AEROSOL-GENERATING CONSUMABLE INCLUDING SENSATE

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority pursuant under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 63/681,296, filed Aug. 9, 2024, which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to consumables comprising an aerosol-generating material for use within a combustible or non-combustible aerosol provision system, and to non-combustible and combustible aerosol provision systems.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapor by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol-generating assemblies or non-combustible aerosol provision systems. One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain a tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products (THP). Various different arrangements for volatilizing at least one component of the solid aerosolizable material are known.

As another example, there are e-cigarette/tobacco heating product hybrid devices, also known as electronic tobacco hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporized by heating to produce an inhalable vapor or aerosol. These devices additionally contain a solid aerosolizable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapor or aerosol to produce the inhaled medium.

For certain types of devices described above, a sensate, such as a cooling agent, is applied to a wrapping material used to enwrap an aerosol-generating material, as set forth in WO2021/176215.

BRIEF SUMMARY

The present disclosure relates to aerosol-generating components and aerosol delivery devices that utilize electrically-generated heat or combustible ignition sources to heat an aerosol-generating material in order to provide an inhalable substance in the form of an aerosol for human consumption. The present disclosure addresses the problem of loss of sensate applied to a wrapping material of a consumable for aerosol delivery systems during manufacture of the consumable. In particular, the problem of sensate volatility during manufacturing is addressed, for example, by spacing a coating containing the sensate from the longitudinal edge of the wrapping material used to seal the wrapping material and/or by mixing the sensate with a carrier material, such as an anionic carrier material, to reduce vapor pressure of the sensate.

The disclosure includes, without limitations, the following embodiments.

Embodiment 1: A consumable for generating an aerosol, the consumable comprising: an aerosol-generating segment and a mouth-end segment, each of the aerosol-generating segment and the mouth-end segment comprising one or more circumscribing wrapping materials, wherein at least one circumscribing wrapping material has a longitudinal edge adapted for sealing the circumscribing wrapping material, and wherein the at least one circumscribing wrapping material includes a coating comprising a sensate spaced at least about 1.0 mm from the longitudinal edge.

Embodiment 2: The consumable of Embodiment 1, wherein the at least one circumscribing wrapping material includes a coating comprising a sensate spaced at least about 1.5 mm from the longitudinal edge, such as about 1.75 mm or more, or about 2.0 mm or more (e.g., spaced from the longitudinal edge by a distance of about 1.5 mm to about 5.0 mm or about 1.75 mm to about 4.0 mm).

Embodiment 3: The consumable of Embodiment 1 or 2, wherein the sensate is a cooling agent.

Embodiment 4: The consumable of any one of Embodiments 1 to 3, wherein the cooling agent is selected from the group consisting of WS-3, WS-23, WS-5, (1R,2S,5R)—N-(4-(cyanomethyl)phenyl) menthylcarboxamide, (1R,2S,5R)—N-(2-(pyridin-2-yl)ethyl) menthylcarboxamide, and combinations thereof.

Embodiment 5: The consumable of any one of Embodiments 1 to 4, wherein the coating comprises from about 0.1 mg to about 5 mg of the sensate, or from about 0.3 mg to about 2.5 mg of the sensate, or from about 0.7 mg to about 2.0 mg of the sensate.

Embodiment 6: The consumable of any one of Embodiments 1 to 5, wherein the at least one circumscribing wrapping material enwraps the aerosol-generating segment.

Embodiment 7: The consumable of any one of Embodiments 1 to 6, wherein the mouth-end segment includes at least one filter material.

Embodiment 8: The consumable of any one of Embodiments 1 to 7, wherein the aerosol-generating segment comprises an aerosol-generating material, the aerosol-generating material comprising one or more of tobacco, a non-tobacco botanical material, a binder, and an aerosol former material.

Embodiment 9: The consumable of any one of Embodiments 1 to 7, wherein the aerosol-generating segment comprises an aerosol-generating material, the aerosol-generating material comprising an aerosol former material selected from the group consisting of water, a polyhydric alcohol, a polysorbate, a sorbitan ester, a fatty acid, a fatty acid ester, a wax, a cannabinoid, a terpene, a sugar alcohol, and combinations thereof.

Embodiment 10: The consumable of Embodiment 9, wherein the aerosol former material comprises a polyhydric alcohol, such as a polyhydric alcohol selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

Embodiment 11: The consumable of any one of Embodiments 1 to 10, wherein the sensate is mixed with a carrier material.

Embodiment 12: The consumable of Embodiment 11, wherein the carrier material comprises a plurality of anionic groups, such as carboxyl groups, sulfate groups, sulfonate groups, nitrate groups, phosphate groups, or salts thereof.

Embodiment 13: The consumable of Embodiment 11 or 12, wherein the carrier material is a polysaccharide such as cellulose or a derivative thereof.

Embodiment 14: A consumable for use in an aerosol delivery device, the consumable comprising: an aerosol-generating segment and a mouth-end segment, each of the aerosol-generating segment and the mouth-end segment comprising one or more circumscribing wrapping materials, and wherein at least one circumscribing wrapping material includes a coating comprising a sensate mixed with a carrier material.

Embodiment 15: The consumable of Embodiment 14, wherein the carrier material comprises a plurality of anionic groups, such as carboxyl groups, sulfate groups, sulfonate groups, nitrate groups, phosphate groups, or salts thereof.

Embodiment 16: The consumable of Embodiment 14 or 15, wherein the carrier material is a polysaccharide such as cellulose or a derivative thereof.

Embodiment 17: The consumable of any one of Embodiments 14 to 16, wherein the sensate is a cooling agent.

Embodiment 18: The consumable of Embodiment 17, wherein the cooling agent is selected from the group consisting of WS-3, WS-23, WS-5, (1R,2S,5R)—N-(4-(cyanomethyl)phenyl) menthylcarboxamide, (1R,2S,5R)—N-(2-(pyridin-2-yl)ethyl) menthylcarboxamide, and combinations thereof.

Embodiment 19: The consumable of any one of Embodiments 14 to 18, wherein the coating comprises from about 0.1 mg to about 5 mg of the sensate, or from about 0.3 mg to about 2.5 mg of the sensate, or from about 0.7 mg to about 2.0 mg of the sensate.

Embodiment 20: The consumable of any one of Embodiments 14 to 19, wherein the at least one circumscribing wrapping material enwraps the aerosol-generating segment.

Embodiment 21: The consumable of any one of Embodiments 14 to 20, wherein the mouth-end segment includes at least one filter material.

Embodiment 22: The consumable of any one of Embodiments 14 to 21, wherein the aerosol-generating segment comprises an aerosol-generating material, the aerosol-generating material comprising one or more of tobacco, a non-tobacco botanical material, a binder, and an aerosol former material.

Embodiment 23: A combustible aerosol provision system comprising the consumable of any one of Embodiments 1 to 22.

Embodiment 24: The combustible aerosol provision system of claim 23, in the form of a cigarette.

