrier (e.g. paper) so that when the gel sets, the carrier is
partially bound
into the gel. This provides a strong binding between the gel and the carrier
(and
between the dried gel and the carrier).
In some embodiments, the aerosol-generating material may be laminated to a
carrier,
such as a paper sheet.
In some embodiments, when the aerosol-generating material is formed from a
slurry as
described herein, the layer of slurry may be formed on a carrier, such as a
paper sheet.
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Additionally, surface roughness may contribute to the strength of bond between
the
aerosol-generating material and the carrier. The paper roughness (for the
surface
abutting the carrier) may suitably be in the range of 50-1000 Bekk seconds,
suitably
50-150 Bekk seconds, suitably loo 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".)
io Conversely, the surface of the carrier 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 carrier 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 carrier 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
20 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 from being absorbed into the paper which could
25 weaken its structural integrity.
In some cases, the carrier is formed from or comprises metal foil, such as
aluminium
foil. A metallic carrier may allow for better conduction of thermal energy to
the
aerosol-generating material. Additionally, or alternatively, a metal foil may
function as
30 a susceptor in an induction heating system. In particular embodiments,
the carrier
comprises a metal foil layer and a support layer, such as cardboard. In these
embodiments, the metal foil layer may have a thickness of less than 20 pan,
such as
from about 1 !_trn to about 10 um, suitably about 5 ium.
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In some cases, the carrier may have a thickness of between about 0.010 mm and
about
2.0 mm, suitably from about 0.015 mm, 0.02 MM, 0.05 min or 0.1 Min to about
1.5
mm, 1.0 mm, or 0.5 mm.
Where the aerosol-generating composition comprises two or more aerosol-
generating
materials in sheet form, the sheets may be formed on the same carrier, may be
formed
on the same type of carrier, or may be formed on different carrier.
The two or more aerosol-generating materials are included in the aerosol-
generating
composition. These aerosol-generating materials include different active
substances.
The aerosol-generating materials may, otherwise, be the same. Alternatively
the
materials may differ in one or more further ways.
For example, the aerosol-generating materials may have different thicknesses
and/or
that may be provided in otherwise different sizes, such as cut to different
dimensions or
average particle sizes.
The density of the aerosol-generating materials may be different.
In some embodiments, the aerosol-generating materials include different
components
or the same components in different amounts.
The two or more aerosol-generating materials may be included in the aerosol-
generating material in different amounts.
In some embodiments, the different aerosol-generating materials may be mixed
to form
a largely homogenous blend. In other embodiments, the distribution of the
different
aerosol-generating materials is controlled to provide a desired distribution
within the
composition, optionally with the materials being unmixed or substantially
unmixed.
Where the aerosol-generating composition comprises a blend of two or more
different
aerosol-generating materials this may control the release of the active
agents. For
example, the blend may provide a consistent release throughout use of the
consumable,
and may be configured/formulated to provide either a rapid release or a slow
release.
Consumable
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In another aspect of the disclosure, there is provided a consumable for use in
a non-
combustible aerosol provision device, the consumable comprising an aerosol-
generating composition comprising a first aerosol-generating material
comprising an
active substance which is a constituent, derivative or extract of cannabis and
a gelling
agent, and a second aerosol-generating material comprising a different active
substance
and a gelling agent, as described above.
In some embodiments, the disclosure relates to consumables comprising aerosol-
generating composition and configured to be used with non-combustible aerosol
io provision devices. These consumables are sometimes referred to as
articles throughout
the disclosure.
Articles of the present invention may be provided in any suitable shape or
configuration. 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 shredded sheets of the two or more aerosol-generating
materials.
Optionally these shredded sheets are blended with another aerosol-generating
material,
such as cut tobacco or another botanical material.
Alternatively, or additionally, the article provided as a rod may include one
or more
sheets of aerosol-generating composition circumscribing a rod of aerosol-
generating
material (e.g. tobacco, an aerosol-generating material such as described
herein or a
combination thereof).
In some embodiments, the two or more different aerosol generating materials
are
arranged or located in different sections of the consumable.
For example, the aerosol-generating composition may be provided in the
consumable
in the form of a rod of material.
