Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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AEROSOL GENERATION
Technical Field
The present invention relates to aerosol generation.
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 aerosol or vapour by releasing compounds from a substrate material
by
heating without burning. These may be referred to as non-combustible smoking
articles or aerosol generating assemblies.
One example of such a product is a heating device which release compounds
by heating, but not burning, a solid aerosol-generating composition. This
solid
aerosol-generating composition 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. Various different
arrangements for volatilising at least one component of the solid aerosol-
generating
composition 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 aerosol-generating composition (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 some embodiments described herein, there is provided an
aerosol-generating composition comprising an amorphous solid, the amorphous
solid
comprising:
(a) aerosol generating agent in an amount of from about 1 to about 80 wt% of
the amorphous solid;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler; and
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(d) a flavourant;
wherein the amount of gelling agent and any filler taken together is from
about 20
to about 75 wt% of the amorphous solid, these weights being calculated on a
dry
weight basis.
According to some embodiments described herein, there is provided an article
for
use with a non-combustible aerosol provision device, the article comprising an
aerosol-generating composition as described herein.
According to some embodiments described herein, there is provided a non-
combustible aerosol provision system comprising an article as described herein
and
a non-combustible aerosol provision device, wherein the non-combustible
aerosol
provision device is configured to generate aerosol from the article when the
article is
used with the non-combustible aerosol provision device.
According to some embodiments described herein, there is provided a slurry
comprising:
(a) about 1 to about 80 wt % aerosol generating agent;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler; and
(d) a flavourant;
the weights c/o being calculated on a dry weight basis, wherein the amount of
gelling agent and any filler taken together is from about 20 to about 75 wt%,
these
weights being calculated on a dry weight basis;
and
(e) a solvent.
According to some embodiments described herein, there is provided a
method of making an aerosol-generating composition, the aerosol-generating
composition comprising an amorphous solid, the method comprising:
(i) combining
(a) about 1 to about 80 wt % aerosol generating agent;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler, wherein the amount of gelling agent and any filler
taken
together is from about 20 to about 75 wt%; and
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(d) a flavourant;
the weights % being calculated on a dry weight basis, and
(e) a solvent,
to form a slurry;
(ii) forming a layer of the slurry;
(iii) setting the slurry to form a gel; and
(iv) drying the gel to form the amorphous solid.
According to some embodiments described herein, there is provided use of a
non-combustible aerosol provision system as described herein.
To the extent that they are combinable, features described herein in relation
to one aspect of the invention are explicitly disclosed in combination with
each and
every other aspect.
Further features and advantages of the invention will become apparent from
the following description of preferred embodiments of the invention, given by
way of
example only, which is made with reference to the accompanying drawings.
Brief Description of the Drawincis
Figure 1 shows a section view of an example of an aerosol-generating article.
Figure 2 shows a perspective view of the article of Figure 1.
Figure 3 shows a sectional elevation of an example of an aerosol-generating
article.
Figure 4 shows a perspective view of the article of Figure 3.
Figure 5 shows a perspective view of an example of an aerosol generating
assembly.
Figure 6 shows a section view of an example of an aerosol generating assembly.
Figure 7 shows a perspective view of an example of an aerosol generating
assembly.
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Detailed Description
The aerosol-generating compositions described herein are compositions that
are capable of generating aerosol, for example when heated, irradiated or
energized
in any other way. Aerosol-generating compositions may, for example, include
features in the form of a solid, liquid or gel which may or may not contain
nicotine.
The aerosol-generating compositions comprise an "amorphous solid", which may
alternatively be referred to as a "monolithic solid" (i.e. non-fibrous). In
some
embodiments, the amorphous solid may be a dried gel. The amorphous solid is a
solid material that may retain some fluid, such as liquid, within it.
In examples, there is provided an aerosol-generating composition. The
aerosol-generating composition is suitable to be comprised in an article for
use with a
non-combustible aerosol provision device.
The aerosol-generating composition comprises an amorphous solid and,
optionally, tobacco material. The amorphous solid comprises:
(a) aerosol generating agent in an amount of from about 1 to about 80 wt% of
the amorphous solid;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler; and
(d) a flavourant;
wherein the amount of gelling agent and any filler taken together is from
about 20
to about 75 wt% of the amorphous solid (i.e. the gelling agent and filler
taken
together account for about 20 to about 75 wt% of the amorphous solid).
In some embodiments, the amorphous solid comprises:
(a) aerosol generating agent in an amount of from about 35 to 80 wt% of the
amorphous solid;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler; and
(d) a flavourant in an amount of up to about 50 wt% of the amorphous solid;
wherein the amount of gelling agent and any filler taken together is from
about 20 to
65 wt% of the amorphous solid.
In examples, the amorphous solid comprises gelling agent and optionally
filler,
taken together, in an amount of from about 20 wt%, 25 wt%, 30 wt%, or 35 wt%
to
about 75 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the amorphous
solid.
In examples, the amorphous solid comprises gelling agent and optionally
filler, taken
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together, in an amount of from about 20 to 65 wt%, 20 to 60 wt%, 25 to 55 wt%,
30 to
50 wt%, or 35 to 45 wt% of the amorphous solid. In particular embodiments, the
amount of gelling agent and optionally filler, taken together, in the
amorphous solid is
from about 40 to about 55 or is about 50 wt%.
5 In examples, the amorphous solid comprises gelling agent (i.e. without
taking into
account the amount of filler) in an amount of from about 5 wt%, 10 wt%, 15
wt%, 20
wt%, 25 wt%, 30 wt%, or 35wt% to about 50wt%, or 45wt% of the amorphous solid.
In examples, the amorphous solid comprises gelling agent (i.e. without taking
into
account the amount of filler) in an amount of from about 5 to 50 wt%, 10 to 50
wt%,
25 to 50 wt%, 30 to 50w0/0, or 35 to 45 wt% of the amorphous solid. In
particular
embodiments, the amount of gelling agent in the amorphous solid is from about
20 to
about 35 wt% or is about 25 wt%.
The gelling agent comprises one or more cellulosic gelling agents. Examples of
cellulosic gelling agents include, but are not limited to, hydroxymethyl
cellulose,
hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC),
hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose,
cellulose
acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate
propionate
(CAP).
For example, in some embodiments, the gelling agent comprises (or is) one or
more of hydroxyethyl cellulose, hydroxypropyl cellulose,
carboxymethylcellulose,
guar gum, or acacia gum.
In addition to the one or more cellulosic gelling agents, the gelling agent
may
further include guar gum, acacia gum and mixtures thereof. In some examples,
guar
gum is comprised in the gelling agent in an amount of from about 3 to 40 wt%
of the
amorphous solid. That is, the amorphous solid comprises guar gum in an amount
of
from about 3 to 40 wt% by dry weight of the amorphous solid. In some examples,
the
amorphous solid comprises guar gum in an amount of from about 5 to 10 wt% of
the
amorphous solid. In some examples, the amorphous solid comprises guar gum in
an
amount of from about 15 to 40 wt% of the amorphous solid, or from about 20 to
40
wt%, or from about 15 to 35 wt%.
In particular embodiments, the gelling agent comprises (or is)
carboxymethylcellulose.
