JP7577750B2 - Aerosol Generation - Google Patents

Description

The present invention relates to the generation of aerosols.

background

Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release compounds from a substrate material by heating without combustion, thereby releasing an inhalable aerosol or vapor. These are sometimes referred to as non-combustion smoking articles or aerosol-generating assemblies.

One example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosol-generating composition. The solid aerosol-generating composition may, in some examples, include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of a solid aerosol-generating composition.

Another example is an e-cigarette/tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-forming composition (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce an inhalation medium.

overview

According to a first aspect of the present invention, there is provided an aerosol-forming composition comprising:
an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
Gelling agent,
optionally a filler, wherein the amount of gelling agent and filler combined is about 10-60% by weight of the amorphous solid; and optionally an active agent in an amount up to about 20% by weight of the amorphous solid;
Tobacco materials;
Equipped with
Here, the aerosol-forming composition has an aerosol-forming material content of about 5-30% by weight of the aerosol-forming composition, these weights being calculated on a dry weight basis.

According to a second aspect of the present invention, there is provided an article for use with a non-combustion aerosol delivery device. The article comprises an aerosol generating composition as described herein.

According to a third aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising an article as described herein and a non-combustion aerosol delivery device configured to generate an aerosol from the article when the article is used with the non-combustion aerosol delivery device.

According to a further aspect of the present invention, there is provided a method of making an aerosol forming composition, the method comprising:
an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
Gelling agent,
providing an amorphous solid comprising, optionally, a filler, wherein the amount of gelling agent and filler together is about 10-60% by weight of the amorphous solid; and, optionally, an active agent in an amount up to about 20% by weight of the amorphous solid;
Providing a tobacco material;
combining the amorphous solid and the tobacco material to obtain an aerosol-forming composition, the aerosol-forming composition having an aerosol-forming material content of about 5-30% by weight of the aerosol-forming composition;
and weights are calculated on a dry weight basis.

According to yet a further aspect of the present invention, there is provided a use of the non-combustion aerosol delivery system described herein.

Features described in this specification in relation to one aspect of the invention are expressly disclosed in combination with each of the other aspects, insofar as they are combinable.

Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which description is given by way of example only with reference to the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of an example of an aerosol product. FIG. 2 is a perspective view of the article of FIG. 1 . FIG. 2 is a cross-sectional elevation view of an example of an aerosol product. FIG. 4 is a perspective view of the article of FIG. FIG. 1 is a perspective view of an example of an aerosol generation assembly. FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. FIG. 1 is a perspective view of an example of an aerosol generation assembly.

Detailed Description

The aerosol-generating compositions described herein are compositions capable of generating an aerosol when energized, e.g., by heating, irradiation, or in any other manner. The aerosol-generating compositions may, for example, include features in the form of a solid, liquid, or gel, and may or may not include nicotine and/or flavorings. The aerosol-generating compositions comprise an "amorphous solid." Amorphous solids are sometimes referred to as "monolithic solids" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that may hold some fluid, e.g., liquid, within it.

In an example, an aerosol generating composition is provided. The aerosol generating composition is suitable for inclusion in an article for use with a non-combustion type aerosol delivery device. The aerosol generating composition comprises an amorphous solid and a tobacco material. The aerosol generating composition has an aerosol-forming material content of 5-30% by weight, weights calculated on a dry weight basis. In an example, the aerosol generating composition comprises the aerosol-forming material in an amount of about 10-20% by weight, or about 13-17% by weight. In an example, the aerosol generating composition comprises the aerosol-forming material in an amount of about 15% by weight.

Typically, cut rag tobacco blends that may be used alone in conventional combustible smoking articles such as cigarettes have been found to be unsuitable for use in non-combustible aerosol delivery devices. Without wishing to be bound by theory, it is believed that cut rag tobacco blends used in cigarettes typically cannot be loaded with sufficient aerosol-forming material to provide the desired inhalable aerosol when heated by a non-combustible aerosol delivery device.

Previous attempts to address this problem have included replacing some or all of the cut rag tobacco in a typical combustible tobacco blend with reconstituted tobacco, such as paper reconstituted tobacco. Paper reconstituted tobacco typically may contain a higher percentage of aerosol-forming materials. However, the inventors have determined that tobacco blends with a high percentage of paper reconstituted tobacco may have undesirable sensory characteristics when heated by a non-combustible aerosol delivery device.

The inventors have determined that by providing an amorphous solid having a high aerosol-forming material content in combination with a tobacco material, it is possible to generate an acceptable aerosol without requiring the presence of large amounts of reconstituted tobacco (thereby reducing undesirable sensory characteristics associated with reconstituted tobacco). In examples, the tobacco material comprises or consists of laminar tobacco (e.g., cut rag tobacco), which provides the desired sensory characteristics. In examples, the tobacco material comprises reconstituted tobacco in an amount of less than about 50%, 30%, 10%, 5%, or 1% by dry weight of the tobacco material. In examples, the tobacco material is substantially free of reconstituted tobacco.

The tobacco material is typically present in the aerosol forming composition in an amount of about 50-95% by weight, or about 60-90% by weight, or about 70-90% by weight, or about 75-85% by weight.

The tobacco material may be present in any form, but is typically fine cut (e.g., chopped into small pieces). Fine cut tobacco material may be advantageously blended with amorphous solids to provide an aerosol generating composition having a uniform distribution of the tobacco material and amorphous solids throughout the aerosol generating composition.