Embodiment 25: A non-combustible aerosol provision system comprising the consumable of any one of Embodiments 1 to 22 and a heating device adapted to generate aerosol from the consumable.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The disclosure includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are exemplary only and should not be construed as limiting the disclosure.

FIGS. 1A and 1B illustrate example embodiments of a wrapping material for an aerosol-generating consumable with different sensate coating configurations;

FIG. 2 illustrates schematic side view of an aerosol-generating consumable according to an example embodiment of the disclosure;

FIG. 3 illustrates an exploded view of an aerosol-generating consumable according to an example embodiment of the present disclosure;

FIG. 4 illustrates a cross-sectional view of an aerosol-generating consumable according to an example embodiment of the disclosure;

FIG. 5 illustrates a perspective view of the aerosol-generating consumable of FIG. 4;

FIG. 6 illustrates a perspective view of a non-combustible aerosol provision system according to an embodiment of the disclosure; and

FIG. 7 illustrates a cross-sectional view of the non-combustible aerosol provision system of FIG. 6.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof. These example embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Reference to “dry weight percent” or “dry weight basis” refers to weight on the basis of dry ingredients (i.e., all ingredients except water). Reference to “wet weight” refers to the weight of the mixture including water. Unless otherwise indicated, reference to “weight percent” of a material reflects the total wet weight of the material (i.e., including water).

As described hereinafter, the present disclosure generally relates to aerosol-generating materials, components, and consumables, as well as methods of making the same. Further provided are combustible and non-combustible aerosol provision system comprising the aerosol-generating materials, components, and consumables. The aerosol-generating components comprise an aerosol-generating material. The aerosol-generating materials, components, and consumables described herein are capable of generating an aerosol, for example when heated, irradiated, or energized in any other way.

The present disclosure provides aerosol-generating consumables comprising a wrapping material coated with a sensate, such as a trigeminal sensate. As used herein, “trigeminal sensate” refers to an agent which has an effect on the trigeminal nerve, producing sensations including heating, cooling, tingling, and the like. Non-limiting examples of trigeminal sensates include capsaicin, citric acid, menthol, Sichuan buttons, crythritol, and cubebol. The wrapping material can include one sensate or a combination of two or more sensates.

In some embodiments, the wrapping material is coated with a sensate that provides a cooling effect. Suitable cooling agents include, but are not limited to, menthane, menthone, menthone ketals, menthone glycerol ketals (e.g., menthone 1,2-glycerol ketal), substituted p-menthanes, substituted p-menthane-carboxamides, acyclic carboxamides, substituted cyclohexanamides, substituted cyclohexane carboxamides, substituted ureas and sulfonamides, substituted menthanols, hydroxymethyl and hydroxymethyl derivatives of p-menthane, hydroxycarboxylic acids with 2-6 carbon atoms, cyclohexanamides, cyclic alpha-keto enamines, and cyclotene derivatives (e.g., 3-methyl-2-(1-pyrrolidinyl)-2-cyclopenten-1-one and 5-methyl-2-(1-pyrrolidinyl)-2-cyclopenten-1-one).

Example cooling agents include monomenthyl glutarate, menthyl acetate, menthyl salicylate, N-ethyl-p-menthane-3-carboxamide (WS-3), ethyl ester of N-[[5-methyl-2-(1-methylethyl)cyclohexyl]carbonyl]glycine (WS-5), WS-14, N,2,3-trimethyl-2-isopropyl butanamide (WS-23), WS-27, WS-30, (−)-Menthyloxyethanol (Coolact® 5), WS-NA (FEMA 4693), WS-116 (FEMA 4603), N-ethyl-2,2-diisopropylbutanamide, isopulegol, menthyloxy propane diol, 3-(1-menthoxy) propane-1,2-diol, 3-(1-menthoxy)-2-methylpropane-1,2-diol, p-menthane-2,3-diol, p-menthane-3,8-diol, 6-isopropyl-9-methyl-1,4-dioxaspiro[4,5]decane-2-methanol, menthyl succinate and its alkaline earth metal salts, trimethylcyclohexanol, N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide, Japanese mint oil, peppermint oil, 3-(1-menthoxy) ethan-1-ol, 3-(1-menthoxy) propan-1-ol, 3-(1-menthoxy) butan-1-ol, 1-menthylacetic acid N-ethylamide, 1-menthyl-4-hydroxypentanoate, 1-menthyl-3-hydroxybutyrate, menthyl glutarate, N,2,3-trimethyl-2-(1-methylethyl)-butanamide, N-ethyl-trans-2-cis-6-nonadienamide, N,N-dimethyl menthyl succinamide, 2-mercapto-cyclo-decanone, N-(2-Hydroxyethyl)-2,3-dimethyl-2-isopropylbutanamide, 2-isopropanyl-5-methylcyclohexanol, menthyl ethylene glycol carbonate, menthone(S)-lactic acid ketal, menthyl acetoacetate, 3-1-menthoxypropane-1,2-diol, menthyl lactate, eucalyptus extract, menthol propylene glycol carbonate, menthol ethylene glycol carbonate, menthol glyceryl ether, N-tert-butyl-p-menthane-3-carboxamide, p-menthane-3-carboxylic acid glycerol ester, methyl-2-isopropyl-bicyclo[2.2.1]heptane-2-carboxamide, (1R,2S,5R)—N-(4-(carbamoylmethyl)phenyl)-menthylcarboxamide, 2-[2-(p-menthan-3-yloxy) ethoxy]ethanol, (1R,2R,4R)-1-(2-Hydroxy-4-methylcyclohexyl) ethenone, 2-(p-tolyloxy)-N-(1H-pyrazol-5-yl)-N-((thiophen-2-yl)methyl) acetamide, menthol methyl ether, menthyl pyrrolidone carboxylate, and 2,5-dimethyl-4-(1-pyrrolidinyl)-3 (2H)-furanone. Other cooling agent compounds include the alpha-keto enamines disclosed in U.S. Pat. No. 6,592,884 to Hofmann et al., which is incorporated in its entirety herein. These and other suitable cooling agents are further described in the following U.S. patents, all of which are incorporated in their entirety by reference hereto: U.S. Pat. Nos. 4,230,688; 4,032,661; 4,459,425; 4,178,459; 4,296,255; 4,136,163; 5,009,893; 5,266,592; 5,698,181; 6,277,385; 6,627,233; 7,030,273. Still other suitable cooling agents are further described in US Patent Application Publications Nos. 2005/0222256 and 2005/0265930, each of which are incorporated in their entirety by reference hereto.

In some embodiments, the cooling agent comprises WS-3, WS-23, WS-5, (1R,2S,5R)—N-(4-(cyanomethyl)phenyl) menthylcarboxamide (Evercool™ 180), (1R,2S,5R)—N-(2-(pyridin-2-yl)ethyl) menthylcarboxamide (Evercool™ 190), or a combination thereof.