In some embodiments, the rod may be made up of cylindrical sections of
different
aerosol-generating material arranged along the longitudinal axis of the rod.
In other
embodiments, the sections of different aerosol-generating material may be
arranged
around the longitudinal axis of the rod. In yet other embodiments, the rod may
comprise an inner section of one aerosol-generating material extending along
the
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longitudinal axis of the rod, and surrounded by one or more sections of other
aerosol-
generating material(s).
In some embodiments, the article comprises a layer portion of aerosol-
generating
material disposed on a carrier. In examples, the article may have at least one
substantially planar (flat) surface. In such embodiments, the consumable may
be
provided in a shape or configuration other than a rod.
In some such embodiments, there is provided a consumable for use in a non-
io combustible aerosol-provision system comprising a planar support with
complete
coverage of the aerosol-generating material (e.g. a continuous aerosol-
generating film
comprising one or more of the aerosol-generating materials described herein).
Figure 8
provides a schematic illustration of an exploded view of such a consumable,
which
includes a support layer 54 and an aerosol-generating material layer 52.
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. Each of
the
20 one or more discrete portions or regions of aerosol-generating material
may comprise
one of the aerosol-generating materials described herein, or may comprise a
combination of two or more aerosol-generating materials. Discrete portions of
different aerosol-generating materials may be heated separately.
25 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-
30 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-
35 generating film (which comprises a discrete portion of aerosol-
generating material
(403)) are provided on the consumable.
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In some embodiments, a planar consumable comprising an aerosol-generating
composition comprising two aerosol-generating materials which can be heated by
a
heater. These may be arranged as two distinct portions or areas of the two
aerosol-
generating materials. The first aerosol-generating material comprises an
active
substance which is a constituent, derivative or extract of cannabis and a
gelling agent,
and the second aerosol-generating material comprises a different active
substance and
a gelling agent.
The portions or areas of the two aerosol-generating materials may be adjoining
or
io abutting, or they may be separated by areas without aerosol-generating
materials.
In a further exemplary embodiment, a planar consumable comprises an aerosol-
generating composition comprising six (as shown in Figure 9) or nine aerosol-
generating materials which can be heated by a planer heater. The first aerosol-
generating material comprises an active substance which is a constituent,
derivative or
extract of cannabis and a gelling agent, and the second and further aerosol-
generating
materials comprise a different active substance and a gelling agent.
The portions or areas of the aerosol-generating materials may be adjoining or
abutting,
or they may be separated by areas without aerosol-generating materials (as
shown in
Figure 9). The portions may be arranged as portions arranged in a single row
or in
multiple rows, such as, for nine portions, three rows of three portions. Two
or more
portions may comprise the same aerosol-generating material. Alternatively, the
portions may all be different.
The consumable may be used with any suitable non-combustible aerosol provision
device.
A consumable is an article comprising or consisting of aerosol-generating
composition,
part or all of which is intended to be consumed during use by a user. A
consumable
may comprise one or more other components, such as an aerosol-generating
composition storage area, an aerosol-generating composition transfer
component, an
aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or
an aerosol-
modifying agent. A consumable may also comprise an aerosol generator, such as
a
heater, that emits heat to cause the aerosol-generating composition to
generate aerosol
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in use. The heater may, for example, comprise combustible material, a material
heatable by electrical conduction, or a susceptor.
A susceptor is a material that is heatable by penetration with a varying
magnetic field,
such as an alternating magnetic field. The susceptor may be an electrically-
conductive
material, so that penetration thereof with a varying magnetic field causes
induction
heating of the heating material. The heating material may be magnetic
material, so that
penetration thereof with a varying magnetic field causes magnetic hysteresis
heating of
the heating material. The susceptor may be both electrically-conductive and
magnetic,
io so that the susceptor is heatable by both heating mechanisms. The device
that is
configured to generate the varying magnetic field is referred to as a magnetic
field
generator, herein.
An aerosol-modifying agent is a substance, typically located downstream of the
aerosol
generation area, that is configured to modify the aerosol generated, for
example by
changing the taste, flavour, acidity or another characteristic of the aerosol.