In some examples, carboxymethylcellulose is comprised in the gelling agent in
an
amount of from about 15 to 40 wt% of the amorphous solid. That is, the
amorphous
solid comprises carboxymethylcellulose in an amount of from about 15 to 40 wt%
by
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dry weight of the amorphous solid. In some examples, the amorphous solid
comprises carboxymethylcellulose in an amount of from about 20 to about 30 wt%
of
the amorphous solid, or in an amount of about 25 wt%.
In examples, the amorphous solid does not contain any alginate or pectin.
Alginate
and pectin gelling agents may be set by adding a setting agent (such as a
calcium
source) during formation of the amorphous solid. The amorphous solid may then
comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
There is
also the possibility that any calcium salts present in solvents used during
preparation
of the amorphous solid can cause premature crosslinking, which may complicate
the
preparation process. When using alginate or pectin gelling agents, distilled
water may
be used as a solvent to assist in avoiding premature crosslinking. Amorphous
solids
which do not comprise any alginate or pectin as the gelling agent may not
require use
of a setting agent and/or may not be at risk of premature crosslinking during
preparation.
The amorphous solid may comprise a filler. In examples, the amorphous solid
comprises filler in an amount of from about 1 wt%, 5 wt%, 10 wt% or 15 wt% of
the
amorphous solid, such as about 15 to 40 wt%. In examples, the amorphous solid
comprises filler in an amount of about 1 to 40 wt%, 5 to 40 wt%, 10 to 40 wt%,
20 to
40 wt%, or about 25 to 35 wt%. In examples, the amorphous solid comprises
filler in
an amount of about 1 to 20 wt%, 5 to 20 wt% or 10 to 20 wt%.
In examples, the amorphous solid comprises less than 20 wt.% filler, such as
less
than 10 wt.%, less than 5 wt.% or less than 1 wt.%. In some cases, the
amorphous
solid does not comprise filler.
The filler may comprise one or more inorganic filler materials, such as
calcium
carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica,
magnesium oxide,
magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such
as molecular sieves. The filler may comprise one or more organic filler
materials
such as wood pulp, cellulose and cellulose derivatives, for example
microcrystalline
cellulose (MCC). In particular cases, the amorphous solid comprises no calcium
carbonate such as chalk.
In some examples, the filler is fibrous. For example, the filler may be a
fibrous
organic filler material such as wood pulp, hemp fibre, cellulose or cellulose
derivatives. Without wishing to be bound by theory, it is believed that
including
fibrous filler in an amorphous solid may increase the tensile strength of the
material.
This may be particularly advantageous in examples wherein the amorphous solid
is
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provided as a sheet, such as when an amorphous solid sheet circumscribes a rod
of
tobacco material. In particular cases, the filler is wood pulp.
In some cases, the filler comprises maltodextrin or microcrystalline cellulose
(MCC).
As would be well understood by the skilled person, microcrystalline cellulose
may
be formed by depolymerising cellulose by a chemical process (e.g. using an
acid or
enzyme). One exemplary method for forming microcrystalline cellulose involves
acid
hydrolysis of cellulose, using an acid such as HCI. The cellulose produced
after this
treatment is crystalline (i.e. no amorphous regions remain). Suitable methods
and
conditions for forming microcrystalline cellulose are well-known in the art.
In some cases, the filler has a density of less than about 2 g/cm3, such as
less
than about 0.5 g/cm3 or less than about 0.3 g/cm3.
Without wishing to be bound by theory, it is also believed that including
filler in an
amorphous solid may facilitate reduction in tackiness of the solid. The
inventors
have found that tackiness may arise when higher wt% levels of aerosol
generating
agents such as glycerol are used in the amorphous solid. Excessive tackiness
may
be undesirable as it can cause problems with handleability when processing the
amorphous solid or the aerosol generating composition. For example, it may be
more difficult to shred a sheet of a tacky amorphous solid.
In particular embodiments, the gelling agent is carboxymethylcellulose and the
filler is wood pulp. Examples include amorphous solids comprising about 15 to
30
wt% or 20 to 30 wt% carboxymethylcellulose and about 15 to 30 wt% or 20 to 30
wt%
wood pulp, such as about 25 wt% carboxymethylcellulose and about 25 wt% wood
pulp.
In examples, the amorphous solid does not comprise tobacco fibres.
The amorphous solid comprises aerosol generating agent in an amount of about
1 wt% to about 80 wt% of the amorphous solid, such as about 10 to 80 wt%, 20
to 80
wt%, 5 to 35 wt%, 10 to 35 wt%, 10 to 30 wt%, 35 to 80 wt%, 40 to 80 wt%, 45
to 70
wt%, 45 to 60 wt%, or 50 to 60 wt%, such as about 50 or about 55 wt%.
The aerosol generating agent typically comprises one or more of glycerol,
propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol,
1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl
laurate, a diethyl
suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate,
benzyl phenyl
acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene
carbonate.
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In particular examples, the aerosol generating agent comprises glycerol,
optionally in
combination with propylene glycol.
The amorphous solid may have any suitable water content, such as from 1 wt %
to 15 wt%. Suitably, the water content of the amorphous solid is from about 5
wt%, 7
wt% or 9 wt% to about 15 wt%, 13 wt% or 11 wt% (VVVVB), for example from about
5
wt% to about 15 wt%, from about 7 wt% to about 13 wt% or from about 9 wt% to
about 11 wt%. The water content of the amorphous solid may, for example, be
determined by Karl-Fischer-titration or Gas Chromatography with Thermal
Conductivity Detector (GC-TCD).
In examples, the amorphous solid consists essentially of, or consists of,
gelling
agent, aerosol generating agent, filler, a flavourant, and water. In examples,
the
amorphous solid consists essentially of, or consists of, gelling agent,
aerosol
generating agent, a flavourant and water.
In examples, the amorphous solid comprises, consists essentially of, or
consists
of, carboxymethylcellulose, wood pulp, a flavourant (e.g. menthol), glycerol
and
water. Examples include amorphous solids comprising, consisting essentially
of, or
consisting of, about 15 to 30 wt% or 20 to 30 wt% carboxymethylcellulose,
about 15
to 30 wt% or 15 to 20 wt% wood pulp, about 30 to 50 wt% flavourant (e.g.
menthol)
and about 15 to 25 wt% glycerol, such as about 23 wt% carboxymethylcellulose,
about 18 wt% wood pulp, about 41 wt% menthol, and about 18 wt% glycerol.
The amorphous solid comprises a flavourant. The flavourant may be present in
an
amount of about 0.1wt%, 0.5 wt%, 1wr/o, 5wt%, 10wt%, 15wtc/o, 20wt%, 25wrk,
30wt% or 35wt% to about 45wV/0, 50wt /0 or 60wt% of flavour (all calculated on
a dry
weight basis). In exemplary embodiments, the aerosol-generating composition
comprises from about 1 wt%, 5 wt%, 10 wt%, 20 wt%, 30wt%, or 35wt% to about
42wt%, 45wt% or 47wV/0 of flavour. For example, the aerosol-generating
composition
may comprise 1-50wt%, 10-50wt 70, 20-50wt%, 30-45wt% or 35-45wt% flavourant
(e.g.
menthol).