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extract. Surprisingly, the inventors have determined that it is possible to use relatively large amounts of laminar tobacco in an aerosol generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material. In certain examples, the tobacco material comprises shredded tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

The amorphous solid is present in the aerosol generating composition in any amount such that the total aerosol-forming material content of the aerosol generating composition is about 5-30% by weight of the aerosol generating composition. In examples, the amorphous solid is included in the aerosol generating composition in an amount of about 5-40%, 10-30%, 15-25%, or 17-23% by weight. In examples, the aerosol generating composition comprises the amorphous solid in an amount of about 20% by weight of the aerosol generating composition. Surprisingly, by configuring the amorphous solid to have a relatively high aerosol-forming material content, a relatively small amount of the amorphous solid (e.g., about 20% by weight) can be used in the aerosol generating composition and still achieve a desired aerosol for use with a non-combustion type aerosol delivery system.

The amorphous solid comprises a gelling agent, an aerosol forming material, an optional filler, and an optional active agent.
an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
a gelling agent, and optionally a filler (i.e., in some instances the filler is present in the amorphous solid and in other instances the filler is absent from the amorphous solid), wherein the amount of gelling agent and filler combined is about 10-60% by weight of the amorphous solid (i.e., the gelling agent and filler combined comprise 10-60% by weight of the amorphous solid), and optionally an active agent in an amount up to about 20% by weight of the amorphous solid (i.e., the amorphous solid comprises ≦20% by weight of the active agent);
Equipped with.

In examples, the amorphous solid comprises gelling agent and filler in an amount, combined, of about 10%, 20%, 25%, 30%, or 35% to about 60%, 55%, 50%, or 45% by weight of the amorphous solid. In examples, the amorphous solid comprises gelling agent and filler in an amount, combined, of about 20-60%, 25-55%, 30-50%, or 35-45% by weight of the amorphous solid.

In examples, the amorphous solid comprises a gelling agent in an amount (i.e., not considering the amount of filler) of about 5%, 10%, 15%, 20%, 25%, 30%, or 35% to about 60%, 55%, 50%, or 45% by weight of the amorphous solid. In examples, the amorphous solid comprises a gelling agent in an amount (i.e., not considering the amount of filler) of about 5-60%, 20-60%, 25-55%, 30-50%, or 35-45% by weight of the amorphous solid.

In examples, the gelling agent comprises a hydrocolloid. In some examples, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some examples, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginate and/or pectin, which may be combined with a hardening agent (such as a calcium source) during formation of the amorphous solid. In some examples, the amorphous solid may comprise calcium cross-linked alginate and/or calcium cross-linked pectin.

The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and combinations thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

In some examples, the amorphous solid comprises alginate and/or pectin and/or guar gum.

In some examples, the alginate is included in the gelling agent in an amount of about 5-40%, or 15-40% by weight of the amorphous solid. That is, the amorphous solid comprises alginate in an amount of about 5-40%, or 15-40% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises alginate in an amount of about 20-40%, or about 15-35% by weight of the amorphous solid.

In some examples, pectin is included in the gelling agent in an amount of about 3-15% by weight of the amorphous solid. That is, the amorphous solid comprises pectin in an amount of about 3-15% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises pectin in an amount of about 5-10% by weight of the amorphous solid.

In some examples, the guar gum is included in the gelling agent in an amount of about 3-40% by weight of the amorphous solid. That is, the amorphous solid comprises guar gum in an amount of about 3-40% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises guar gum in an amount of about 5-10% by weight of the amorphous solid. In some examples, the amorphous solid comprises guar gum in an amount of about 15-40%, or about 20-40%, or about 15-35% by weight of the amorphous solid.

In examples, the alginate is present in an amount of at least about 50% by weight of the gelling agent. In examples, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is typically >1:1, i.e., the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is 2:1 to 8:1, or 3:1 to 8:1, or 3:1 to 6:1, or approximately 4:1.

The amorphous solid may comprise a filler. In summary, the amorphous solid typically comprises a gelling agent and a filler (if present) in an amount of about 10-60% by weight of the amorphous solid. In examples, the amorphous solid comprises a filler in an amount of 1-15% by weight of the amorphous solid, e.g., 5%-15% by weight, or 8-12% by weight. In examples, the amorphous solid comprises a filler in an amount of more than 1%, 5%, or 8% by weight of the amorphous solid. In examples, the amorphous solid comprises a filler in an amount of less than 40%, 30%, 20%, 15%, 12%, 10%, 5%, or 1% by weight of the amorphous solid. In other examples, the amorphous solid does not comprise a filler.

When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In some instances, the amorphous solid does not comprise an inorganic filler material. In certain instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

In some instances including a filler, the filler is fibrous. For example, the filler is a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose or a cellulose derivative. Without wishing to be bound by theory, it is believed that including a fibrous filler in the amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in instances where the amorphous solid is provided as a sheet, for example, when an amorphous solid sheet surrounds a rod of tobacco material.

In examples, the amorphous solid does not comprise tobacco fiber. In certain examples, the amorphous solid does not comprise fibrous material.

The amorphous solid typically comprises aerosol-forming material in an amount up to about 80% by weight of the amorphous solid, e.g., about 40-80%, 40-75%, 50-70%, or 55-65% by weight.

In examples, the tobacco material comprises an aerosol-forming material. Typically, the tobacco material comprises tobacco that is fine cut, and the aerosol-forming material is loaded onto the tobacco pieces. In examples, the tobacco material comprises the aerosol-forming material in an amount of about 1-10% by weight, e.g., 3-6% by weight, of the tobacco material.

In examples, the aerosol generating composition comprises the aerosol-forming material in an amount of about 5-30% by weight of the aerosol generating composition, e.g., 10-20% by weight, or 13-17% by weight. In examples, the aerosol generating composition comprises the aerosol-forming material in an amount of about 15% by weight of the aerosol generating composition. This amount includes any aerosol-forming material present in the aerosol generating composition, e.g., aerosol-forming material provided in an amorphous solid and aerosol-forming material loaded onto fine cut tobacco.

The aerosol forming material 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, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol forming material comprises glycerol. For example, the amorphous solid and/or tobacco material comprises glycerol.