The aerosol-
modifying agent may be provided in an aerosol-modifying agent release
component
that is operable to selectively release the aerosol-modifying agent.
The aerosol-modifying agent may, for example, be an additive or a sorbent. The
aerosol-modifying agent may, for example, comprise one or more of a
flavourant, a
colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for
example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in
powder,
thread or granule form. The aerosol-modifying agent may be free from
filtration
material.
An aerosol generator is an apparatus configured to cause aerosol to be
generated from
the aerosol-generating material. In some embodiments, the aerosol generator is
a
heater configured to subject the aerosol-generating composition to heat
energy, so as to
release one or more volatiles from the aerosol-generating composition to form
an
aerosol. In some embodiments, the aerosol generator is configured to cause an
aerosol
to be generated from the aerosol-generating composition without heating. For
example, the aerosol generator may be configured to subject the aerosol-
generating
composition to one or more of vibration, increased pressure, or electrostatic
energy.
Non-combustible aerosol provision system
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In another aspect of the disclosure, there is provided a non-combustible
aerosol
provision system comprising the consumable described herein and a non-
combustible
aerosol provision device.
According to the present disclosure, a "non-combustible" aerosol provision
system is
one where a constituent aerosol-generating composition of the aerosol
provision
system (or component thereof) is not combusted or burned in order to
facilitate
delivery of at least one substance to a user.
io In some embodiments, the delivery system is a non-combustible aerosol
provision
system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an
aerosol-
generating material heating system, also known as a heat-not-burn system. An
example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision device is a heat-
not-burn
device.
In some embodiments, the non-combustible aerosol provision system is a hybrid
system to generate aerosol using a combination of aerosol-generating
compositions,
one or a plurality of which may be heated. In some embodiments, the hybrid
system
comprises the aerosol-generating composition described herein comprising or
consisting of the aerosol-generating material and an additional liquid or gel
aerosol-
generating composition.
In some embodiments, the non-combustible aerosol provision device is an
electronic
tobacco hybrid device.
Typically, the non-combustible aerosol provision system may comprise a non-
combustible aerosol provision device and a consumable for use with the non-
combustible aerosol provision device.
In some embodiments, the non-combustible aerosol provision system, such as a
non-
combustible aerosol provision device thereof, may comprise a power source and
a
controller. The power source may, for example, be an electric power source or
an
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exothermic power source. In some embodiments, the exothermic power source
comprises a carbon substrate which may be energised so as to distribute power
in the
form of heat to an aerosol-generating material or to a heat transfer material
in
proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system, such as a
non-
combustible aerosol provision device thereof, may comprise an area for
receiving the
consumable, an aerosol generator, an aerosol generation area, a housing, a
mouthpiece,
a filter and/or an aerosol-modifying agent.
The non-combustible aerosol provision system or device may comprise a heater
configured to heat but not burn the aerosol generating substrate. 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. In yet further cases, the heater may
be a
combustible heat source or a chemical heat source which undergoes an
exothermic
reaction to produce heat in use.
In some cases, the heater may heat but not burn the aerosolisable material(s)
to
between 120 C and 350 C in use. In some cases, the heater may heat but not
burn the
aerosolisable material(s) to between 140 C and 250 C in use. In some cases in
use,
substantially all of the aerosol-generating material is less than about 4 mm,
3 mm, 2
mm or 1 mm from the heater. In some cases, the solid is disposed between about
0.017
mm and 2.0 mm from the heater, suitably between about 0.1 mm and 1.0 mm. These
minimum distances may, in some cases, reflect the thickness of a carrier that
supports
the aerosol-generating material. In some cases, a surface of the aerosol-
generating
material may directly abut the heater.
In some cases, the heater may be embedded in the aerosol-generating
composition. In
some such cases, the heater may be an electrically resistive heater (with
exposed
contacts for connection to an electrical circuit). In other such cases, the
heater may be
a susceptor embedded in the aerosol-generating composition, which is heated by
induction.
The non-combustible aerosol provision system 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
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such that they condense to form an aerosol. It may also act to space the very
hot parts
of the apparatus from the user. The filter, if present, may comprise any
suitable filter
known in the art such as a cellulose acetate plug.