As used herein, the terms "flavour" and/or "flavourant" which, where local
regulations permit, may be used to create a desired taste, aroma or other
somatosensorial sensation in a product for adult consumers. In some instances
such
constituents may be referred to as flavours, flavourants, cooling agents,
heating
agents, or sweetening agents. They may include naturally occurring flavour
materials, botanicals, extracts of botanicals, synthetically obtained
materials, or
combinations thereof (e.g., tobacco, cannabis, licorice (liquorice),
hydrangea,
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eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove,
maple,
matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian
spices,
Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach,
apple,
orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb,
grape,
durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie,
bourbon,
scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe
vera,
cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat,
naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil,
orange oil,
orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang,
sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from
any
species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass,
rooibos,
flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea
such as green
tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin,
oregano,
paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma,
cilantro,
myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm,
lemon
basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour
enhancers, bitterness receptor site blockers, sensorial receptor site
activators or
stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame
potassium,
aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose,
sorbitol, or
mannitol), and other additives such as charcoal, chlorophyll, minerals,
botanicals, or
breath freshening agents. They may be imitation, synthetic or natural
ingredients or
blends thereof. They may be in any suitable form, for example, liquid such as
an oil,
solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint. In some embodiments, the flavour comprises flavour components of
cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the
flavour
comprises eugenol. In some embodiments, the flavour comprises flavour
components extracted from tobacco. In some embodiments, the flavour comprises
flavour components extracted from cannabis. In some embodiments, the flavour
may
comprise a sensate, which is intended to achieve a somatosensorial sensation
which
are usually chemically induced and perceived by the stimulation of the fifth
cranial
nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves,
and these
may include agents providing heating, cooling, tingling, numbing effect. A
suitable
heat effect agent may be, but is not limited to, vanillyl ethyl ether and a
suitable
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cooling agent may be, but not limited to eucalyptol, or WS-3 (N-ethy1-2-
isopropy1-5-
methylcyclohexanecarboxamide).
In some embodiments, the flavour comprises, consists essentially of or
consists
of menthol, spearmint and/or peppermint. In some embodiments, the flavour
5 comprises, consists essentially of or consists of menthol.
In some embodiments, the amorphous solid additionally comprises an active
substance. For example, in some cases, the amorphous solid additionally
comprises
a tobacco material and/or nicotine. In some cases, the amorphous solid may
comprise
5-60wt% (calculated on a dry weight basis) of a tobacco material and/or
nicotine. In
10 some cases, the amorphous solid may comprise from about 1wr/o, 5wt 70,
10wt%,
15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or
30wt% (calculated on a dry weight basis) of an active substance. In some
cases, the
amorphous solid may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or
25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated
on a dry weight basis) of a tobacco material. For example, the amorphous solid
may
comprise 10-50wt%, 15-40wP/0 or 20-35wt% of a tobacco material. In some cases,
the
amorphous solid may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about
20wt%, 18wt%, 15wt% or 12wtc/o (calculated on a dry weight basis) of nicotine.
For
example, the amorphous solid may comprise 1-20wt%, 2-18wt% or 3-12wt% of
nicotine.
In particular examples, the amorphous solid does not comprise an active
substance. In particular examples, the amorphous solid does not comprise any
tobacco or tobacco extract.
The active substance, if present, may comprise a physiologically and/or
olfactory
active substance which is included in the aerosol-generating composition in
order to
achieve a physiological and/or olfactory response. The active substance may
for
example be selected from nutraceuticals, nootropics, and psychoactives. The
active
substance may be naturally occurring or synthetically obtained. The active
substance may comprise for example nicotine, caffeine, taurine, theine, a
vitamin
such as B6 or B12 or C, melatonin, a cannabinoid, or a constituent,
derivative, or
combinations thereof. In some embodiments, the active substance comprises
nicotine. In some embodiments, the active substance comprises caffeine,
melatonin
or vitamin B12. The active substance may comprise a constituent, derivative or
extract of tobacco or of another botanical such as cannabis, such as a
cannabinoid
or terpene. In some embodiments, the active substance is a physiologically
active
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substance and may be selected from nicotine, nicotine salts (e.g. nicotine
ditartrate/nicotine bitartrate), nicotine-free tobacco substitutes, other
alkaloids such
as caffeine, cannabinoids, or mixtures thereof.
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. Two of the most important cannabinoids are
tetrahydrocannabinol (THC) and cannabidiol (CBD). Cannabinoids may be
naturally
occurring (Phytocannabinoids) from plants such as cannabis, (endocannabinoids)
from animals, or artificially manufactured (Synthetic cannabinoids).
Cannabinoids
are cyclic molecules exhibiting particular properties such as the ability to
easily cross
the blood-brain barrier, weak toxicity, and few side effects. 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) and
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 (CB0), tetrahydrocannabmolic acid (THCA), and
tetrahydrocannabivarinic acid (THCV A).
In some embodiments, the active substance comprises one or more cannabinoid
compounds selected from the group consisting of: cannabidiol (CBD),
tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic
acid
(CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC),
cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV),
cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran
(CBT).
The active substance may comprise one or more cannabinoid compounds
selected from the group consisting of cannabidiol (CBD) and THC
(tetrahydrocannabinol).
The active substance may comprise cannabidiol (CBD).
The active substance may comprise nicotine and cannabidiol (CBD).
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The active substance may comprise nicotine, cannabidiol (CBD), and THC
(tetrahydrocannabinol).
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
or flavourant 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. Examples of botanicals are
tobacco,
eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint,
spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus,
laurel,
licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such
as green
tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay
leaves,
cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron,
lavender,
lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant,
curcuma,
turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis,
valerian,
pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi,
verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca,
ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof.
The mint may be chosen from the following mint varieties: Mentha arvensis,
Mentha
c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha
piperita
c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha
suaveolens
variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the botanical is selected from eucalyptus, star anise,
cocoa and hemp, particularly eucalyptus or star anise
In some embodiments, the botanical is selected from rooibos and fennel.
In some embodiments, the amorphous solid does not contain any botanical.
The aerosol-generating composition or the amorphous solid may comprise an
acid. The acid may be an organic acid. In some of these embodiments, the acid
may be at least one of a monoprotic acid, a diprotic acid and a triprotic
acid. In some
such embodiments, the acid may contain at least one carboxyl functional group.
In
some such embodiments, the acid may be at least one of an alpha-hydroxy acid,
carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some
such
embodiments, the acid may be an alpha-keto acid.
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In some such embodiments, the acid may be at least one of succinic acid,
lactic acid, benzoic acid, citric acid, tartaric acid, funnaric acid,
levulinic acid, acetic
acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and
pyruvic acid.
Suitably the acid is lactic acid. In other embodiments, the acid is benzoic
acid.
In other embodiments the acid may be an inorganic acid. In some of these
embodiments the acid may be a mineral acid. In some such embodiments, the acid
may be at least one of sulphuric acid, hydrochloric acid, boric acid and
phosphoric
acid. In some embodiments, the acid is levulinic acid.
Inclusion of an acid is particularly preferred in embodiments in which the
aerosol-generating composition or the amorphous solid comprises nicotine. In
such
embodiments, the presence of an acid may stabilise dissolved species in the
slurry
from which the aerosol-generating composition or the amorphous solid is
formed.
The presence of the acid may reduce or substantially prevent evaporation of
nicotine
during drying of the slurry, thereby reducing loss of nicotine during
manufacturing.
The amorphous solid may comprise a colourant. The addition of a colourant
may alter the visual appearance of the amorphous solid. The presence of
colourant
in the amorphous solid may enhance the visual appearance of the amorphous
solid
and the aerosol-generating composition. By adding a colourant to the amorphous
solid, the amorphous solid may be colour-matched to other components of the
aerosol-generating composition or to other components of an article comprising
the
amorphous solid.