In some embodiments, the aerosol forming material comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and/or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In examples, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol-forming material, an active agent, and water. In examples, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol-forming material, and water.

The aerosol generating composition can include one or more active agents. In examples, the amorphous solid comprises, for example, up to about 20% of one or more active agents by weight of the amorphous solid. In examples, the amorphous solid comprises an amount of active agent from about 1%, 5%, 10%, or 15% to about 20%, 15%, 15%, or 5% by weight of the amorphous solid.

In examples, the amorphous solid does not include a flavoring, and in certain examples, the amorphous solid does not include an active agent.

The active substance may comprise a physiologically and/or olfactory active substance that is included in the aerosol generating composition to achieve a physiological and/or olfactory response. The active substance may be selected from, for example, functional foods, nootropics, and psychoactive substances. The active substance may be naturally occurring or synthetically derived. The active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, 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 component, derivative, or extract of another botanical substance such as tobacco or cannabis, such as a cannabinoid or a terpene. In some embodiments, the active substance is a physiologically active substance and may be selected from nicotine, nicotine salts (e.g., nicotine ditartrate/nicotine bitartrate), nicotine-free tobacco substitutes, other alkaloids, e.g., caffeine, cannabinoids, or mixtures thereof. Cannabinoids are a class of natural or synthetic compounds that act on cannabinoid receptors (i.e., CB1 and CB2) in cells that inhibit neurotransmitter release in the brain. Two of the most important cannabinoids are tetrahydrocannabinol (THC) and cannabidiol (CBD). Cannabinoids may be found naturally in plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabinoids are cyclic molecules that exhibit certain properties, such as the ability to easily cross the blood-brain barrier, low toxicity, and few side effects. Cannabis species exhibit at least 85 different phytocannabinoids, divided into several subcategories, including cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol and cannabinodiol, as well as other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, 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), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol 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 substances may include nicotine and cannabidiol (CBD).

Active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

In some embodiments, the active is an olfactory active and may be selected from "flavors" and/or "flavorings" that can be used to create a desired taste, aroma, or other somatic sensation in a product for adult consumers, where local regulations permit. In some instances, such ingredients may be referred to as flavors, flavorings, cooling agents, heating agents, or sweetening agents. They may be naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, thyme, thyme leaves ... Ya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, 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, ca Lawei, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pi menthol, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanical materials, or breath fresheners. 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 flavoring comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and/or red berry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis. In some embodiments, the flavoring may comprise a sensory agent intended to achieve somatic sensations typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

The term botanical material includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, skins, etc. Alternatively, the material may comprise active compounds that are naturally present in the plant material or that are obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical materials include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be any of the following mint varieties: Mentha arvensis, Grapefruit mint, Egyptian mint, Peppermint, Lime mint, Chocolate mint, Curly mint, Wild mint, Horse mint, Pineapple mint, Pennyroyal mint, and Common mint. In some embodiments, the botanical material is selected from eucalyptus, star anise, cacao, and hemp. In some embodiments, the botanical material is selected from rooibos and fennel.

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 monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

Preferably, 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 sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

The inclusion of an acid is particularly preferred in embodiments in which the aerosol generating composition or amorphous solid comprises nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry in which the aerosol generating composition or amorphous solid is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

In certain embodiments, the aerosol generating composition or amorphous solid comprises a gelling agent, including a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active agent, and an acid.

The amorphous solid may comprise a colorant. The addition of a colorant can change the visual appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the visual appearance of the amorphous solid and the aerosol generating composition. By adding a colorant to the amorphous solid, the amorphous solid can match the color of other components of the aerosol generating composition or other components of an article comprising the amorphous solid.

Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) in the aerosol generating composition comprising the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid renders the amorphous solid visually indistinguishable from other components in the aerosol generating composition.

The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry with the materials that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

The amorphous solid may have any suitable water content, for example, from 1% to 15% by weight. Preferably, the water content of the amorphous solid is from about 5%, 7%, or 9% to about 15%, 13%, or 11% by weight (WWB). The water content of the amorphous solid may be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

The amorphous solid is present in the aerosol generating composition in any suitable form. In examples, the amorphous solid is present in sheet form. In examples, the amorphous solid is present as a shredded sheet (e.g., the aerosol generating composition comprises pieces of the amorphous solid). In examples, the amorphous solid is present as a shredded sheet and is blended with tobacco material that is fine cut and/or shredded, e.g., the amorphous solid and the tobacco material are in a similar form. Advantageously, providing both the amorphous solid and the tobacco material as shredded/fine cut portions allows for an aerosol generating composition blend with a uniform distribution of the amorphous solid and the tobacco material throughout the aerosol generating composition.

The amorphous solid may be present on or in a support to form a substrate. The support serves as a support on which the amorphous solid layer is formed to facilitate manufacturing. The support may also provide rigidity to the amorphous solid layer to facilitate handling.

The support may be any suitable material that can be used to support an amorphous solid. In some examples, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or combinations thereof. In some examples, the support may comprise or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some examples, the support comprises paper. In some examples, the support itself is a laminated structure comprising multiple layers of materials selected from the aforementioned list. In some examples, the support may also function as a flavor support. For example, the support may be impregnated with flavors or tobacco extracts.

Suitably, the thickness of the support layer may range from about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The support may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

In some instances, the surface of the support that abuts the amorphous solid may be porous. For example, in one instance, the support comprises paper. The inventors have found that porous supports such as paper are particularly suitable for the present invention, where a porous (e.g., paper) layer abuts and forms a strong bond with a layer of amorphous solid. The amorphous solid is formed by drying a gel, and, without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous support (e.g., paper) such that the support is partially bonded to the gel as the gel cures and forms crosslinks. This results in a strong bond between the gel and the support (and between the dried gel and the support).