In some cases, the non-combustible aerosol provision system may be a heat-not-
burn
system. That is, it may contain a solid material (and no liquid aerosolisable
material).
A heat-not-burn device is disclosed in WO 2015/062983 A2, which is
incorporated by
reference in its entirety.
io In some cases, the non-combustible aerosol provision system may comprise
an
electronic tobacco hybrid device. That is, it may contain a solid
aerosolisable material
and a liquid aerosolisable material. The separate aerosolisable materials may
be heated
by separate heaters, the same heater or, in one case, a downstream
aerosolisable
material may be heated by a hot aerosol which is generated from the upstream
aerosolisable material. An electronic tobacco hybrid device is disclosed in WO
2016/135331 Al, which is incorporated by reference in its entirety.
The consumable may alternatively be referred to herein as a cartridge. The
consumable
may be adapted for use in a THP, an electronic tobacco hybrid device or
another
20 aerosol generating device. In some cases, the consumable may
additionally comprise a
filter and/or cooling element, as described previously. In some cases, the
consumable
may be circumscribed by a wrapping material such as paper.
The consumable may additionally comprise ventilation apertures. These may be
25 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.
30 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
35 the aerosol particles of the heated volatilised components increases by
further
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condensation of the heated volatilised components and by coagulation of newly
formed
droplets from the heated volatilised components.
In some cases, the ratio of the cool air to the sum of the heated volatilised
components
and the cool air, known as the ventilation ratio, is at least 15%. A
ventilation ratio of
15% enables the heated volatilised components to be made visible by the method
described above. The visibility of the heated volatilised components enables
the user to
identify that the volatilised components have been generated and adds to the
sensory
experience of the smoking experience.
In another example, the ventilation ratio is between 50% and 85% to provide
additional
cooling to the heated volatilised components. In some cases, the ventilation
ratio may
be at least 60% or 65%.
Referring to Figures 1 and 2, there are shown a partially cut-away section
view and a
perspective view of an example of article consumable 101 ("article"). The
article 101 is
adapted for use with a device having a power source and a heater. The article
101 of
this embodiment is particularly suitable for use with the device 51 shown in
Figures 5 to
7, described below. In use, the article 101 may be removably inserted into the
device
shown in Figure 5 at an insertion point 20 of the device 51.
The article 101 of one example is in the form of a substantially cylindrical
rod that
includes a body of aerosol-generating composition 103 and a filter assembly
105 in the
form of a rod. The aerosol-generating composition comprises 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 in. 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
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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
in. The
mouth end segment 111 is located towards the proximal end 113 of the article
101,
adjacent the filter segment 109. In one example, the filter segment 109 is in
an abutting
relationship with the mouth end segment iii. In one embodiment, the total
length of
the filter assembly 105 is between 37 mm and 45 mm, more preferably, the total
length
io of the filter assembly 105 is 41 mm.
In one example, the rod of aerosol-generating composition 103 is between 34 mm
and
50 mm in length, suitably between 38 mm and 46 mm in length, suitably 42 mm in
length.
In one example, the total length of the article 101 is between 71 mm and 95
mm,
suitably between 79 mm and 87 mm, suitably 83 mm.
An axial end of the body of aerosol-generating composition 103 is visible at
the distal
20 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
25 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 58 GSM standard tipping base paper.
In one
example the tipping paper has a length of between 42 mm and 50 mm, suitably of
46
30 mm.
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
35 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
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bending moments that might arise during manufacture and whilst the article 101
is in
use during insertion into the device 51. In one example, the thickness of the
wall of the
cooling segment 107 is approximately 0.29 MM.
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 C between a heated
volatilised
io 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 6o C
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 51. 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 51, then the
temperature sensitive filter segment may 109 become damaged in use, so it
would not
perform its required functions as effectively.
In one example the length of the cooling segment 107 is at least 15 mm. In one
example,
the length of the cooling segment 107 is between 20 mm and 30 mm, more
particularly
23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm.