A variety of colourants may be used depending on the desired colour of the
amorphous solid. The colour of amorphous solid may be, for example, white,
green,
red, purple, blue, brown or black. Other colours are also envisaged. Natural
or
synthetic colourants, such as natural or synthetic dyes, food-grade colourants
and
pharmaceutical-grade colourants may be used. In certain embodiments, the
colourant is caramel, which may confer the amorphous solid with a brown
appearance. In such embodiments, the colour of the amorphous solid may be
similar
to the colour of other components (such as tobacco material) in an aerosol-
generating composition comprising the amorphous solid. In some embodiments,
the
addition of a colourant to the amorphous solid renders it visually
indistinguishable
from other components in the aerosol-generating composition.
The colourant may be incorporated during the formation of the amorphous
solid (e.g. when forming a slurry comprising the materials that form the
amorphous
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solid) or it may be applied to the amorphous solid after its formation (e.g.
by spraying
it onto the amorphous solid).
The amorphous solid may be present on or in a support to form a substrate.
The support functions as a support on which the amorphous solid layer forms,
easing
manufacture. The support may provide rigidity to the amorphous solid layer,
easing
handling.
The support may be any suitable material which can be used to support an
amorphous solid. In some cases, the support may be formed from materials
selected
from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon
allotropes
such as graphite and graphene, plastic, cardboard, wood or combinations
thereof. In
some cases, the support may comprise or consist of a tobacco material, such as
a
sheet of reconstituted tobacco. In some cases, the support may be formed from
materials selected from metal foil, paper, cardboard, wood or combinations
thereof.
In some cases, the support comprises paper. In some cases, the support itself
be a
laminate structure comprising layers of materials selected from the preceding
lists. In
some cases, the support may also function as a flavour support. For example,
the
support may be impregnated with a flavourant or with tobacco extract.
Suitably, the thickness of any support layer may be in the range of about
10pm, 15pm, 17pm, 20pm, 23pm, 25pm, 50pm, 75pm or 0.1mm to about 2.5mm,
2.0mm, 1.5mm, 1.0mm or 0.5mm. The support may comprise more than one layer,
and the thickness described herein refers to the aggregate thickness of those
layers.
In some cases, the support may have a thickness of between about 0.017mm
and about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm,
1.0mm, or 0.5mm.
In some cases, the surface of the support that abuts the amorphous solid may
be porous. For example, in one case, the support comprises paper. It has been
found that a porous support such as paper is particularly suitable: the porous
(e.g.
paper) layer abuts the amorphous solid layer and forms a strong bond. The
amorphous solid is formed by drying a gel and, without being limited by
theory, it is
thought that the slurry from which the gel is formed partially impregnates the
porous
support (e.g. paper) so that when the gel sets, the support is partially bound
into the
gel. This provides a strong binding between the gel and the support (and
between
the dried gel and the support).
Additionally, surface roughness may contribute to the strength of bond
between the amorphous material and the support. Paper roughness (for the
surface
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abutting the support) may suitably be in the range of 50-1000 Bekk seconds,
suitably
50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure
interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used
to
determine the smoothness of a paper surface, in which air at a specified
pressure is
5 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")
In some cases, the support is formed from or comprises metal foil, such as
aluminium foil. A metallic support may allow for better conduction of thermal
energy
10 to the amorphous solid. Additionally, or alternatively, a metal foil may
function as a
susceptor in an induction heating system.
The amorphous solid may have any suitable area density, such as from 30
g/m2 to 120 g/m2. In examples, the amorphous solid has an area density of from
about 30 to 70 g/m2, or about 40 to 60 g/m2. In examples, the amorphous solid
has
15 an area density of from about 80 to 120 g/m2, or from about 70 to 110
g/m2, or
particularly from about 90 to 110 g/m2. Such area densities may be
particularly
suitable where the amorphous solid is included in an aerosol-generating
article/assembly in sheet form, or as a shredded sheet (described further
herein
below).
In some examples, the amorphous solid in sheet form may have a tensile
strength of from around 150 N/m to around 1,200 N/m. In some examples, the
amorphous solid may have a tensile strength of from 600 N/m to 1,200 N/m, or
from
700 N/m to 900 N/m, or around 800 N/m.
Another aspect of the invention provides a method of making an aerosol-
generating composition described herein.
According to some embodiments described herein, there is provided a first
method of making an aerosol-generating composition, the aerosol-generating
composition comprising an amorphous solid, the method comprising:
(i) combining
(a) about 1 to about 80 wt % aerosol generating agent;
(b) one or more gelling agents selected from cellulosic gelling agents;
(c) optionally a filler, wherein the amount of gelling agent and any filler
taken
together is from about 20 to about 75 wt%; and
(d) a flavourant;
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the weights c/o being calculated on a dry weight basis, and
(e) a solvent,
to form a slurry;
(ii) forming a layer of the slurry;
(iii) setting the slurry to form a gel; and
(iv) drying the gel to form the amorphous solid.
In examples, the amorphous solid is provided as a shredded sheet. In
particular examples, the providing the amorphous solid comprises shredding a
sheet
of the amorphous solid to provide the amorphous solid as a shredded sheet.
In examples, the providing the amorphous solid comprises (i) forming a slurry
comprising components of the amorphous solid or precursors thereof, (ii)
forming a
layer of the slurry, (iii) setting the slurry to form a gel, and (iv) drying
to form an
amorphous solid.
The (ii) forming a layer of the slurry typically comprises spraying, casting
or
extruding the slurry. In examples, the slurry layer is formed by
electrospraying the
slurry. In examples, the slurry layer is formed by casting the slurry.
In some examples, (ii) and/or (iii) and/or (iv), at least partially, occur
simultaneously (for example, during electrospraying). In some examples, (ii),
(iii) and
(iv) occur sequentially, in that order.
In some examples, the slurry is applied to a support. The layer may be
formed on a support.
In examples, the slurry comprises gelling agent, aerosol generating agent,
filler and active substance. The slurry may comprise these components in any
of the
proportions given herein in relation to the composition of the amorphous
solid. For
example, the slurry may comprise (on a dry weight basis):
- gelling agent and optionally a filler, wherein the amount of gelling
agent
and any filler taken together is about 20 to 80 wt% of the slurry;
- aerosol generating agent in an amount of about 1 to 80 wt% of the slurry;
and
- a flavourant.
In examples, the drying (iv) removes from about 50 wt%, 60 wt%, 70 wt%, 80
wt% or 90 wt% to about 80 wt%, 90 wt% or 95 wt% (wet weight basis, WWB) of
water in the slurry.
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In examples, the drying (iv) reduces the cast material thickness by at least
80%, suitably 85% or 87%. For instance, if the slurry is cast at a thickness
of 2 mm,
the resulting dried amorphous solid material may have a thickness of 0.2 mm.
In embodiments, the dried amorphous solid material forms a sheet or layer
with 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 0.05-0.3 or 0.15-0.3 mm. A material having a thickness of 0.2 mm may
be
particularly suitable.
The slurry itself also forms part of the invention. In some examples, the
slurry
solvent consists essentially of or consists of water. In some examples, the
slurry
comprises from about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% of solvent
(VWVB).