One example cooling agent, WS-3, is a TRPM8 receptor agonist that provides an intense and lingering cooling trigeminal effect without noticeable smell or taste.

Various names for WS-3 include N-ethyl-5-methyl-2-propan-2-ylcyclohexane-1-carboxamide; N-ethyl-5-methyl-2-(1-methylethyl)cyclohexane carboxamide; N-ethyl-2-isopropyl-5-methylcyclohexane carboxamide; ethyl menthane carboxamide; and N-ethyl-p-menthane-3-carboxamide. Its molecular formula is C₁₃H₂₅NO.

In some embodiments, the composition comprises a sensate that provides a warming effect. Suitable warming agents include, but are not limited to, ethers of vanillyl alcohol (e.g., methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, isoamyl, n-hexyl), gingerol, shogaol, paradol, zingerone, capsaicin, dihydrocapsaicin, nordihydrocapsaicin, homocapsaicin, homodihydrocapsaicin, benzyl alcohol, and combinations thereof. In some embodiments, the warming agent comprises vanillyl butyl ether, vanillyl ethyl ether, capsaicin, or a combination thereof.

It has been discovered that the presence of sensate on a wrapping material of an aerosol-generating consumable during manufacturing of the consumable can cause, in some embodiments, undesirable vaporization of sensate during manufacture, which results in loss of the sensory impact of sensate when the consumable is used by the consumer and a potential environmental hazard during manufacturing. In particular, it has been discovered that the presence of sensate in the region of the wrapping material subjected to a heating bar for seam sealing of the wrapping material can vaporize the sensate, in some embodiments. For example, when a sensate is coated on the entirety of the wrapping material, or in circumscribing bands, as set forth in WO2021/176215, the undesired vaporization can occur.

According to the present disclosure, in some embodiments, wrapping materials for an aerosol-generating consumable are provided with a coating of sensate in discrete sections in spaced relation from the longitudinal edge of the wrapping material such that sealing of a seal by heating the longitudinal edge of the wrapping material is less likely to cause vaporization of sensate. A typical sealing region for an aerosol-generating consumable wrapping material is about 1 to about 2 mm in width (i.e., the width of the region where the wrapping material overlaps for scaling when placed in circumscribing arrangement around a consumable rod). In some embodiments, the sensate coating is spaced from the opposing longitudinal edges of the wrapping material by about 1.0 mm or more, such as about 1.25 mm or more, or about 1.5 mm or more, or about 1.75 mm or more, or about 2.0 mm or more, or about 2.25 mm or more, or about 2.5 mm or more, or about 2.75 mm or more, or about 3.0 mm or more (e.g., spaced from the longitudinal edge by a distance of about 1.5 mm to about 5.0 mm or about 1.75 mm to about 4.0 mm). As used herein, reference to the longitudinal edge of a wrapping material refers to the edge extending in the longitudinal direction of the consumable and which is used for to form a lap seam to secure the wrapping material in a circumscribing arrangement around an interior component of the consumable (e.g., a filter section or an aerosol-generating section).

Other than the spacing of the sensate coating from the longitudinal edge of the wrapping material, the sensate coating can have a variety of configurations or patterns. As shown in FIGS. 1A and 1B, the wrapping material 10 having longitudinal edges 12, 12′ can include a single longitudinal band 14 (FIG. 1A) or multiple longitudinal bands 14′ (FIG. 1B). The sections of sensate coating need not extend in continuous bands along the entire length of the wrapping material 10 as shown, but rather may be placed in discrete, discontinuous sections if desired.

In some embodiments, the sensate is provided in a band having a length (noted as L in FIG. 1A), of at least about 0.1 mm, at least about 1 mm, at least about 5 mm, at least about 7 mm, at least about 10 mm, at least about 15 mm, at least about 20 mm, or at least about 25 mm. In some embodiments, the sensate is provided in a band having a width of up to about 73 mm, up to about 60 mm, up to about 50 mm, up to about 45 mm, up to about 40 mm, up to about 35 mm, up to about 30 mm, or up to about 25 mm.

In some embodiments, the sensate is provided in a band having a width (noted as W in FIG. 1A), of at least about 0.1 mm, at least about 1 mm, at least about 5 mm, at least about 7 mm, at least about 10 mm, at least about 15 mm, at least about 20 mm, or at least about 25 mm. In some embodiments, the sensate is provided in a band having a width of up to about 50 mm, up to about 40 mm, up to about 35 mm, up to about 30 mm, up to about 25 mm, up to about 20 mm, up to about 15 mm, or up to about 10 mm.

In some embodiments, the wrapping material contains from about 0.1 mg to about 5 mg sensate, or from about 0.3 mg to about 2.5 mg sensate or from about 0.7 mg to about 2.0 mg sensate, or from about 0.9 mg to about 1.5 mg sensate. In some embodiments, a wrapping material is provided comprising up to about 10 mg of sensate.

In another embodiment, volatility of sensates such as WS-3 can be reduced by combining the sensate with a carrier material, such as a carrier material capable of forming hydrogen bonding or ionic bonding with the sensate. Although not bound by a theory of operation, it is believed that associating the sensate with such a carrier material can increasing the transition temperature and/or reduce the vapor pressure of the sensate such that the sensate is less likely to vaporize during the application of heat applied during manufacture (e.g., such as heat applied by a heater bar during scaling of a lap seam to seal the circumscribing wrapping material together). Example carrier materials include cellulosic materials or other polysaccharides, including cellulosic materials or other polysaccharides modified to incorporate anionic functional groups, such as carboxyl groups, sulfate groups, sulfonate groups, nitrate groups, phosphate groups, or salts thereof (such as alkali metal salts).

Cellulose is a linear polysaccharide consisting of from several hundred to many thousands of B (1→4) linked D-glucose units and having the general chemical formula (C₆H₁₀O₅)_n where n refers to the number of repeating glucose units. In cellulose obtained from plants, the number n may range from 800 to 10,000. Cellulose may be graphically represented by the corresponding formula:

Each glucose residue comprises three free hydroxyl groups: one at the 2-position relative to the anomeric center, one at the 3-position relative to the anomeric center, and one comprising the hydroxymethyl group at the 5-position relative to the anomeric center.

Examples of modified cellulose materials include carboxymethylcellulose (CMC), sodium carboxymethylcellulose (SCMC), cellulose phosphate, and cellulose sulfate. In some embodiments, the cellulose materials can be used in forms such as nanocrystals (e.g., CNCs) or nanofibers (e.g., TEMPO-oxidized CNFs). Other polysaccharides could also be used, such as anionic derivatives of alginate, xanthan gum, carrageenan, chitosan, starch, trehalose, and pectin.