The cooling segment 107 is made of paper, which means that it is comprised of
a
material that does not generate compounds of concern, for example, toxic
compounds
when in use adjacent to the heater of the device 51. In one example, the
cooling
segment 107 is manufactured from a spirally wound paper tube which provides a
hollow internal chamber yet maintains mechanical rigidity. Spirally wound
paper tubes
are able to meet the tight dimensional accuracy requirements of high-speed
manufacturing processes with respect to tube length, outer diameter, roundness
and
straightness.
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In another example, the cooling segment 107 is a recess created from stiff
plug wrap or
tipping paper. The stiff plug wrap or tipping paper is manufactured to have a
rigidity
that is sufficient to withstand the axial compressive forces and bending
moments that
might arise during manufacture and whilst the article 101 is in use during
insertion into
the device 51.
The filter segment 109 may be formed of any filter material sufficient to
remove one or
more volatilised compounds from heated volatilised components from the aerosol-
generating material. In one example the filter segment 109 is made of a mono-
acetate
io 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 flavour or aerosol-former
composition.
20 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.
In one example, the filter segment 109 is between 6 mm to lo mm in length,
suitably 8
mm.
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The mouth end segment 111 is an annular tube and is located around and defines
an air
gap within the mouth end segment iii. The air gap provides a chamber for
heated
volatilised components that flow from the filter segment 109. The mouth end
segment
tit is hollow to provide a chamber for aerosol accumulation yet rigid enough
to
withstand axial compressive forces and bending moments that might arise during
manufacture and whilst the article is in use during insertion into the device
51. In one
example, the thickness of the wall of the mouth end segment 111 is
approximately 0.29
mm. In one example, the length of the mouth end segment in is between 6 mm to
10
io mm, suitably 8 mm.
The mouth end segment in 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 iii 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 in 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.
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 the
article 301.
The ventilation holes may be located in the cooling segment 307 to aid with
the cooling
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of the article 301. In one example, the ventilation region 317 comprises one
or more
rows of holes, and preferably, each row of holes is arranged circumferentially
around
the article 301 in a cross-section that is substantially perpendicular to a
longitudinal
axis of the article 301.
In one example, there are between one to four rows of ventilation holes to
provide
ventilation for the article 301. Each row of ventilation holes may have
between 12 to 36
ventilation holes 317. The ventilation holes 317 may, for example, be between
100 to
500 p.m in diameter. In one example, an axial separation between rows of
ventilation
io holes 317 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.
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 iimm
from the
proximal end 313 of the article, suitably between 17 mm and 20 mm 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 17 mm and 20 mm from the
proximal
end 313 of the article 301 enables the ventilation holes 317 to be located
outside of the
device 51, when the article 301 is fully inserted in the device 51, as can be
seen in
Figures 6 and 7. By locating the ventilation holes outside of the device, non-
heated air
is able to enter the article 301 through the ventilation holes from outside
the device 51
to aid with the cooling of the article 301.
The length of the cooling segment 307 is such that the cooling segment 37 will
be
partially inserted into the device 51, when the article 301 is fully inserted
into the device
51. The length of the cooling segment 307 provides a first function of
providing a
physical gap between the heater arrangement of the device 51 and the heat
sensitive
filter arrangement 309, and a second function of enabling the ventilation
holes 317 to
be located in the cooling segment, whilst also being located outside of the
device 51,
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when the article 301 is fully inserted into the device 51. As can be seen from
Figures 6
and 7, the majority of the cooling element 307Th located within the device 51.
However,
there is a portion of the cooling element 307 that extends out of the device
51. It is in
this portion of the cooling element 307 that extends out of the device 51 in
which the
ventilation holes 317 are located.
Referring now to Figures 5 to 7 in more detail, there is shown an example of a
device 51
arranged to heat aerosol-generating composition to volatilise at least one
component of
said aerosol-generating composition, typically to form an aerosol which can be
inhaled.
io The device 51 is a heating device which releases compounds by heating,
but not
burning, the aerosol-generating composition.
A first end 53 is sometimes referred to herein as the mouth or proximal end 53
of the
device 51 and a second end 55 is sometimes referred to herein as the distal
end 55 of the
device 51. The device 51 has an on/off button 57t0 allow the device 51 as a
whole to be
switched on and off as desired by a user.