In addition, surface roughness can contribute to the strength of the bond between the amorphous material and the support. The inventors have found that the roughness of the paper (of the surface abutting the support) can be preferably in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure range of 50.66-48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of a paper surface. In this tester, air at a specific pressure is inserted between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

In some examples, the support is formed from or comprises a metal foil (such as aluminum foil). A metal support may allow for better transfer of thermal energy to the amorphous solid. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system.

In some examples, the support may have a thickness of about 0.017 mm to about 2.0 mm, preferably about 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

The amorphous solid may have any suitable areal density, for example, from 30 g/ ^m to 120 g/ ^m . In examples, the amorphous solid has an areal density of about 30 to 70 g/ ^m , or about 40 to 60 g/ ^m . In examples, the amorphous solid has an areal density of about 80 to 120 g/ ^m , or about 70 to 110 g/ ^m , or especially about 90 to 110 g/ ^m . Such areal densities may be particularly suitable when the amorphous solid is included in the aerosol product article/assembly in sheet form or as chopped sheets (discussed further below).

In examples, the amorphous solid has an areal density that is about 90-110% of the areal density of the tobacco material. That is, the amorphous solid and the tobacco material have similar areal densities. The inventors have determined that configuring the amorphous solid and the tobacco material to have similar areal densities allows for better blending of the amorphous solid and the tobacco material, typically when provided as shredded sheets. For example, shredded amorphous solid sheets and shredded rag tobacco having similar areal densities can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition).

Fine cut tobacco (e.g., shredded rag tobacco) has a cut width, typically expressed as CPI (cuts per inch) and referred to as the cut width of the tobacco. Amorphous solids provided as solid sheets have a cut width. In some instances where the tobacco material is fine cut (e.g., where the tobacco material comprises shredded rag tobacco) and the amorphous solid is a shredded sheet, the cut width of the amorphous solid is about 90-110% of the cut width of the shredded rag tobacco. That is, the amorphous solid and the tobacco material have a cut or shred width. The inventors have determined that configuring the amorphous solid and the tobacco material to have similar cut widths allows for better blending of the amorphous solid and the tobacco material. For example, shredded amorphous solid sheets and shredded rag tobacco having similar cut widths can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition).

In some examples, the amorphous solid in sheet form may have a tensile strength of about 150 N/m to about 1,200 N/m. In some examples, such as examples where the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 150 N/m to 500 N/m, or 200 N/m to 300 N/m, or about 250 N/m. In some examples, such as examples where the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N/m to 1,200 N/m, or 700 N/m to 900 N/m, or about 800 N/m.

Aspects of the invention relate to articles for use with non-combustion aerosol delivery systems. The articles comprise an aerosol generating composition as described herein. A consumable is an article intended to be consumed in part or in whole during use by a user. The consumable may comprise or consist of the aerosol generating composition. The consumable may comprise one or more other elements, e.g., a filter or an aerosol modifying substance. The consumable may comprise a heating element that generates heat during use to cause aerosol generation from the aerosol generating composition. The heating element may comprise, for example, a combustible material or may comprise a susceptor that can be heated by passing it through a varying magnetic field.

The susceptor is a material that can be heated by passing it through a varying magnetic field, such as an alternating magnetic field. The heating material can be an electrically conductive material, in which case passing it through a varying magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material, in which case passing it through a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material can be both electrically conductive and magnetic, in which case the heating material can be heated by both heating mechanisms.

Induction heating is a process in which an electrically conductive object is heated by passing the object through a changing magnetic field. The process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a changing current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another so that the resulting changing magnetic field generated by the electromagnet passes through the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to heat up. This process is called Joule, Ohmic or resistive heating.

In an example, the susceptor is in the form of a closed circuit. When the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet in use is enhanced, resulting in stronger or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by passing the object through a changing magnetic field. A magnetic material can be thought of as comprising many atomic-scale magnets or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align along the magnetic field. Thus, when a changing magnetic field, for example an alternating magnetic field produced by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes with the variation of the applied magnetic field. This reorientation of the magnetic dipoles causes the generation of heat in the magnetic material.

When an object is both electrically conductive and magnetic, passing the object through a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can intensify Joule heating.

In each of the above processes, when heat is generated within the object itself rather than by an external heat source via thermal conduction, a more rapid temperature rise and more uniform heat distribution in the object can be achieved, especially by selecting the appropriate object material and geometry, and the appropriate varying magnetic field strength and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require physical contact between the source of the varying magnetic field and the object, allowing for greater design freedom and control over the heating profile and reducing costs.

The articles of the present invention may be provided in any suitable shape. In some examples, the articles are provided as rods (e.g., substantially cylindrical).

In examples, the aerosol generating composition includes an amorphous solid as a shredded sheet, optionally blended with a tobacco material (e.g., cut tobacco). In examples, an article having a substantially cylindrical shape is provided that includes an aerosol generating composition including an amorphous solid as a shredded sheet blended with a tobacco material.

Alternatively or additionally, an article provided as a rod may comprise an amorphous solid as a sheet, e.g., a sheet surrounding the rod of tobacco material.

Aspects of the invention provide a non-combustion aerosol delivery system comprising an article according to that described herein and a non-combustion aerosol delivery device comprising a heater configured to heat but not combust the aerosol product article. The non-combustion aerosol delivery system may also be referred to as an aerosol generation assembly. The non-combustion aerosol delivery device may also be referred to as an aerosol generation apparatus.

In some examples, the heater, in use, may heat the aerosol generating composition to a temperature of up to 350° C., such as between 120° C. and 350° C., without combusting the aerosol generating composition. In some examples, the heater, in use, may heat the aerosol generating composition to a temperature of between 140° C. and 250° C., or between 220° C. and 280° C., without combusting the aerosol generating composition.