In some embodiments, the carrier material can be combined with a sensate by mixing sensate powder with the carrier material in particulate form, optionally in the presence of one or more solvents, such as water or a mixture of water with water-miscible co-solvents such as various alcohols (e.g., ethanol). The slurry of sensate and carrier material in the solvent can be mixed together for a suitable period of time, such as a few minutes to a few hours, at room temperature and pressure. Thereafter, the solvent can be removed by, for example, filtration and drying at elevated temperature (e.g., about 40 to about 100° C.). Due to the reduced volatility of sensate in this embodiment, it may be unnecessary to restrict placement of the sensate coating to a location spaced from the longitudinal edge of a wrapping material as described above and, instead, the sensate coating can be placed on the entirety of the wrapping material, for example.

In some embodiments, regardless of whether sensate is combined with a carrier material or not, sensate may be applied to the wrapping material in the form of a solution or in solid form, for example in powder form. Particles of sensate may be attached to the wrapper using an adhesive. In some embodiments, the sensate is present on the inner surface of the wrapping material, which faces the circumscribed portion of the consumable (e.g., a filter element or an aerosol-generating material). In some embodiments, sensate is applied to a discrete layer of sheet material which is disposed on or adjacent to the wrapping surrounding the aerosol-generating material or other portion of a consumable.

In some embodiments, sensate is added to a wrapping material in the form of a solution or slurry including one or more solvents. For example, some sensates like WS-3 are readily soluble in alcohol, such as ethanol, and in DMSO (dimethyl sulfoxide) and thus the sensate can be applied in a solution form including such a solvent. Alternatively, if the sensate is combined with an insoluble carrier material, the sensate/carrier material combination can be coated on a wrapping material in the form of a slurry using the same solvents.

In some embodiments, the solution comprising sensate and a solvent further comprises a humectant such as propylene glycol, glycerol, or other glycols. In addition to being a convenient means of including the humectant in a consumable, the inclusion of the humectant in the sensate solution has the benefit of lowering the flash point of the solution. This is of particular benefit when the solvent is an alcohol such as ethanol. While in some embodiments a humectant, such as propylene glycol, may be used as the solvent (without an alcohol or DMSO), a combination of alcohol or DMSO and the humectant can be advantageous as such a combination reduces the total volume of liquid required to solubilize a given amount of sensate, since the solubility of some sensates like WS-3 is higher in alcohol or DMSO solvents than in humectants such as propylene glycol. In one particular embodiment, the solution comprises 1 part propylene glycol, 2 parts ethanol and 3 parts sensate. Obviously, the proportions of the components may be adjusted as desired.

In some embodiments, a liquid formulation comprising sensate is printed onto the wrapping material that circumscribes a rod of aerosol-generating material (or other portion of a consumable). Any suitable printing process maybe used, such as gravure printing, flexographic printing, off-set printing, screen printing, ink-jet printing, or other appropriate printing methods. Sensate is optionally added to further components of an article containing the sensate coated wrapping material, such as addition of sensate to the aerosol-generating materials noted below.

The wrapping materials of the present disclosure can vary, and can include wrapping materials circumscribing any portion of the consumable, such as a mouth-end segment (e.g., filter element) or an aerosol-generating segment (e.g., a tobacco-containing rod). The wrapping material typically incorporates a fibrous material (e.g., a cellulosic material) and at least one filler material imbedded or dispersed within the fibrous material. Example filler materials are typically water-insoluble particles, and can include inorganic components, such as calcium salts. Example wrapping materials can include plug wrap and tipping paper, as conventionally found in cigarette rods.

Typically, the wrapping material is a paper material, such as the type of paper material typically used in cigarette manufacture. The wrapping material can have a wide range of compositions and properties. The selection of a particular wrapping material will be readily apparent to those skilled in the art of cigarette design and manufacture. Exemplary types of wrapping materials, wrapping material components and treated wrapping materials are described in U.S. Pat. No. 5,105,838 to White et al.; U.S. Pat. No. 5,271,419 to Arzonico et al., U.S. Pat. No. 5,220,930 to Gentry, U.S. Pat. No. 6,908,874 to Woodhead et al., U.S. Pat. No. 6,929,013 to Ashcraft et al., U.S. Pat. No. 7,195,019 to Hancock et al., U.S. Pat. No. 7,276,120 to Holmes, U.S. Pat. No. 7,275,548 to Hancock et al.; PCT WO 01/08514 to Fournier et al.; and PCT WO 03/043450 to Hajaligol et al., which are incorporated herein by reference in their entireties. Representative wrapping materials are commercially available as R. J. Reynolds Tobacco Company Grades 119, 170, 419, 453, 454, 456, 465, 466, 490, 525, 535, 557, 652, 664, 672, 676 and 680 from Schweitzer-Maudit International. The porosity of the wrapping material can vary, and frequently is between about 5 CORESTA units and about 30,000 CORESTA units, often is between about 10 CORESTA units and about 90 CORESTA units, and frequently is between about 8 CORESTA units and about 80 CORESTA units.

The material use for the plug wrap can vary, and can include either porous or non-porous paper material. Exemplary plug wrap papers ranging in porosity from about 1,100 CORESTA units to about 26,000 CORESTA units are available from Schweitzer-Maudit International as Porowrap 17-M1, 33-M1, 45-M1, 70-M9, 95-M9, 150-M4, 150-M9, 240M9S, 260-M4 and 260-M4T; and from Miquel-y-Costas as 22HP90 and 22HP150. Non-porous plug wrap materials typically exhibit porosities of less than about 40 CORESTA units, and often less than about 20 CORESTA units. Exemplary non-porous plug wrap papers are available from Olsany Facility (OP Paprina) of the Czech Republic as PW646; Wattenspapier of Austria as FY/33060; Miquel-y-Costas of Spain as 646; and Schweitzer-Mauduit International as MR650 and 180. Plug wrap paper can be coated, particularly on the surface that faces the filter material, with a layer of a film-forming material. Such a coating can be provided using a suitable polymeric film-forming agent (e.g., ethylcellulose, ethylcellulose mixed with calcium carbonate, nitrocellulose, nitrocellulose mixed with calcium carbonate, or a so-called lip release coating composition of the type commonly employed for cigarette manufacture). Alternatively, a plastic film (e.g., a polypropylene film) can be used as a plug wrap material. For example, non-porous polypropylene materials that are available as ZNA-20 and ZNA-25 from Treofan Germany GmbH & Co. KG can be employed as plug wrap materials. See also, for example, U.S. Pat. No. 4,174,719 to Martin, which is incorporated by reference.

The tipping material can vary, and exemplary materials are the types conventionally used as tipping material in the manufacture of cigarettes. Typical tipping materials are papers exhibiting relatively high opacities. Representative tipping materials have TAPPI opacities of greater than about 81 percent, often in the range of about 84 percent to about 90 percent, and sometimes greater than about 90 percent. Typical tipping materials are printed with inks, typically nitrocellulose based, which can provide for a wide variety of appearances and “lip release” properties. Representative tipping papers materials have basis weights ranging from about 25 m/m² to about 60 g/m², often about 30 g/m² to about 40 g/m². Representative tipping papers are available as Tervakoski Reference Nos. 3121, 3124, TK 652, TK674, TK675, A360 and A362; and Schweitzer-Mauduit International Reference Nos. GSR270 and GSR265M2. See also, for example, the types of tipping materials, the methods for combining cigarette components using tipping materials, and techniques for wrapping various portions of cigarettes using tipping materials, that are set forth in US Pat. Appl. Pub. Nos. 2007/0215167 to Crooks et al. and 2009/0293894 to Cecchetto et al., which are incorporated by reference herein.