In examples where the solvent consists of water, the dry weight content of the
slurry may match the dry weight content of the amorphous solid. Thus, the
discussion herein relating to the composition of the amorphous solid is
explicitly
disclosed in combination with the slurry aspect of the invention.
Article for use with a non-combustible aerosol provision system
An aspect of the present invention relates to an article for use with a non-
combustible aerosol provision system. The article comprises the aerosol-
generating
composition described herein. A consumable is an article, part or all of which
is
intended to be consumed during use by a user. A consumable may comprise or
consist of aerosol-generating composition. A consumable may comprise one or
more other elements, such as a filter or an aerosol modifying substance. A
consumable may comprise a heating element that emits heat to cause the aerosol-
generating composition to generate aerosol in use. The heating element may,
for
example, comprise combustible material, or may comprise a susceptor that is
heatable by penetration with a varying magnetic field.
A susceptor is material that is heatable by penetration with a varying
magnetic
field, such as an alternating magnetic field. The heating material may be an
electrically-conductive material, so that penetration thereof with a varying
magnetic
field causes induction heating of the heating material. The heating material
may be
magnetic material, so that penetration thereof with a varying magnetic field
causes
magnetic hysteresis heating of the heating material. The heating material may
be
both electrically-conductive and magnetic, so that the heating material is
heatable by
both heating mechanisms.
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Induction heating is a process in which an electrically-conductive object is
heated by penetrating the object with a varying magnetic field. The process is
described by Faraday's law of induction and Ohm's law. An induction heater may
comprise an electromagnet and a device for passing a varying electrical
current,
such as an alternating current, through the electromagnet. When the
electromagnet
and the object to be heated are suitably relatively positioned so that the
resultant
varying magnetic field produced by the electromagnet penetrates the object,
one or
more eddy currents are generated inside the object. The object has a
resistance to
the flow of electrical currents. Therefore, when such eddy currents are
generated in
the object, their flow against the electrical resistance of the object causes
the object
to be heated. This process is called Joule, ohmic, or resistive heating.
In examples, the susceptor is in the form of a closed circuit. It has been
found
that, when the susceptor is in the form of a closed circuit, magnetic coupling
between
the susceptor and the electromagnet in use is enhanced, which results in
greater or
improved Joule heating.
Magnetic hysteresis heating is a process in which an object made of a
magnetic material is heated by penetrating the object with a varying magnetic
field.
A magnetic material can be considered to comprise many atomic-scale magnets,
or
magnetic dipoles. When a magnetic field penetrates such material, the magnetic
dipoles align with the magnetic field. Therefore, when a varying magnetic
field, such
as an alternating magnetic field, for example as produced by an electromagnet,
penetrates the magnetic material, the orientation of the magnetic dipoles
changes
with the varying applied magnetic field. Such magnetic dipole reorientation
causes
heat to be generated in the magnetic material.
When an object is both electrically-conductive and magnetic, penetrating the
object with a varying magnetic field can cause both Joule heating and magnetic
hysteresis heating in the object. Moreover, the use of magnetic material can
strengthen the magnetic field, which can intensify the Joule heating.
In each of the above processes, as heat is generated inside the object itself,
rather than by an external heat source by heat conduction, a rapid temperature
rise
in the object and more uniform heat distribution can be achieved, particularly
through
selection of suitable object material and geometry, and suitable varying
magnetic
field magnitude and orientation relative to the object. Moreover, as induction
heating
and magnetic hysteresis heating do not require a physical connection to be
provided
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between the source of the varying magnetic field and the object, design
freedom and
control over the heating profile may be greater, and cost may be lower.
Articles of the present invention may be provided in any suitable shape. In
some examples, the article is provided as a rod (e.g. substantially
cylindrical).
In examples, the aerosol-generating composition includes the amorphous
solid as a shredded sheet, optionally blended with the tobacco material (e.g.
cut
tobacco). In examples, there is provided an article having a substantially
cylindrical
shape comprising aerosol-generating composition which includes amorphous solid
as a shredded sheet blended with tobacco material.
Alternatively, or additionally, the article provided as a rod may include the
amorphous solid as a sheet, such as a sheet circumscribing a rod of tobacco
material.
Non-combustible aerosol provision system
An aspect of the invention provides non-combustible aerosol provision system
comprising an article according as described herein and non-combustible
aerosol
provision device comprising a heater which is configured to heat not burn the
aerosol-generating article. A non-combustible aerosol provision system may
also be
referred to as an aerosol generating assembly. A non-combustible aerosol
provision
device may be referred to as an aerosol generating apparatus.
In some cases, in use, the heater may heat, without burning, the aerosol-
generating composition to a temperature equal to or less than 350 C, such as
between 120 C and 350 C. In some cases, the heater may heat, without burning,
the aerosol-generating composition to between 140 C and 250 C in use, or
between 220 C and 280 C.
The heater is configured to heat not burn the aerosol-generating article, and
thus the aerosol-generating composition. The heater may be, in some cases, a
thin
film, electrically resistive heater. In other cases, the heater may comprise
an
induction heater or the like. The heater may be a combustible heat source or a
chemical heat source which undergoes an exothermic reaction to product heat in
use. The aerosol generating assembly may comprise a plurality of heaters. The
heater(s) may be powered by a battery.
The aerosol-generating article may additionally comprise a cooling element
and/or a filter. The cooling element, if present, may act or function to cool
gaseous
or aerosol components. In some cases, it may act to cool gaseous components
such
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that they condense to form an aerosol. It may also act to space the very hot
parts of
the non-combustible aerosol provision device from the user. The filter, if
present,
may comprise any suitable filter known in the art such as a cellulose acetate
plug.
In some cases, the aerosol generating assembly may be a heat-not-burn
5 device. That is, it may contain a solid tobacco-containing material (and
no liquid
aerosol-generating material). In some cases, the amorphous solid may comprise
the
tobacco material. A heat-not-burn device is disclosed in WO 2015/062983 A2,
which
is incorporated by reference in its entirety.
The aerosol-generating article (which may be referred to herein as an article,
10 a cartridge or a consumable) may be adapted for use in a THP, an
electronic tobacco
hybrid device or another aerosol generating device. In some cases, the article
may
additionally comprise a filter and/or cooling element (which have been
described
above). In some cases, the aerosol-generating article may be circumscribed by
a
wrapping material such as paper. In particular examples, the article is
adapted for
15 use with a tobacco heating product.
The aerosol-generating article may additionally comprise ventilation
apertures. These may be provided in the sidewall of the article. In some
cases, the
ventilation apertures may be provided in the filter and/or cooling element.
These
apertures may allow cool air to be drawn into the article during use, which
can mix
20 with the heated volatilised components thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised
components from the article when it is heated in use. The heated volatilised
components are made visible by the process of cooling the heated volatilised
components such that supersaturation of the heated volatilised components
occurs.
The heated volatilised components then undergo droplet formation, otherwise
known
as nucleation, and eventually the size of the aerosol particles of the heated
volatilised
components increases by further condensation of the heated volatilised
components
and by coagulation of newly formed droplets from the heated volatilised
components.
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.
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In another example, the ventilation ratio is between 50% and 85% to provide
additional cooling to the heated volatilised components. In some cases, the
ventilation ratio may be at least 60% or 65%.
In some cases, the aerosol generating composition and/or the amorphous
solid may be included in the article/assembly in sheet form. In some cases,
the
aerosol generating composition may be included as a planar sheet. In some
cases,
the aerosol generating composition may be included as a planar sheet, as a
bunched
or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form
of a tube).