The heater is configured to heat but not combust the aerosol product, and thus the aerosol generating composition. The heater may in some examples be a thin-film electrical resistance heater. In other examples, the heater may comprise an induction heater or other heater. The heater may be a combustible heat source or may be a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol generating assembly may comprise multiple heaters. The heaters may be powered by a battery.

The heater may comprise one or more electrical resistance heaters, including, for example, one or more nichrome resistance heater(s) and/or one or more ceramic heater(s). The one or more heaters may comprise one or more induction heaters, including a configuration comprising one or more susceptors, which, in use, may form a chamber into which an article comprising the aerosolized material is inserted or otherwise disposed. Alternatively or additionally, one or more susceptors may be disposed within the aerosolized material. Other heating configurations may be used.

The aerosol product may further comprise a cooling element and/or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components such that they condense to form an aerosol. The cooling element may also act to move a hot portion of the non-combustion aerosol delivery device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

In some examples, the aerosol generating assembly may be a heat-not-burn device. That is, the aerosol generating assembly may include a solid tobacco-containing material (and no liquid aerosol-generating material). In some examples, the amorphous solid may comprise a tobacco material. A heat-not-burn device is disclosed in WO 2015/062983 A2, the entirety of which is incorporated herein by reference.

The aerosol product article (sometimes referred to herein as an article, cartridge, or consumable) may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some examples, the article may further comprise a filter and/or a cooling element (as described above). In some examples, the aerosol product article may be surrounded by a packaging material, such as paper. In certain examples, the article is adapted for use with a tobacco heating product.

The aerosol product may further comprise vent holes. These may be provided in the sidewalls of the article. In some instances, the vent holes may be provided in the filter and/or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

Ventilation facilitates the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by a process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation) and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of the newly formed droplets from the heated volatiles.

In some instances, the ratio of cool air to the sum of heated volatiles and cool air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

In some examples, the aerosol-generating material may be included in the article/assembly in sheet form. In some examples, the aerosol-generating material may be included as a flat sheet. In some examples, the aerosol-generating material may be included as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some such examples, the amorphous solid of these embodiments may be included in the aerosol product article/assembly as a sheet, for example, as a sheet surrounding a rod of tobacco material. In some other examples, the aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article. In some examples, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

The assembly may comprise an integrated aerosol product and heater, or may comprise a heating device into which the article is inserted during use.

With reference to Figures 1 and 2, a partially cutaway cross-sectional view and a perspective view of an example aerosol product article 101 are shown. The article 101 is adapted for use with a device having a power source and a heater. This embodiment of the article 101 is particularly suited for use with the device 51 shown in Figures 5-7, described below. In use, the article 101 can be removably inserted into the device at the insertion point 20 of the device 51 shown in Figure 5.

The example article 101 is in the form of a substantially cylindrical rod including a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the amorphous solid as described herein may be incorporated in both sheet form and chopped form.

The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral end or proximal end, and a second end 115, also known as the distal end. The body of aerosol-generating material 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the body of aerosol-generating material 103 between the body of aerosol-generating material 103 and the filter segment 109 such that the cooling segment 107 is in abutting relationship with the aerosol-generating material 103 and the filter segment 109. In another example, there may be a separation between the body of aerosol-generating material 103 and the cooling segment 107 and between the body of aerosol-generating material 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. The oral end segment 111 is disposed toward the proximal end 113 of the article 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the oral end segment 111. In one embodiment, the overall length of the filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of the filter assembly 105 is 41 mm.

In one example, the rod of aerosol-generating material 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably 42 mm.

In one example, the overall length of the item 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

One axial end of the aerosol-generating material body 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 include an end member (not shown) that covers one axial end of the aerosol-generating material body 103.

The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

In one example, the cooling segment 107 is an annular tube that is disposed around and defines a gap in the cooling segment. The gap provides a chamber through which heated volatile components generated from the body of aerosol-generating material 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 101 during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol generating material 103 when the aerosol generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the body of aerosol-generating material 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may become damaged during use and may no longer effectively perform its required function.

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 specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, preferably 25 mm.

The cooling segment 107 is made of paper, meaning that it is constructed from a material that does not produce compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 51 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

In another example, the cooling segment 107 is a recess made from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and while the article 101 is in use during insertion into the device 51.

The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be substantially centered within the filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, the capsule, if present, may contain a volatile component, such as a flavoring or an 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 resistance to suction of the article 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the resistance to suction of the article 101. Furthermore, the filter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting the cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips against the surface of the filter segment 109.

In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

The mouth end segment 111 is an annular tube that is disposed around and defines a cavity within the mouth end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacture and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness and straightness.

The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

It should be appreciated that in one example, the oral end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 disposed within the tube to separate the oral end segment 111 and the cooling segment 107.

Referring to Figures 3 and 4, a partial cutaway cross-sectional view and a perspective view of an example of an article 301 are shown. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

In the example of article 301 shown in Figures 3 and 4, a ventilation area 317 is provided in article 301 to allow air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation area 317 takes the form of one or more ventilation holes 317 formed through an outer layer of article 301. The ventilation holes may be located in cooling segment 307 to aid in cooling article 301. In one example, ventilation area 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of a laser technique, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

In one example, the row of ventilation holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The ventilation holes 317 are located such that the user does not block the ventilation holes 317 when the article 301 is in use.

By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 51 when the article 301 is fully inserted into the device 51, as seen in Figures 6 and 7. By locating the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 51 through the vent holes to help cool the article 301.

The length of the cooling segment 307 is such that when the item 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 provides a first function of providing a physical gap between the heating device of the device 51 and the heat-sensitive filter device 309, and a second function of allowing the vent 317 to be located within the cooling segment while also being located outside the device 51 when the item 301 is fully inserted into the device 51. As can be seen from Figures 6 and 7, most of the cooling element 307 is located within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vent 317 is located in this portion of the cooling element 307 that extends outside the device 51.