Aerosol-Generating Materials

Example embodiments of the present disclosure include an aerosol-generating material for use in an aerosol delivery device. The aerosol-generating materials of the disclosure generally comprise one or more of a tobacco material, a non-tobacco botanical material, a binder, and an aerosol former material.

The aerosol-generating materials as disclosed herein may comprise a tobacco material. The tobacco material can vary in species, form, and type. Generally, the tobacco material is obtained from a harvested plant of the Nicotiana species. Tobacco material can include tobacco lamina, tobacco stem, expanded tobacco, reconstituted tobacco, extruded tobacco, and the like. The tobacco material is typically used in a form that can be described as particulate, for example, shredded, ground, granulated, pulp, or powder form.

In some embodiments, tobacco materials that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Madole, Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the foregoing tobaccos.

In some embodiments, the aerosol-generating material includes a tobacco extract, such as an aqueous tobacco extract, added either as a component of the aerosol former material, or added separately (e.g., during aerosol-generating material preparation, or impregnated in the aerosol-generating material after formation). “Tobacco extract” as used herein refers to the isolated components of a tobacco material that are extracted from solid tobacco pulp by a solvent (e.g., water) that is brought into contact with the tobacco material in an extraction process.

The quantity of tobacco material present in the aerosol-generating material may vary based on the physical form of the aerosol-generating material (e.g., extruded sheet, cast sheet, beads, paper recon sheets, and the like) and the specific application. Generally, the quantity of tobacco material present is at least about 20% by weight of the aerosol-generating material, and up to about 90% by weight, based on the total weight of the aerosol-generating material. For example, a tobacco material may be present in a quantity from about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, or about 55%, to about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, or about 90% by weight of the aerosol-generating material, based on the total weight of the aerosol-generating material.

The aerosol-generating materials as disclosed herein can comprise a non-tobacco botanical material. As used herein, the term “botanical material” or “botanical” refers to any plant material or fungal-derived material, including plant material in its natural form and plant material derived from natural plant materials, such as extracts or isolates from plant materials or treated plant materials (e.g., plant materials subjected to heat treatment, fermentation, chemical, or other treatment processes capable of altering the chemical or biological nature of the material). For the purposes of the present disclosure, a “botanical material” includes but is not limited to “herbal materials,” which refer to seed-producing plants that do not develop persistent woody tissue and are often valued for their medicinal or sensory characteristics (e.g., teas or tisanes). Reference to botanical material as “non-tobacco” is intended to exclude tobacco materials (i.e., does not include any Nicotiana species). The non-tobacco botanical material can be used in particulate form or in the form of an extract.

Non-limiting examples of botanical materials include without limitation acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, Angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), bee balm, beet root, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberries, boldo (Peumus boldus), borage, bugleweed, cacao, calamus root, camu (Myrcaria dubia), cannabis/hemp, caraway seed, catnip, catuaba, cayenne, cayenne pepper, chaga mushroom, chamomile, cherry, chervil, chocolate, cinnamon (Cinnamomum cassia), citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), coffee, comfrey leaf and root, coriander seed, cranberry, dandelion, Echinacea, elderberry, elderflower, endro (Anethum graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale), gingko biloba, ginseng, goji berries, goldenseal, grape seed, grapefruit, grapefruit rosé (Citrus paradisi), graviola (Annona muricata), green tea, gutu kola, hawthorn, hibiscus flower (Hibiscus sabdariffa), honeybush, jiaogulan, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limon), licorice, lilac, Lion's mane, maca (Lepidium meyenii), marjoram, milk thistle, mints (menthe), oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quince, red clover, rooibos (red or green), roschip (Rosa canina), rosemary, sage, Saint John's Wort, salvia (Salvia officinalis), savory, saw palmetto, Silybum marianum, slippery elm bark, sorghum bran hi-tannin, sorghum grain hi-tannin, spearmint (Mentha spicata), spirulina, sumac bran, thyme, turmeric, uva ursi, valerian, vanilla, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa.

The quantity of non-tobacco botanical material present may vary based on the physical form of the aerosol-generating material (e.g., extruded sheet, cast sheet, beads, paper recon sheets, and the like) and the specific application. Generally, the quantity of non-tobacco botanical material present is less than about 50% by weight of the aerosol-generating material, based on the total weight of the aerosol-generating material. For example, a non-tobacco botanical material may be present in a quantity from about 0.1%, about 0.5%, about 1%, about 5%, about 10%, about 15%, about 20%, or about 25%, to about 30%, about 35%, about 40%, about 45%, or about 50% by weight of the aerosol-generating material, based on the total weight of the aerosol-generating material.

The aerosol-generating materials as disclosed herein can comprise a binder. A binder (or combination of binders) is employed in amounts sufficient to provide the desired physical attributes and physical integrity to the aerosol-generating material. The amount of binder utilized can vary based on the physical form of the aerosol-generating material (e.g., extruded sheet, cast sheet, beads, reconstituted paper sheets, and the like) and the specific application. Typically, the amount of binder present is up to about 25% by weight, and certain embodiments are characterized by a binder content of at least about 0.5% by weight, based on the total weight of the aerosol-generating material. In some embodiments, the binder is present in an amount by weight in a range from about 0.6 to about 25% based on the total weight of the aerosol-generating material, such as from about 0.6%, about 1%, about 1.5%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8, about 9%, about 10%, about 11%, or about 12%, to about 15%, about 20%, or about 25% by weight, based on the total weight of the aerosol-generating material In some embodiments, the binder is present in an amount by weight from about 0.6 to about 1% based on the total weight of the aerosol-generating material. In some embodiments, the binder is present in an amount by weight from about 6 to about 25%, such as from about 8 to about 12%, based on the total weight of the substrate.

Typical binders can be organic or inorganic, or a combination thereof. Representative binders include povidone, sodium alginate, pectin, gums, carrageenan, pullulan, zein, cellulose derivatives, and the like, and combinations thereof. In some implementations, combinations or blends of two or more binder materials may be employed.

In some embodiments, the aerosol-generating materials as disclosed herein comprise one or more fillers. The one or more fillers may comprise materials such as calcium carbonate starches, wood fibers, pulps, cellulose and cellulose derivatives, crushed seashells, inert materials, and the like.

When present, the amount of filler can vary. In some embodiments, the aerosol-generating material comprises up to about 30% by weight of one or more fillers, based on the total weight of the substrate. For example, in some embodiments, the aerosol-generating material comprises from about 0 to about 25% of one or more fillers, such as from about 0.1%, about 1%, or about 5%, to about 10%, about 15%, about 20%, or about 25% filler by weight, based on the total weight of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises from about 3 to about 5%, from about 5 to about 15%, or from about 15 to about 25%, such as from about 16 to about 24% filler by weight, based on the total weight of the aerosol-generating material.