The device 51 comprises a housing 59 for locating and protecting various
internal
components of the device 51. In the example shown, the housing 59 comprises a
uni-
body sleeve ii that encompasses the perimeter of the device 51, capped with a
top panel
17 which defines generally the 'top' of the device 51 and a bottom panel 19
which defines
generally the 'bottom' of the device 51. In another example the housing
comprises a
front panel, a rear panel and a pair of opposite side panels in addition to
the top panel
17 and the bottom panel 19.
The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-
body
sleeve ii, to permit easy access to the interior of the device 51, or may be
"permanently"
fixed to the uni-body sleeve ii, for example to deter a user from accessing
the interior of
the device 51. In an example, the panels 17 and 19 are made of a plastics
material,
including for example glass-filled nylon formed by injection moulding, and the
uni-
body sleeve ii is made of aluminium, though other materials and other
manufacturing
processes may be used.
The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the
device 51
through which, in use, the article 101, 301 including the aerosol-generating
composition
may be inserted into the device 51 and removed from the device 51 by a user.
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The housing 59 has located or fixed therein a heater arrangement 23, control
circuitry
25 and a power source 27. In this example, the heater arrangement 23, the
control
circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent
when
viewed from an end), with the control circuitry 25 being located generally
between the
heater arrangement 23 and the power source 27, though other locations are
possible.
The control circuitry 25 may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the aerosol-
generating
io 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 composition without causing
the aerosol-
generating composition to burn).
An advantage of locating the power source 27 laterally adjacent to the heater
arrangement 23 is that a physically large power source 25 may be used without
causing
the device 51 as a whole to be unduly lengthy. As will be understood, in
general a
physically large power source 25 has a higher capacity (that is, the total
electrical
energy that can be supplied, often measured in Amp-hours or the like) and thus
the
battery life for the device 51 can be longer.
In one example, the heater arrangement 23 is generally in the form of a hollow
cylindrical tube, having a hollow interior heating chamber 29 into which the
article 101,
301 comprising the aerosol-generating composition 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
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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
io material 103, 303 of the article 101, 301 is inserted into the heater
arrangement 23
when the article 101, 301 is inserted into the device 51.
The or each heating element may be arranged so that selected zones of the
aerosol-
generating composition can be independently heated, for example in turn (over
time, as
discussed above) or together (simultaneously) as desired.
The heater arrangement 23 in this example is surrounded along at least part of
its
length by a thermal insulator 31. The insulator 31 helps to reduce heat
passing from the
heater arrangement 23 to the exterior of the device 51. This helps to keep
down the
power requirements for the heater arrangement 23 as it reduces heat losses
generally.
The insulator 31 also helps to keep the exterior of the device 51 cool during
operation of
the heater arrangement 23. In one example, the insulator 31 may be a double-
walled
sleeve which provides a low pressure region between the two walls of the
sleeve. That
is, the insulator 31 may be for example a "vacuum" tube, i.e. a tube that has
been at
least partially evacuated so as to minimise heat transfer by conduction and/or
convection. Other arrangements for the insulator 31 are possible, including
using heat
insulating materials, including for example a suitable foam-type material, in
addition to
or instead of a double-walled sleeve.
The housing 59 may further comprises various internal support structures 37
for
supporting all internal components, as well as the heating arrangement 23.
The device 51 further comprises a collar 33 which extends around and projects
from the
opening 20 into the interior of the housing 59 and a generally tubular chamber
35
which is located between the collar 33 and one end of the vacuum sleeve 31.
The
chamber 35 further comprises a cooling structure 35f, which in this example,
comprises
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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 51 over at least part of the length of the hollow
chamber 35. The
air gap 36 is around all of the circumference of the article Ka, 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
6o take
io 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 6o. The ridges 6o are configured to engage with an article
101, 301
inserted into the device to assist in securing it within the device 51. Open
spaces (not
shown in the Figures) defined by adjacent pairs of ridges 6o and the article
101, 301
form ventilation paths around the exterior of the article 101, 301. These
ventilation
paths allow hot vapours that have escaped from the article 101, 301 to exit
the device 51
and allow cooling air to flow into the device 51 around the article 101, 301
in the air gap
36.