5-7 in more detail, there is shown an example of a device 51 configured to heat an aerosol-forming material to volatilize at least one component of said aerosol-forming material, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, but not combusting, the aerosol-forming material.
The first end 53 may be referred to herein as the oral or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button 57, allowing the entire device 51 to be activated/deactivated as desired by the user.

The device 51 includes a housing 59 for arranging and protecting the various internal components of the device 51. In the illustrated example, the housing 59 includes a unitary sleeve 11 that surrounds the outer edge of the device 51 and is capped with a top panel 17 that generally forms the "top" of the device 51 and a bottom panel 19 that generally forms the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

The top panel 17 and/or bottom panel 19 may be removably secured to the unitary sleeve 11 to allow easy access to the interior of the device 51, or may be "permanently" secured to the unitary sleeve 11, for example to prevent a user from accessing the interior of the device 51. In one example, the panels 17 and 19 are made of a plastic material (including glass-filled nylon formed by injection molding, etc.) and the unitary sleeve 11 is made of aluminum, although 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 a user can insert and remove an article 101, 301 containing an aerosol-generating material into and from the device 51 during use.

The housing 59 has disposed therein or secured thereto the heating device 23, the control circuitry 25, and the power source 27. In this example, the heating device 23, the control circuitry 25, and the power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuitry 25 is generally located between the heating device 23 and the power source 27, although other arrangements are possible.

The control circuitry 25 may include a controller, such as a microprocessor device, configured and arranged to control the heating of the aerosol generating material within the article 101, 301, as discussed further below.

The power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically coupled to the heating device 23 and provides power under the control of the control circuitry 25 when needed to heat the aerosol-forming material within the article (to volatilize the aerosol-forming material without burning it, as described above).

The advantage of placing the power source 27 laterally adjacent to the heating apparatus 23 is that a physically larger power source 25 can be used without making the overall device 51 excessively long. Of course, a physically larger power source 25 will generally have a higher capacity (i.e., total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore may provide a longer battery life for the device 51.

In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride ceramics, as well as silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), resistive heating elements formed by resistive electrical windings, and the like.

In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the article 101, 301 is inserted into the device 51, substantially the entire body of the article 101, 301, which is made of aerosol-generating material 103, 303, is inserted into the heating device 23.

The or each heating element may be arranged to heat selected zones (areas) of the aerosol-generating material independently, for example sequentially (over time as described above) or together (simultaneously), as desired.

The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heating device 23 to the exterior of the device 51. This generally reduces heat loss and therefore helps to keep the power requirements of the heating device 23 low. The insulation 31 also helps to keep the exterior of the device 51 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and/or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (including, for example, a suitable foam-type material) in addition to or instead of the double-walled sleeve.

The housing 59 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23.

The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 disposed 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 along the outer surface of the chamber 35, each fin being disposed to surround the outer surface of the chamber 35. When the article 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, there is a gap 36 between the hollow chamber 35 and the article 101, 301. The gap 36 surrounds the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

The collar 33 includes a number of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage an article 101, 301 inserted into the device to help secure it within the device 51. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the articles 101, 301 form ventilation paths around the outer surfaces of the articles 101, 301. These ventilation paths allow hot steam escaping from the articles 101, 301 to exit the device 51, and allow cooling air to flow around the articles 101, 301 in the gap 36 into the device 51.

In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. With particular reference to Figure 6, in one example, the body of aerosol-generating material 103, 303 (which is disposed at the distal end 115, 315 of the article 101, 301) is completely contained within the heating arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

During operation, the heating device 23 heats the article 101, 301 to volatilize at least one component of the aerosol-generating material from the aerosol-generating material body 103, 303.

The primary flow path for the heated volatile components from the aerosol-generating body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating body is between 60° C. and 250° C., which may be above an acceptable inhalation temperature for a user. The heated volatile components cool as they travel through the cooling segment 107, 307, and some of the volatile components condense on the inner surface of the cooling segment 107, 307.

In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

Another aspect of the invention provides a method of making the aerosol-generating compositions described herein.

The method typically comprises the steps of providing an amorphous solid as described herein above, providing a tobacco material as described herein above, and combining the amorphous solid and the tobacco material in a ratio to obtain an aerosol generating composition having an aerosol-forming material content of about 5-30% by weight of the aerosol generating composition.

In examples, the amorphous solid is provided as a shredded sheet. In particular examples, the step of providing the amorphous solid comprises shredding a sheet of the amorphous solid to provide the amorphous solid as a shredded sheet. In examples, the tobacco material is fine cut, and the step of combining the amorphous solid and the tobacco material comprises blending the shredded sheet of the amorphous solid with the fine cut tobacco material.

In an example, the step of providing the amorphous solid comprises (a) forming a slurry comprising components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form the amorphous solid.

Forming the layer of slurry (b) typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrostatically spraying the slurry. In an example, the slurry layer is formed by casting the slurry.

In some instances, (b) and/or (c) and/or (d) are performed at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (b), (c) and (d) are performed sequentially.

In some instances, the slurry is applied to a substrate. A layer of the slurry may be formed on the substrate.

In an example, the slurry comprises a gelling agent, an aerosol forming material, and an active agent. The slurry may comprise these components in any of the proportions set forth herein for compositions of amorphous solids. For example, the slurry may comprise (on a dry weight basis):
a gelling agent, and optionally a filler, wherein the amount of gelling agent and filler combined is about 10-60% by weight of the slurry;
an aerosol forming material in an amount of about 40-80% by weight of the slurry;
Optionally, an active agent in an amount of up to about 20% by weight of the slurry; and
The present invention may also include:

Hardening the gel (c) may include providing a hardening agent to the slurry. For example, the slurry may comprise sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a hardening agent comprising a calcium source (e.g., calcium chloride) may be added to the slurry to form a calcium alginate gel.