In some such cases, the amorphous solid of these embodiments may be included
in
an aerosol-generating article/assembly as a sheet, such as a sheet
circumscribing a
rod of tobacco material. In some other cases, the aerosol generating
composition
may be formed as a sheet and then shredded and incorporated into the article.
In
some cases, the shredded sheet may be mixed with cut rag tobacco and
incorporated into the article.
The assembly may comprise an integrated aerosol-generating article and
heater, or may comprise a heater device into which the article is inserted in
use.
Referring to Figures 1 and 2, there are shown a partially cut-away section
view and a perspective view of an example of an aerosol-generating article
101. The
article 101 is adapted for use with a device having a power source and a
heater. The
article 101 of this embodiment is particularly suitable for use with the
device 51
shown in Figures 5 to 7, described below. In use, the article 101 may be
removably
inserted into 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 the
amorphous
solid 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 amorphous solid described herein may be incorporated in
sheet form and in shredded form.
The filter assembly 105 includes three segments, a cooling segment 107, a
filter segment 109 and a mouth end segment 111. The article 101 has a first
end
113, also known as a mouth end or a proximal end and a second end 115, also
known as a distal end. The body of aerosol generating composition 103 is
located
towards the distal end 115 of the article 101. In one example, the cooling
segment
107 is located adjacent the body of aerosol generating composition 103 between
the
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body of aerosol generating composition 103 and the filter segment 109, such
that the
cooling segment 107 is in an abutting relationship with the aerosol generating
composition 103 and the filter segment 103. In other examples, there may be a
separation between the body of aerosol generating composition 103 and the
cooling
segment 107 and between the body of aerosol generating composition 103 and the
filter segment 109. The filter segment 109 is located in between the cooling
segment
107 and the mouth end segment 111. The mouth end segment 111 is located
towards the proximal end 113 of the article 101, adjacent the filter segment
109. In
one example, the filter segment 109 is in an abutting relationship with the
mouth end
segment 111. In one embodiment, the total length of the filter assembly 105 is
between 37mm and 45mm, more preferably, the total length of the filter
assembly
105 is 41mm.
In one example, the rod of aerosol generating composition 103 is between
34mm and 50mm in length, suitably between 38mm and 46mm in length, suitably
42mm in length.
In one example, the total length of the article 101 is between 71mm and
95mm, suitably between 79mm and 87mm, suitably 83mm.
An axial end of the body of aerosol generating composition 103 is visible at
the distal end 115 of the article 101. However, in other embodiments, the
distal end
115 of the article 101 may comprise an end member (not shown) covering the
axial
end of the body of aerosol generating composition 103.
The body of aerosol generating composition 103 is joined to the filter
assembly 105 by annular tipping paper (not shown), which is located
substantially
around the circumference of the filter assembly 105 to surround the filter
assembly
105 and extends partially along the length of the body of aerosol generating
composition 103. In one example, the tipping paper is made of 583SM standard
tipping base paper. In one example the tipping paper has a length of between
42mm
and 50mm, suitably of 46mm.
In one example, the cooling segment 107 is an annular tube and is located
around and defines an air gap within the cooling segment. The air gap provides
a
chamber for heated volatilised components generated from the body of aerosol
generating composition 103 to flow. The cooling segment 107 is hollow to
provide a
chamber for aerosol accumulation yet rigid enough to withstand axial
compressive
forces and bending moments that might arise during manufacture and whilst the
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article 101 is in use during insertion into the device 51. In one example, the
thickness of the wall of the cooling segment 107 is approximately 0.29mm.
The cooling segment 107 provides a physical displacement between the
aerosol generating composition 103 and the filter segment 109. The physical
displacement provided by the cooling segment 107 will provide a thermal
gradient
across the length of the cooling segment 107. In one example the cooling
segment
107 is configured to provide a temperature differential of at least 40 degrees
Celsius
between a heated volatilised component entering a first end of the cooling
segment
107 and a heated volatilised component exiting a second end of the cooling
segment
107. In one example the cooling segment 107 is configured to provide a
temperature
differential of at least 60 degrees Celsius between a heated volatilised
component
entering a first end of the cooling segment 107 and a heated volatilised
component
exiting a second end of the cooling segment 107. This temperature differential
across the length of the cooling element 107 protects the temperature
sensitive filter
segment 109 from the high temperatures of the aerosol generating composition
103
when it is heated by the device 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 109 may become damaged in use, so it would not perform its required
functions as effectively.
In one example the length of the cooling segment 107 is at least 15mm. In
one example, the length of the cooling segment 107 is between 20mm and 30mm,
more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.
The cooling segment 107 is made of paper, which means that it is comprised
of a material that does not generate compounds of concern, for example, toxic
compounds when in use adjacent to the heater of the device 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.
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
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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 composition. In one example the filter segment 109 is
made
of a mono-acetate material, such as cellulose acetate. The filter segment 109
provides cooling and irritation-reduction from the heated volatilised
components
without depleting the quantity of the heated volatilised components to an
unsatisfactory level for a user.
In some embodiments, a capsule (not illustrated) may be provided in filter
segment 109. It may be disposed substantially centrally in the filter segment
109,
both across the filter segment 109 diameter and along the filter segment 109
length.
In other cases, it may be offset in one or more dimension. The capsule may in
some
cases, where present, contain a volatile component such as a flavourant or
aerosol
generating agent.
The density of the cellulose acetate tow material of the filter segment 109
controls the pressure drop across the filter segment 109, which in turn
controls the
draw resistance of the article 101. Therefore the selection of the material of
the filter
segment 109 is important in controlling the resistance to draw of the article
101. In
addition, the filter segment performs a filtration function in the article
101.
In one example, the filter segment 109 is made of a 8Y15 grade of filter tow
material, which provides a filtration effect on the heated volatilised
material, whilst
also reducing the size of condensed aerosol droplets which result from the
heated
volatilised material.
The presence of the filter segment 109 provides an insulating effect by
providing further cooling to the heated volatilised components that exit the
cooling
segment 107. This further cooling effect reduces the contact temperature of
the
user's lips on the surface of the filter segment 109.
In one example, the filter segment 109 is between 6mm to 10mm in length,
suitably 8mm.
The mouth end segment 111 is an annular tube and is located around and
defines an air gap within the mouth end segment 111. The air gap provides a
chamber for heated volatilised components that flow from the filter segment
109.
The mouth end segment 111 is hollow to provide a chamber for aerosol
accumulation
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yet rigid enough to withstand axial compressive forces and bending moments
that
might arise during manufacture and whilst the article is in use during
insertion into the
device 51. In one example, the thickness of the wall of the mouth end segment
111
is approximately 0.29mm. In one example, the length of the mouth end segment
5 111 is between 6mm to lOmm, suitably 8mm.
The mouth end segment 111 may be manufactured from a spirally wound
paper tube which provides a hollow internal chamber yet maintains critical
mechanical rigidity. Spirally wound paper tubes are able to meet the tight
dimensional accuracy requirements of high-speed manufacturing processes with
10 respect to tube length, outer diameter, roundness and straightness.
The mouth end segment 111 provides the function of preventing any liquid
condensate that accumulates at the exit of the filter segment 109 from coming
into
direct contact with a user.