The moisture (e.g., water) content of the aerosol-generating material may vary. For example, in some embodiments, the aerosol-generating material comprises from about 0% to about 30% water. In some embodiments, the aerosol-generating material is dried to remove at least a portion of the water present during preparation. In some embodiments, after drying, the aerosol-generating material comprises from about from about 3 to about 21% water, based on the total weight of the substrate. In some embodiments, after drying, the aerosol-generating material comprises from about 8 to about 10, or from about 12 to about 18% water, based on the total weight of the aerosol-generating material. In some embodiments, after drying, the aerosol-generating material comprises from about 15 to about 21% water, based on the total weight of the aerosol-generating material. The water content of the aerosol-generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

The aerosol-generating materials as disclosed herein comprise an aerosol former material, which may also be referred to as a humectant. Suitable aerosol former materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, and combinations thereof. In some embodiments, the aerosol former material may include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extract, or a combination of any thereof.

The amount of aerosol former material that is present in the aerosol-generating material may vary. For example, in certain embodiments, sufficient amounts of aerosol former material are employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol former materials present may be dependent upon factors such as the number of puffs desired per aerosol-generating component. Generally, the aerosol-generating material includes a relatively large percentage by weight of the aerosol former material (e.g., one or more polyhydric alcohols, such as glycerol), allowing for aerosol production from the aerosol-generating material when heated.

In some embodiments, the aerosol former material comprises one or more polyhydric alcohols. Examples of polyhydric alcohols include glycerol, propylene glycol, and other glycols such as 1,3-propanediol, diethylene glycol, and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

In some embodiments, the aerosol-generating material comprises the aerosol former material in an amount of at least about 1% by weight, at least about 10% by weight, of at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, at least about 40% by weight, at least about 45% by weight, at least about 50% by weight, at least about 55% by weight, or at least about 60% by weight, based on a total weight of the substrate. Example ranges of total aerosol former materials include about 15% to about 60% by weight, such as about 15% to about 55%, or about 15% to about 25%, based on the total weight of the aerosol-generating material.

In some embodiments, the aerosol-generating material comprises a flavorant. As used herein, reference to a “flavorant” refers to compounds or components that can be aerosolized and delivered to a user and which impart a sensory experience in terms of taste and/or aroma. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. Flavorants may be natural or synthetic, and the character of the flavors imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity, or spicy. Some examples of flavorants include, but are not limited to, aloe vera, aniseed, apple, Asian spices, bacopa monniera, basil, bay leaves, beefsteak plant, bergamot, berry, betel, blueberry, bourbon, camphene, cannabis, caraway, cardamom, carvi, cascarilla, cassia, cassis, celery, chamomile, cherry, cherry blossom, chive, cilantro, cinnamon, citrus fruits, clementine, clove, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, curcuma, damien, dragon fruit, Drambuic, durian, elderflower, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, Ginkgo biloba, grape, guayusa, hazel, hemp, hibiscus, honeybush, honey essence, hydrangea, Indian spices, jasmine, juniper, khat, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, Japanese white bark magnolia leaf, mango, maple, marjoram, matcha, mate, menthol, mint, myrtle, mulberry, naswar, nutmeg, olive, orange blossom, orange oil, orange skin, oregano, papaya, paprika, peach, peppermint, piment, pimento, pine, rhubarb, rooibos, rosemary, rose hip, rose oil, rum, saffron, sage, sandalwood, scotch, shisha, spearmint, strawberry, tarragon, tea such as green tea or black tea, tequila, terpenes, thyme, tobacco, tropical fruit, turmeric, valerian, vanilla, verbena, wasabi, whiskey, wintergreen, withania somnifera, yerba mate, yerba santa, ylang-ylang, and combinations thereof.

The flavorant may be a component of the aerosol former material or may be impregnated separately into the aerosol-generating material. The impregnation may be performed during preparation of the aerosol-generating material, after aerosol-generating material formation, or both.

The quantity of flavorant present may vary, and when present, is generally less than about 30%, or less than about 20% by weight of the aerosol-generating material. For example, a flavorant may be present in a quantity of from about 0.1%, about 0.5%, about 1%, or about 5%, to about 10%, about 20%, or about 30% by weight of the aerosol-generating material.

In some embodiments, the aerosol-generating material comprises a colorant. The addition of a colorant may alter the visual appearance of the aerosol-generating material. The presence of colorant may enhance the visual appearance of the aerosol-generating material and/or an aerosol-generating component comprising the substrate. By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color-matched to other portions of the aerosol-generating component or to other components of an article comprising the aerosol-generating material.

A variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown or black. Other colors are also contemplated herein. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants and pharmaceutical-grade colorants may be used. In certain embodiments, the colorant is caramel, which may confer the substrate with a brown appearance. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (such as tobacco material) in an aerosol-generating component comprising the aerosol-generating material. In some embodiments, the addition of a colorant to the aerosol-generating material renders it visually indistinguishable from other components.

In some embodiments, the aerosol-generating material may further comprise a burn retardant material, conductive fibers or particles for heat conduction/induction, or any combination thereof. One example of a burn retardant material is ammonium phosphate. In some embodiments, other flame/burn retardant materials and additives may be included within the aerosol-generating material, and may include organo-phosphorus compounds, borax, hydrated alumina, graphite, potassium, silica, tripolyphosphate, dipentaerythritol, pentaerythritol, and polyols. Other burn retardant materials, such as nitrogenous phosphonic acid salts, mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide, ammonium borate, ethanolammonium borate, ammonium sulphamate, halogenated organic compounds, thiourea, and antimony oxides may also be used. In each aspect of flame-retardant, burn-retardant, and/or scorch-retardant materials used in the aerosol-generating material and/or other components (whether alone or in combination with each other and/or other materials), the desirable properties are independent of and resistant to undesirable off-gassing or melting-type behavior. Various manners and methods for incorporating tobacco into smoking articles, and particularly smoking articles that are designed so as to not purposefully burn virtually all of the tobacco within those smoking articles are set forth in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 8,079,371 to Robinson et al.; U.S. Pat. No. 7,290,549 to Banerjee et al.; and U.S. Pat. App. Pub. No. 2007/0215167 to Crooks et al.; the disclosures of which are incorporated herein by reference in their entireties.

The aerosol-generating material may also include conductive fibers or particles for heat conduction or heating by induction. In some embodiments, the conductive fibers or particles may be arranged in a substantially linear and parallel pattern. In some embodiments, the conductive fibers or particles may have a substantially random arrangement. In some embodiments, the conductive fibers or particles may be constructed of or more of an aluminum material, a stainless-steel material, a copper material, a carbon material, and a graphite material. In some embodiments, one or more conductive fibers or particles with different Curie temperatures may be included in the aerosol-generating material to facilitate heating by induction at varying temperatures.