In examples, the hardener comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the hardener comprises or consists of calcium formate and/or calcium lactate. In certain examples, the hardener comprises or consists of calcium formate. The inventors have determined that the use of calcium formate as a hardener typically results in an amorphous solid having higher tensile strength and higher resistance to elongation.

The total amount of hardening agent, e.g., calcium source, may be 0.5 to 5 wt. % (calculated on a dry weight basis). Preferably, the total amount may be about 1 wt. %, 2.5 wt. %, or 4 wt. % to about 4.8 wt. %, or 4.5 wt. %. The inventors have found that adding too little hardening agent may result in an amorphous solid that does not stabilize the amorphous solid components, causing these components to fall out of the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

When the amorphous solid does not include tobacco, it may be necessary to apply a larger amount of hardener. In some instances, therefore, the total amount of hardener may be 0.5 to 12% by weight, for example 5 to 10% by weight, calculated on a dry weight basis. Suitably, the total amount may be from about 5%, 6%, or 7% to about 12%, or 10% by weight. In this instance, the amorphous solid generally does not include tobacco.

In an example, providing the hardener to the slurry includes spraying the hardener onto the slurry, e.g., onto a top surface of the slurry.

Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. The inventors have determined that alginates having a high G monomer content form gels more readily upon addition of a calcium source. Thus, in some examples, the gel precursor may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

In examples, drying (d) removes from about 50%, 60%, 70%, 80%, or 90% to about 80%, 90%, or 95% of the water (by weight, WWB) in the slurry.

In an example, drying (d) reduces the cast material thickness by at least 80%, preferably 85% or 87%. For example, the slurry is cast to a thickness of 2 mm and the resulting dried amorphous solid material has a thickness of 0.2 mm.

The slurry itself also forms part of the invention. In some examples, the slurry solvent consists essentially of water or consists of water. In some examples, the slurry comprises about 50%, 60%, 70%, 80%, or 90% solvent by weight (WWB).

In examples where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the amorphous solids. Thus, discussion herein of the composition of solids is expressly disclosed in combination with the slurry aspects of the invention.

According to aspects of the invention, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system described herein. In examples, the method comprises heating the aerosol generating composition to a temperature of 350° C. or less. The method typically comprises heating the aerosol generating composition to a temperature of 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 about 220° C. to about 280° C. over a use session.

As used herein, a "use session" refers to a single period of use of a non-combustion aerosol delivery system by a user. A use session begins when power is first applied to at least one heating unit present in the heating assembly. The device is ready for use after a period of time has elapsed since the start of the use session. A use session ends when power is not applied to any of the heating elements of the aerosol delivery device. The end of a use session may coincide with the point at which the smoking article is depleted (the point at which the user considers the total particulate matter yield (mg) per puff to be unacceptably low). A session has a duration of multiple puffs. The session may have a duration of 7 minutes, or 6 minutes, or 5 minutes, or 4 minutes 30 seconds, or less than 4 minutes, or 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, or 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or preferably 4 minutes. A session may be initiated by a user activating a button or switch on the device, initiating a temperature increase in at least one heating element.

According to an aspect of the present invention, there is provided a use of the non-combustion aerosol delivery system described herein. The use of the non-combustion aerosol delivery system may comprise interacting with the non-combustion aerosol delivery device (e.g., actuating an actuator) to initiate a smoking session.

Example 1
Two amorphous solids (AS1 and AS2) were prepared according to the methods described herein. Each amorphous solid was formed from a slurry comprising water and the following ingredients:

AS1 was formed by providing calcium lactate as a hardening agent to the slurry, and AS2 was formed by providing calcium formate as a hardening agent to the slurry. The compositions exhibited the following physical properties (measurements were obtained from standard protocols known to those skilled in the art):

Example 2
A third, fourth and fifth amorphous solid (AS3, AS4 and AS5) were prepared according to the methods described herein. The amorphous solids were formed from a slurry comprising water and the following ingredients:

AS3 was formed without the addition of a hardening agent, AS4 was formed by providing calcium lactate as a hardening agent to the slurry, and AS5 was formed by providing calcium formate as a hardening agent to the slurry. The compositions exhibited the following physical properties (measurements were obtained from standard protocols known to those skilled in the art):

Each of the amorphous solids prepared in Examples 1 and 2 was blended with tobacco to provide an aerosol-generating composition that was found to have desirable sensory characteristics and aerosol generation.

All weight percentages (designated as wt. %) set forth herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights listed on a dry weight basis refer to the totality of the extract or slurry or material other than water, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages listed on a wet weight basis refer to all ingredients, including water.

For the avoidance of doubt, where the term "comprising" is used herein in defining the invention or features of the invention, there are also disclosed embodiments in which the invention or features may be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material "comprising" certain features means that those features are contained in, contained in, or retained within the material.

Any feature described in connection with one aspect of the invention is expressly disclosed in combination with any other aspect described herein.

The above-described embodiments should be understood as illustrative of the present invention. Further embodiments of the present invention are envisioned. It should be understood that any feature described in connection with 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 embodiment, or any combination of any other embodiments. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the present invention, which is defined in the appended claims.