In operation, the article 101, 301 is removably inserted into an insertion
point 20 of the
device 51, as shown in Figures 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 51. The proximal end 113, 313 of the article 104
301
extends from the device 51 and acts as a mouthpiece assembly for a user.
In operation, the heater arrangement 23 will heat the article 101, 301 to
volatilise at
least one component of the aerosol-generating 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
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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.
io Method of manufacture
In another aspect, there is provided a method of forming an aerosol-generating
composition comprising a first aerosol-generating material comprising an
active
substance which is a constituent, derivative or extract of cannabis and a
gelling agent,
and a second aerosol-generating material comprising a different active
substance and a
gelling agent, as described above.
The method comprises forming each aerosol generating material by:
(a) providing a slurry comprising the active substance, gelling agent,
aerosol-forming agent, a solvent and any optional further components of the
aerosol-
generating material;
(b) forming a layer of the slurry;
(c) optionally setting the layer of the slurry; and
(d) drying the slurry to form the aerosol-generating material.
Another aspect of the invention provides a method of making the consumable or
system
as previously described. This method comprises a method of making the aerosol-
generating materials and incorporating these aerosol-generating materials into
the
consumable or system. The method may comprise (a) forming a slurry comprising
components of the aerosol-generating material or precursors thereof, (b)
forming a
layer of the slurry, and (c) optionally setting the slurry, (d) drying to form
an aerosol-
generating material, and (e) incorporating the resulting aerosol-generating
material
into the consumable or system.
In step (a), the constituent, derivative or extract of cannabis and/or other
active
substance may first be dissolved in the aerosol-former material and the
resulting
solution then added to the other components of the slurry.
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The step (b) in the above methods of forming a layer of the slurry may
comprise
spraying, casting or extruding the slurry, for example. In some cases, the
layer is
formed by electrospraying the slurry. In some cases, the layer is formed by
casting the
slurry.
In some cases, the steps (b) and/or (c) and/or (d) may, at least partially,
occur
simultaneously (for example, during electrospraying). In some cases, these
steps may
occur sequentially.
In some cases, a setting agent (such as a calcium source) may be added to the
slurry
before or during step (b). This is appropriate in instances where gelation
occurs
relatively slowly (e.g. with alginate gelling agent), and thus the slurry may
be, e.g. cast,
after the setting agent is added.
In other cases, the step (c) of optionally setting the slurry may comprise the
addition of
a setting or cross-linking agent to the slurry layer. The setting or cross-
linking agent
may be sprayed onto the slurry, for example, or may be preloaded onto the
surface on
which the slurry is layered. Step (c) therefore involves cross-linking, for
example cross-
linking the gelling agent.
For example, a setting or cross-linking agent comprising a calcium source
(such as
calcium chloride or calcium citrate), may be added to a slurry containing
alginate
and/or pectin to form a calcium-crosslinked alginate/pectin gel. In some cases
where
gelation occurs rapidly (such as those in which a pectin gelling agent is
used), the
calcium should be added after casting (because the slurry is too viscous to
cast).
The total amount of the setting or cross-linking agent, such as a calcium
source, may be
0.5-5 wt% (calculated on a dry weight basis). It has been found that the
addition of too
little setting or cross-linking agent may result in a gel which does not
stabilise any
optional flavour and results in the flavour dropping out of the gel. It has
also been
found that the addition of too much setting or cross-linking agent results in
a gel that is
very tacky or very brittle and consequently has poor handleability.
Alginate salts are derivatives of alginic acid and are typically high
molecular weight
polymers (10-600 kDa). Alginic acid is a copolymer of P-D-mannuronic (M) and a-
L-
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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 may 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%, 6o% or 70% of the
monomer
units in the alginate copolymer are a-L-guluronic acid (G) units.
In some cases, the slurry may be warmed prior to and during casting. This can
slow
gelation, improving handleability and easing the casting process. Further,
warming the
slurry may melt optional flavour components (e.g. menthol) easing
handleability.
In some cases, menthol or other optional flavours may be distributed through
the slurry
in powder form. In some cases, menthol or other flavours may be molten in the
slurry
(where it is warmed). In such cases, an emulsifying agent such as acacia gum
may be
added to disperse molten menthol in the slurry.