In still other implementations, the aerosol-generating material may comprise inorganic fibers of various types (e.g., fiber glass, metal wires/screens, etc.) and/or (organic) synthetic polymers. In various implementations, these “fibrous” materials could be unstructured (e.g., randomly distributed) or structured (e.g., a wire mesh).

Aerosol Provision Consumable

An aspect of the disclosure provides a combustible or non-combustible aerosol provision system including a consumable that comprises a wrapping material treated with sensate as described above, an aerosol-generating material, and optionally further comprising one or more other elements, such as a filter or an aerosol modifying substance. The form of the aerosol-generating material may vary, including such forms as extruded sheet, cast sheet, paper recon sheet, beaded, shredded, particulate, and the like.

Example filter materials include fibrous cellulose acetate, polypropylene material, polyethylene material, or gathered paper material. The filter may, in some embodiments, comprise an adsorbent material, such as activated carbon. In some embodiments, the filter may include on or more capsules. The capsule may comprise an aerosol modifying agent, such as a flavor.

A consumable may comprise a heating element that emits heat to cause the aerosol-generating component to generate aerosol in use. The heating element may, for example, comprise combustible material, or may comprise a susceptor that is heatable by penetration with a varying magnetic field.

A susceptor is material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The heating material may be an electrically conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both electrically conductive and magnetic, so that the heating material is heatable by both heating mechanisms.

Induction heating is a process in which an electrically conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating.

In some embodiments, the susceptor is in the form of a closed circuit. It has been found that, when the susceptor is in the form of a closed circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

In a combustible aerosol provision system, an aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user. In some embodiments, the combustible aerosol provision system is selected from the group consisting of a cigarette, a cigarillo, and a cigar. Combustible aerosol provision systems according to the present disclosure may conform to any size or dimensions known for combustible aerosol provision systems.

A non-combustible aerosol provision system includes an aerosol-generating consumable and one or more heaters configured to heat but not burn the aerosol-generating consumable. In some cases, in use, the heater may heat, without burning, the aerosol-generating consumable to a temperature equal to or less than 350° C., such as between 120° C. and 350° C. The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to produce heat in use. The heater(s) may be powered by a battery. An example heat-not-burn device is disclosed in International Patent Application Publication No. WO2015/062983, which is incorporated by reference in its entirety.

The aerosol-generating consumable may additionally comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the non-combustible aerosol provision device from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

In some cases, the aerosol-generating system may be an electronic tobacco hybrid device. That is, it may contain a solid aerosol-generating component and a liquid aerosol-generating material. In some cases, the aerosol-generating material may comprise nicotine. In some cases, the aerosol-generating material may comprise a tobacco material. In some cases, the aerosol-generating material may comprise a tobacco material and a separate nicotine source. The separate aerosol-generating components may be heated by separate heaters, the same heater or, in one case, a downstream aerosol-generating material may be heated by a hot aerosol which is generated from the upstream aerosol-generating component. An example electronic tobacco hybrid device is disclosed in International Patent Application Publication No. WO2016/135331, which is incorporated by reference in its entirety.

The aerosol-generating consumable may additionally comprise ventilation apertures. These may be provided in the sidewall of the consumable. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilized components thereby cooling the aerosol.

In some cases, the aerosol-generating component of the consumable may be in sheet form, such as a planar sheet, a bunched or gathered sheet, a crimped sheet, or a rolled sheet (i.e. in the form of a rod or tube). In some embodiments, the aerosol-generating component may be formed as a sheet and then shredded and incorporated into the consumable. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the consumable.

Referring to FIGS. 2 and 3, for the purpose of illustration and not limitation, an aerosol provision consumable 1 is provided, which according to example embodiments of the present disclosure, comprises a filter 2 and a cylindrical rod of aerosol-generating material 3. The rod of aerosol-generating material 3 is aligned with the filter 2 such that one end of the rod of aerosol-generating material 3 abuts the end of the filter 2. The filter 2 is filter material 4 wrapped in a plug wrap 5 and the plug of aerosol-generating material 6, such as tobacco, is circumscribed by a paper wrapper 7 to form the rod of aerosol-generating material 3. The rod of aerosol-generating material 3 is joined to the filter 2 by tipping paper 8 in a conventional manner. In the embodiment illustrated in FIG. 3, the wrapper 7 has two sensate coating bands 9, 9′ applied thereto spaced from the longitudinal edge of the wrapper. As noted above, the sensate coating could be applied in other patterns or configurations, and with greater or fewer bands, than illustrated in FIG. 3. In addition, the sensate coating could also be applied to other wrapping materials within the consumable, such as tipping paper 8 or plug wrap 5.

Referring to FIGS. 4 and 5, partially cut-away section and perspective views of another example consumable are provided, the consumable being particularly adapted for use in a non-combustible aerosol provision system. The consumable 301 includes an aerosol-generating material 303 and a filter assembly 305, which includes a cooling segment 307, a filter segment 309, a mouth end segment 311, and a ventilation region 317. The consumable 301 has a proximal end 313 and a distal end 315. For case of illustration, wrapping materials coated with sensate are not shown in FIGS. 4 and 5, but such wrapping materials can be used to circumscribe any of the portions of the consumable 301 in a manner similar to FIGS. 2 and 3.

The cooling segment 307 provides a physical gap between the heater arrangement of a heating device (as illustrated in FIGS. 6 and 7) and the heat sensitive filter arrangement 309, enables the ventilation holes 317 to be located in the cooling segment. In one example, the cooling segment 307 is an annular paper tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilized components generated from the body of aerosol-generating component 303 to flow. In one example the length of the cooling segment 307 is at least 15 mm, such as between 20 mm and 30 mm.

The filter segment 309 may be formed of any filter material sufficient to remove one or more volatilized compounds from heated volatilized components from the aerosol-generating material. In one example the filter segment 309 is made of a mono-acetate material, such as cellulose acetate. The filter segment 309 provides cooling and irritation-reduction from the heated volatilized components without depleting the quantity of the heated volatilized components to an unsatisfactory level for a user. In one example, the filter segment 309 is between 6 mm to 10 mm in length.

The density of the cellulose acetate tow material of the filter segment 309 controls the pressure drop across the filter segment 309, which in turn controls the draw resistance of the article 301. In one example, the filter segment 309 is made of an 8Y15 grade of filter tow material.

The mouth end segment 311 can be an annular paper tube and is located around and defines an air gap within the mouth end segment 311. The air gap provides a chamber for heated volatilized components that flow from the filter segment 309. In one example, the length of the mouth end segment 311 is between 6 mm to 10 mm.

In one embodiment, the total length of the filter assembly 305 is between 37 mm and 45 mm. In one example, the rod of aerosol-generating component 303 is between 34 mm and 50 mm in length. In one example, the total length of the article 301 is between 71 mm and 95 mm.