It should be appreciated that, in one example, the mouth end segment 111
15 and the cooling segment 107 may be formed of a single tube and the
filter segment
109 is located within that tube separating the mouth end segment 111 and the
cooling segment 107.
Referring to Figures 3 and 4, there are shown a partially cut-away section and
perspective views of an example of an article 301. The reference signs shown
in
20 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
25 317 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 of the article 301. In one example, the
ventilation region
317 comprises one or more rows of holes, and preferably, each row of holes is
arranged circumferentially around the article 301 in a cross-section that is
substantially perpendicular to a longitudinal axis of the article 301.
In one example, there are between one to four rows of ventilation holes to
provide ventilation for the article 301. Each row of ventilation holes may
have
between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for
example,
be between 100 to 500pm in diameter. I n one example, an axial separation
between
rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.
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In one example, the ventilation holes 317 are of uniform size. In another
example, the ventilation holes 317 vary in size. The ventilation holes can be
made
using any suitable technique, for example, one or more of the following
techniques:
laser technology, mechanical perforation of the cooling segment 307 or pre-
perforation of the cooling segment 307 before it is formed into the article
301. The
ventilation holes 317 are positioned so as to provide effective cooling to the
article
301.
In one example, the rows of ventilation holes 317 are located at least 11mm
from the proximal end 313 of the article, suitably between 17mm and 20mm from
the
proximal end 313 of the article 301. The location of the ventilation holes 317
is
positioned such that user does not block the ventilation holes 317 when the
article
301 is in use.
Providing the rows of ventilation holes between 17mm and 20mm from the
proximal end 313 of the article 301 enables the ventilation holes 317 to be
located
outside of the device 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 307
will be partially inserted into the device 51, when the article 301 is fully
inserted into
the device 51. The length of the cooling segment 307 provides a first function
of
providing a physical gap between the heater arrangement of the device 51 and
the
heat sensitive filter arrangement 309, and a second function of enabling the
ventilation holes 317 to be located in the cooling segment, whilst also being
located
outside of the device 51, when the article 301 is fully inserted into the
device 51. As
can be seen from Figures 6 and 7, the majority of the cooling element 307 is
located
within the device 51. However, there is a portion of the cooling element 307
that
extends out of the device 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. The device 51 is a heating device which releases compounds by
heating, but not burning, the aerosol generating composition.
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27
A first end 53 is sometimes referred to herein as the mouth or proximal end
53 of the device 51 and a second end 55 is sometimes referred to herein as the
distal
end 55 of the device 51. The device 51 has an on/off button 57 to allow the
device
51 as a whole to be switched on and off as desired by a user.
The device 51 comprises a housing 59 for locating and protecting various
internal components of the device 51. In the example shown, the housing 59
comprises a uni-body sleeve 11 that encompasses the perimeter of the device
51,
capped with a top panel 17 which defines generally the 'top' of the device 51
and a
bottom panel 19 which defines generally the 'bottom' of the device 51. In
another
example the housing comprises a front panel, a rear panel and a pair of
opposite
side panels in addition to the top panel 17 and the bottom panel 19.
The top panel 17 and/or the bottom panel 19 may be removably fixed to the
uni-body sleeve 11, to permit easy access to the interior of the device 51, or
may be
"permanently" fixed to the uni-body sleeve 11, for example to deter a user
from
accessing the interior of the device 51. I n an example, the panels 17 and 19
are
made of a plastics material, including for example glass-filled nylon formed
by
injection moulding, and the uni-body sleeve 11 is made of aluminium, though
other
materials and other manufacturing processes may be used.
The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of
the device 51 through which, in use, the article 101, 301 including the
aerosol
generating composition may be inserted into the device 51 and removed from the
device 51 by a user.
The housing 59 has located or fixed therein a heater arrangement 23, control
circuitry 25 and a power source 27. In this example, the heater arrangement
23, the
control circuitry 25 and the power source 27 are laterally adjacent (that is,
adjacent
when viewed from an end), with the control circuitry 25 being located
generally
between the heater arrangement 23 and the power source 27, though other
locations
are possible.
The control circuitry 25 may include a controller, such as a microprocessor
arrangement, configured and arranged to control the heating of the aerosol
generating composition in the article 101, 301 as discussed further below.
The power source 27 may be for example a battery, which may be a
rechargeable battery or a non-rechargeable battery. Examples of suitable
batteries
include for example a lithium-ion battery, a nickel battery (such as a
nickel¨cadmium
battery), an alkaline battery and/ or the like. The battery 27 is electrically
coupled to
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28
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 a ceramics material. Examples of suitable ceramics
materials include alumina and aluminium nitride and silicon nitride ceramics,
which
may be laminated and sintered. Other heating arrangements are possible,
including
for example inductive heating, infrared heater elements, which heat by
emitting
infrared radiation, or resistive heating elements formed by for example a
resistive
electrical winding.
In one particular example, the heater arrangement 23 is supported by a
stainless steel support tube and comprises a polyimide heating element. The
heater
arrangement 23 is dimensioned so that substantially the whole of the body of
aerosol
generating composition 103, 303 of the article 101, 301 is inserted into the
heater
arrangement 23 when the article 101, 301 is inserted into the device 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
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29
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 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 101, 301 over at least part of the cooling segment 307.
The collar 33 comprises a plurality of ridges 60 arranged circumferentially
around the periphery of the opening 20 and which project into the opening 20.
The
ridges 60 take up space within the opening 20 such that the open span of the
opening 20 at the locations of the ridges 60 is less than the open span of the
opening
20 at the locations without the ridges 60. The ridges 60 are configured to
engage with
an article 101, 301 inserted into the device to assist in securing it within
the device
51. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges
60
and the article 101, 301 form ventilation paths around the exterior of the
article 101,
301. These ventilation paths allow hot vapours that have escaped from the
article
101, 301 to exit the device 51 and allow cooling air to flow into the device
51 around
the article 101, 301 in the air gap 36.
In operation, the article 101, 301 is removably inserted into an insertion
point
20 of the device 51, as shown in Figures 5 to 7. Referring particularly to
Figure 6, in
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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
101, 301 extends from the device 51 and acts as a mouthpiece assembly for a
user.
5 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,
10 through the chamber inside the cooling segment 107, 307, through the
filter segment
109, 309, through the mouth end segment 111, 313 to the user. In one example,
the
temperature of the heated volatilised components that are generated from the
body
of aerosol generating composition is between 60 C and 250 C, which may be
above
the acceptable inhalation temperature for a user. As the heated volatilised
15 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
20 cooling segment 307. This cool air will mix with the heated volatilised
components to
provide additional cooling to the heated volatilised components.
According to an aspect of the present invention there is provided a method of
generating an aerosol using a non-combustible aerosol provision system as
described herein. In examples, the method comprises heating the aerosol-
generating
25 composition to a temperature of less than or equal to 350 C. The method
typically
comprises heating the aerosol-generating composition to a temperature of from
about 220 C to about 280 'C. In some examples, the method comprises heating
at
least a portion of the aerosol-generating composition to a temperature of from
about
220 00 to about 280 00 over a session of use.