In some cases, the slurry may be cast onto a bandcast sheet. The sheet may be
loaded
with a releasing agent, such as lecithin, which can aid separation of the
bandcast and
the aerosol-generating material.
In some embodiments the slurry solvent comprises, or is, one or more of water,
ethanol, methanol, dimethyl sulfoxide, acetone, hexane, and toluene.
In particular embodiments, the slurry solvent may comprise water. In some
cases, the
slurry solvent may consist essentially of or consist of water.
In some cases, the slurry may comprise from about 50 wt%, 6o wt%, 70 wt%, 8o
wt% or
90 wt% of solvent (WWB).
In some examples, the slurry has a viscosity of from about 1 to about 20 Pa.s
at 46.5 C,
such as from about 10 to about 20 Pa-s at 46.5 C, such as from about 14 to
about 16
Pa-s at 46.5 C.
The discussion herein relating to the aerosol-generating material is
explicitly disclosed
in combination with any slurry aspect of the invention.
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Example
An exemplary first aerosol-generating material comprising an active substance
which is
a constituent, derivative or extract of cannabis was formulated as follows:
Inclusion level
Ingredient
(% w/w)
Glycerol 30
Propylene glycol (PG) 20
Carboxymethyl cellulose (CMC) 40
Cannabidiol (CBD) 10
The resultant sheet or film of aerosol-generating material had a total mass of
400 g, of
which 340 g (or 340 ml) was water, providing a total dry mass of 6o g.
A second aerosol-generating material comprising a different active substance
may be
made, for example, by replacing the CBD with 10% w/w of a different active
agent.
Definitions
As used herein, the term "tobacco material" refers to any material comprising
tobacco
or derivatives therefore. The term "tobacco material" may include one or more
of
tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or
tobacco
substitutes. The tobacco material may comprise one or more of ground tobacco,
tobacco fibre, cut tobacco, extruded tobacco, tobacco stern, reconstituted
tobacco
and/or tobacco extract.
The tobacco used to produce tobacco material may be any suitable tobacco, such
as
single grades or blends, cut rag or whole leaf, including Virginia and/or
Burley and/or
Oriental. It may also be tobacco particle 'fines' or dust, expanded tobacco,
stems,
expanded stems, and other processed stem materials, such as cut rolled stems.
The
tobacco material may be a ground tobacco or a reconstituted tobacco material.
The
reconstituted tobacco material may comprise tobacco fibres, and may be formed
by
casting, a Fourdrinier-based paper making-type approach with back addition of
tobacco
extract, or by extrusion.
All percentages by weight described herein (denoted wt%) are calculated on a
dry
weight basis (DWB), unless explicitly stated otherwise. All weight ratios are
also
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calculated on a dry weight basis. A weight quoted on a dry weight basis refers
to the
whole of the extract or slurry or material, other than the water or other
solvent, 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 or other solvent.
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'
io or "consists of" in place of "comprises". Reference to a material
"comprising" certain
features means that those features are included in, contained in, or held
within the
material.
The above embodiments are to be understood as illustrative examples of the
invention.
It is to be understood that any feature described in relation to any one
embodiment
may be used alone, or in combination with other features described, and may
also be
used in combination with one or more features of any other of the embodiments,
or any
combination of any other of the embodiments. Furthermore, equivalents and
modifications not described above may also be employed without departing from
the
scope of the invention, which is defined in the accompanying claims.
The various embodiments described herein are presented only to assist in
understanding
and teaching the claimed features. These embodiments are provided as a
representative sample of embodiments only, and are not exhaustive and/or
exclusive. It
is to be understood that advantages, embodiments, examples, functions,
features,
structures, and/or other aspects described herein are not to be considered
limitations on
the scope of the invention as defined by the claims or limitations on
equivalents to the
claims, and that other embodiments maybe utilised and modifications may be
made
without departing from the scope of the claimed invention. Various embodiments
of the
invention may suitably comprise, consist of, or consist essentially of,
appropriate
combinations of the disclosed elements, components, features, parts, steps,
means, etc.,
other than those specifically described herein. In addition, this disclosure
may include
other inventions not presently claimed, but which maybe claimed in future.
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