Claims (43)

an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
Gelling agent,
optionally a filler, wherein the amount of gelling agent and filler combined is about 10-60% by weight of said amorphous solid; and optionally an active agent in an amount of up to about 20% by weight of said amorphous solid;
Tobacco materials;
1. An aerosol forming composition comprising:
An aerosol-forming composition, wherein the aerosol-forming composition has an aerosol-forming material content of about 5-30% by weight of the aerosol-forming composition, these weights being calculated on a dry weight basis. The aerosol generating composition of claim 1, wherein the aerosol forming material content is about 10-20% by weight of the aerosol generating composition. The aerosol generating composition of claim 1 or 2, wherein the amorphous solid is contained in the aerosol generating composition in an amount of about 5 to 40% by weight of the aerosol generating composition. The aerosol generating composition of any one of claims 1 to 3, wherein the bulking agent is present in the amorphous solid in an amount of about 1 to 15% by weight of the amorphous solid. The aerosol generating composition of any one of claims 1 to 3, wherein the amorphous solid does not comprise a filler. The aerosol generating composition according to any one of claims 1 to 5, wherein the aerosol forming material is contained in the amorphous solid in an amount of 50 to 70% by weight of the amorphous solid. The aerosol generating composition of any one of claims 1 to 6, wherein the gelling agent is present in the amorphous solid in an amount of about 5 to 50% by weight of the amorphous solid. The aerosol generating composition of any one of claims 1 to 7, wherein the active agent comprises a flavoring agent. The aerosol generating composition of any one of claims 1 to 7, wherein the amorphous solid does not comprise an active agent. The aerosol generating composition of any one of claims 1 to 9, wherein the aerosol forming material comprises glycerol. The aerosol generating composition of any one of claims 1 to 10, wherein the gelling agent comprises alginate and/or pectin and/or guar gum. The aerosol generating composition of claim 11, wherein the alginate is present in an amount of at least 50% by weight of the gelling agent. The aerosol-forming composition of any one of claims 1 to 12, wherein the tobacco material is fine cut. The aerosol forming composition of any one of claims 1 to 13, wherein the tobacco material comprises laminar tobacco. The aerosol forming composition of claim 14, wherein the tobacco material comprises laminar tobacco in an amount of at least about 60% by weight of the tobacco material. The aerosol forming composition of claim 15, wherein the tobacco material comprises laminar tobacco in an amount of at least about 95% by weight of the tobacco material. The aerosol-forming composition of claim 16, wherein the tobacco material comprises laminar tobacco. The aerosol forming composition of any one of claims 1 to 16, wherein the tobacco material comprises less than 1% by weight of reconstituted tobacco. The aerosol-forming composition of any one of claims 1 to 16, wherein the tobacco material is substantially free of reconstituted tobacco. The aerosol-forming composition of any one of claims 1 to 19, wherein the tobacco material comprises cut rag tobacco. 21. The aerosol forming composition of claim 20, wherein the cut rag tobacco is present in an amount of at least 90% by weight of the tobacco material. The aerosol-forming composition of any one of claims 1 to 21, wherein the tobacco material comprises an aerosol-forming material in an amount of 1 to 10% by weight of the tobacco material. The aerosol generating composition of any one of claims 1 to 22, wherein the amorphous solid is a shredded sheet. 24. The aerosol forming composition of claim 23, wherein the shredded sheet of amorphous solid is blended with the tobacco material. The aerosol-forming composition of claim 23 or 24, wherein the tobacco material comprises shredded rag tobacco having a cut width, the amorphous solid shredded sheet has a cut width, and the cut width of the amorphous solid is about 90-110% of the cut width of the shredded rag tobacco. The aerosol-forming composition of any one of claims 1 to 25, wherein the tobacco material has an areal density, the amorphous solid has an areal density, and the areal density of the amorphous solid is about 90-110% of the areal density of the tobacco material. An article for use with a non-combustion aerosol delivery device, comprising the aerosol generating composition of any one of claims 1 to 26. An article for use with a non-combustion type aerosol delivery device, comprising the aerosol generating composition of any one of claims 1 to 22 and 26, wherein the amorphous solid is disposed in the article in sheet form. 29. The article of claim 28, wherein the tobacco material is in the form of a substantially cylindrical rod and the sheet of amorphous solid surrounds the rod of tobacco material. The article of any one of claims 27 to 29, which is in the form of a substantially cylindrical rod. A non-combustion aerosol delivery system comprising an article according to any one of claims 27 to 30 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device being configured to generate aerosol from the article when the article is used with the non-combustion aerosol delivery device. The system of claim 31, wherein the non-combustion aerosol delivery device comprises a heater configured to heat but not combust the item. 1. A method of making an aerosol-forming composition, comprising:
an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
Gelling agent,
providing an amorphous solid comprising, optionally, a filler, wherein the amount of gelling agent and filler combined is about 10-60% by weight of said amorphous solid; and, optionally, an active agent in an amount up to about 20% by weight of said amorphous solid;
Providing a tobacco material;
combining the amorphous solid and a tobacco material to obtain an aerosol-forming composition, the aerosol-forming composition having an aerosol-forming material content of about 5-30% by weight of the aerosol-forming composition;
wherein weight is calculated on a dry weight basis. providing the amorphous solid,
Providing a slurry comprising a gelling agent, an aerosol forming material, optionally a filler, and optionally an active agent;
forming a layer of said slurry;
hardening the slurry to form a gel; and drying the gel to form the amorphous solid.
34. The method of claim 33, comprising: 35. The method of claim 34, wherein the hardening comprises providing a hardener to the slurry. 36. The method of claim 35, wherein delivering the hardener comprises spraying the hardener onto a surface of the slurry. The method of claim 35 or 36, wherein the hardener comprises calcium formate. The method of any one of claims 33 to 37, wherein the step of providing the amorphous solid comprises shredding a sheet of the amorphous solid to provide the amorphous solid as a shredded sheet. The method of any one of claims 33 to 37, wherein the amorphous solid is a shredded sheet. The method of any one of claims 33 to 39, wherein the tobacco material is fine cut. 41. The method of claim 40, wherein the step of combining the amorphous solids and tobacco material comprises blending the amorphous solid shredded sheet and the fine cut tobacco material. A method of generating an aerosol using the non-combustion aerosol delivery system of claim 31 or 32, comprising heating the aerosol generating composition to a temperature of less than 350°C. Use of the non-combustion aerosol delivery system according to claim 31 or 32.

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