30 "Session of use" as used herein refers to a single period of use of
the non-
combustible aerosol provision system by a user. The session of use begins at
the
point at which power is first supplied to at least one heating unit present in
the
heating assembly. The device will be ready for use after a period of time has
elapsed from the start of the session of use. The session of use ends at the
point at
which no power is supplied to any of the heating elements in the aerosol-
generating
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31
device. The end of the session of use may coincide with the point at which the
smoking article is depleted (the point at which the total particulate matter
yield (mg) in
each puff would be deemed unacceptably low by a user). The session will have a
duration of a plurality of puffs. Said session may have a duration less than 7
minutes,
or 6 minutes, or 5 minutes, or 4 minutes and 30 seconds, or 4 minutes, or 3
minutes
and 30 seconds. In some embodiments, the session of use may have a duration of
from 2 to 5 minutes, or from 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or
suitably 4
minutes. A session may be initiated by the user actuating a button or switch
on the
device, causing at least one heating element to begin rising in temperature.
According to an aspect of the invention there is provided use of the non-
combustible aerosol provision system as described herein. Use of the non-
combustible aerosol provision system may comprise interacting with the non-
combustible aerosol provision device (e.g. activating an actuator) to initiate
a
smoking session.
Examples
Example 1
Amorphous solids (AS) were prepared according to the following method.
The gelling agent (CMC), aerosol generating agent (glycerol) and any filler
(wood pulp) were mixed with approximately 500 ml of distilled water in a high
shear
mixer until a free flowing slurry was formed. The slurry was cast onto a metal
tray at
the desired casting thickness using a casting knife. The tray was then placed
in an
oven at about 65 C for sufficient time (typically 1 to 2.5 hours) to set and
dry the
slurry to form a sheet of the amorphous solid.
The amorphous solids were formed from slurries comprising water and the
following components (all values are wt% on a dry weight basis):
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Table 1
Component
AS1* AS2* AS3* AS4* AS5 AS6 AS7 AS8
CMC 45 50 40 60 25 20 25 15
Wood pulp 25 25 25 35
Glycerol 55 50 60 40 50 55 50 50
Total 100 100 100 100 100 100 100 100
*Amorphous solids AS1, AS2, AS3 and AS4 are comparative
Amorphous solid AS8, with lower levels of CMC, held together less well than
solids AS5 to AS7.
140 mm x 15 mm samples of the amorphous solids were tested using
standard protocols known to the skilled person.
Tackiness was measured using a Texture Analyser. It is the force necessary
to overcome the attractive forces between the surface of the product
(amorphous
solid) and the surface of the material (the probe) with which the product
comes in
contact. A lower value indicates a less tacky material.
Sample thickness was measured using callipers.
The amorphous solids exhibited the following physical properties
(measurements averaged over 3 samples):
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Table 2
AS 1* 2* 3* 4* 5 6 7 8
Casting 2 2 2 2 2 2 1 1
thickness
(mm)
Sheet 283 223 267 230 353 330 197
thickness
(pm)
area 423 270 407 227 320 327 167
weight
(gm-2)
Tensile 11.4 10.7 12.7 7.1
strength
(N per 15
mm)
Tackiness 0.48 0.45 0.99 0.10 0.09 0.21 0.25
(N)
Example 2
Thermogravimetirc analysis was carried out of AS2 and AS5 using the following
temperature profile: held at 30 C for 1 minute, ramped to 250 C at 100 C/min
and
held for 4 minutes. AS2 and ASS both contained 50 wt% glycerol. A55,
containing
CMC and wood pulp, showed a 27% greater weight loss due to volatilisation of
glycerol and any water in the solid than did AS2 which did not contain any
wood pulp.
The replacement of some of the gelling agent with filler appeared to increase
volatilisation of the aerosol generating agent. AS5 also showed reduced
tackiness
compared to A52.
Example 3
Sample articles in the form of sticks (glo DS commercial sticks with 70%
ventilation made up of 20 mm tobacco section, 14 mm gel section) were formed
using tobacco material and 0.014 m x 0.1 m sheets of AS1, AS2, AS3, AS4, AS5,
AS7 and AD8. The tobacco material was a high nicotine tobacco blend containing
glycerol. The composition of the sticks is shown in Table 3.
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Table 3
AS1 AS2 AS3 AS4 AS5 AS7 AS8
Average 462 378 497 360 457 225 224
mass of
AS per
stick
(mg)
Glycerol 254 189 298 144 251 113 112
(mg)
The pressure drops of the sticks, i.e. the resistance to air flow through the
stick measured in mm per water gauge, was measured before and after vaping in
a
glo Hyper device hooked up to a smoke engine. The smoke engine ran a
standardised testing programme for the devices (55 ml puff, 2 sec puff
duration, 30
secs between each puff, 10 puffs per session). Aerosol was collected on
Cambridge
filter pads, weighed and analysed for nicotine and glycerol.
The sticks made from AS1 to AS4 exhibited higher pressure drop values than
those made from AS5, AS7 and AS8. Visual inspection of the sticks after
heating
appeared to show that the amorphous solids which did not contain filler stuck
together and hardened, thus impeding air flow.
The sticks made from AS5 to AS8 showed higher aerosol collective mass,
glycerol transfer and nicotine delivery than did those made from AS1.
Exemplary embodiments include aerosol-generating compositions, methods,
slurries, articles and systems as previously defined wherein:
any filler in the amorphous solid comprises, or is, wood pulp, and/or
the gelling agent in the amorphous solid comprises, or is, CMC, and/or
the aerosol generating agent in the amorphous solid comprises, or is,
glycerol, optionally in combination with propylene glycol, and/or
the flavourant in the amorphous solid comprises, or is, menthol.
Exemplary embodiments include aerosol-generating compositions, methods,
slurries, articles and systems as previously defined wherein the amorphous
solid
comprises:
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about 1 to about 40 wt% filler, such as wood pulp;
about 20 to about 50 wt% flavour, such as menthol;
about 20 to about 40 wt%, such as CMC, and
about 10 to about 50 wt%, aerosol generating agent, such as glycerol
optionally
5 in combination with propylene glycol.
Exemplary embodiments include aerosol-generating compositions, methods,
slurries, articles and systems as previously defined wherein the amorphous
solid
comprises:
10 about 10 to 25 wt%, filler, such as wood pulp;
about 35 to 45 wt%, flavour, such as menthol;
about 20 to 35 wt% gelling agent, such as CMC, and
about 15 to about 25 wt%, aerosol generating agent, such as glycerol
optionally
in combination with propylene glycol.
All percentages by weight described herein (denoted wt%) are calculated on
a dry weight basis (DWB), unless explicitly stated otherwise. All weight
ratios are
also calculated on a dry weight basis. A weight quoted on a dry weight basis
refers to
the whole of the extract or slurry or material, other than the water, and may
include
components which by themselves are liquid at room temperature and pressure,
such
as glycerol. Conversely, a weight percentage quoted on a wet weight basis
(VVVVB)
refers to all components, including water.
For the avoidance of doubt, where in this specification the term "comprises"
is
used in defining the invention or features of the invention, embodiments are
also
disclosed in which the invention or feature can be defined using the terms
"consists
essentially of" or "consists of" in place of "comprises". Reference to a
material
"comprising" certain features means that those features are included in,
contained in,
or held within the material.
Any feature described in relation to one aspect of the invention is expressly
disclosed in combination with any other aspect described herein.
The above embodiments are to be understood as illustrative examples of the
invention. Further embodiments of the invention are envisaged. 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
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36
combination of any other of the embodiments. Furthermore, equivalents and
modifications not described above may also be employed without departing from
the
scope of the invention, which is defined in the accompanying claims.
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