Heating Device for Non-Combustible Aerosol Provision System

Referring now to FIGS. 6 to 7 in more detail, there is shown an example of a device 20 arranged to heat aerosol-generating component to volatilize at least one component of said aerosol-generating component, typically to form an aerosol which can be inhaled. The device 20 is a heating device which releases compounds by heating, but not burning, the aerosol-generating component.

A first end 22 is sometimes referred to herein as the mouth or proximal end of the device 20 and a second end 24 is sometimes referred to herein as the distal end of the device. The device 20 has an on/off button 26 to allow the device as a whole to be switched on and off as desired by a user.

The device 20 comprises a housing 28 for locating and protecting various internal components of the device. In the example shown, the housing 28 comprises a unibody sleeve 30 that encompasses the perimeter of the device 20, capped with a top panel 32 which defines generally the ‘top’ of the device and a bottom panel 34 (FIG. 7) which defines generally the ‘bottom’ of the device. In another example the housing comprises a front panel, a rear panel and a pair of opposite side panels in addition to the top panel 32 and the bottom panel 34.

The top panel 32 and/or the bottom panel 34 may be removably fixed to the unibody sleeve 30, to permit easy access to the interior of the device 20 or may be “permanently” fixed to the unibody sleeve, for example to deter a user from accessing the interior of the device. In an example, the panels 32 and 34 are made of a plastics material, including for example glass-filled nylon formed by injection molding, and the uni-body sleeve 30 is made of aluminum, though other materials and other manufacturing processes may be used.

The top panel 32 of the device 20 has an opening 21 at the mouth end 22 of the device through which, in use, the article 301 including the aerosol-generating component may be inserted into the device and removed from the device by a user.

The housing 28 has located or fixed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed from an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.

The control circuitry 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol-generating component in the article 301 as discussed further below.

The power source 27 may be for example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include for example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under control of the control circuitry 25 to heat the aerosol-generating component in the article (as discussed, to volatilize the aerosol-generating material without causing the aerosol-generating component to burn).

An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 20 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, often measured in Amp-hours or the like) and thus the battery life for the device 20 can be longer.

In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber into which the article 301 comprising the aerosol-generating material is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed of plural heating elements aligned along the longitudinal axis of the heater arrangement. Each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, each heating element may be a thin film heater. In another example, each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating arrangements are possible, including for example inductive heating, infrared heater elements, which heat by emitting infrared radiation, or resistive heating elements formed by for example a resistive electrical winding.

In one particular example, the heater arrangement 23 is supported by a stainless-steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned so that substantially the whole of the body of aerosol-generating component 303 of the article 301 is inserted into the heater arrangement 23 when the article 301 is inserted into the device 20.

Each heating element may be arranged so that selected zones of the aerosol-generating material can be independently heated, for example in turn (over time, as discussed above) or together (simultaneously) as desired.

The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing from the heater arrangement 23 to the exterior of the device 20. This helps to keep down the power requirements for the heater arrangement 23 as it reduces heat losses generally. The insulator 31 also helps to keep the exterior of the device 20 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve which provides a low-pressure region between the two walls of the sleeve. That is, the insulator 31 may be for example a “vacuum” tube, i.e., a tube that has been at least partially evacuated so as to minimize heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including using heat insulating materials, including for example a suitable foam-type material, in addition to or instead of a double-walled sleeve.

The housing 28 may further comprise various internal support structures 37 for supporting all internal components, as well as the heating arrangement 23.

The device 20 further comprises a collar 33 which extends around and projects from the opening 21 into the interior of the housing 28 and a generally tubular chamber 35 which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example, comprises a plurality of cooling fins 35f spaced apart along the outer surface of the chamber 35, and each arranged circumferentially around outer surface of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 301 when it is inserted in the device 20 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumference of the article 301 over at least part of the cooling segment 307.

The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 21 and which project into the opening 20. The ridges 60 take up space within the opening 21 such that the open span of the opening at the locations of the ridges 60 is less than the open span of the opening at the locations without the ridges 60. The ridges 60 are configured to engage with an article 301 inserted into the device to assist in securing it within the device 20. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 301 form ventilation paths around the exterior of the article 301. These ventilation paths allow hot vapors that have escaped from the article 301 to exit the device 20 and allow cooling air to flow into the device around the article in the air gap 36.

The article 301 is removably inserted into the opening 21 of the device 20. In operation, the heater arrangement 23 will heat the article 301 to volatilize at least one component of the aerosol-generating component from the body of aerosol-generating component 303. The primary flow path for the heated volatilized materials from the body of aerosol-generating component 303 is axially through the article 301, through the chamber inside the cooling segment 307, through the filter segment 309, through the mouth end segment 311 to the user. In one example, the temperature of the heated volatilized components that are generated from the body of aerosol-generating component is between 60° C. and 250° C., which may be above the acceptable inhalation temperature for a user. As the heated volatilized material travels through the cooling segment 307, it will cool and some volatilized materials will condense on the inner surface of the cooling segment 307. In the illustrated example of the article 301 shown in FIGS. 4 and 5, cool air will be able to enter the cooling segment 307 via the ventilation holes 317 formed in the cooling segment 307. This cool air will mix with the heated volatilized components to provide additional cooling to the heated volatilized components.

Sensate Delivery

In some embodiments, a combustible aerosol provision system comprises sufficient sensate (e.g., WS-3) to provide delivery of, on average, at least about 1.7, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or at least 95 pg sensate in a puff of aerosol generated by the combustible aerosol provision system under the ISO smoking regime. In some embodiments, the maximum amount of sensate delivered in a puff of aerosol generated by the combustible aerosol provision system under the ISO smoking regime is about too pg. In some embodiments, a combustible aerosol provision system includes sufficient sensate to provide delivery of, on average, no more than 100 pg sensate in a puff, or no more than about 95, 90, 85, 80, 75, 70, 65, or no more than about 60 pg sensate in a puff under an ISO smoking regime.

In some embodiments, a combustible aerosol provision system includes sufficient sensate to provide delivery of, on average, at least about 30 pg sensate in a puff, at least about 35 pg, at least about 40 pg, at least about 45 pg, at least about 50 pg, at least about 55 pg, at least about 60 pg, at least about 65 pg, at least about 70 pg, at least about 75 pg, at least about 80 pg sensate in a puff under the ISO smoking regime. In some embodiments, a combustible aerosol provision system includes sufficient sensate to provide delivery of, on average, no more than 100 pg sensate in a puff, no more than 95 μg, 90 pg, 85 μg, 80 pg, 75 μg, 70 pg, 65 pg, or no more than about 60 pg sensate in a puff under the ISO smoking regime. The estimated rate of transfer of sensate from the combustible aerosol provision system to the aerosol generated upon combustion is between about 1 and about 2% per 1 mg of tar or nicotine-free dry particulate material (NFDPM) under the ISO smoking regime.

In an embodiment where the rate of sensate transfer from the combustible aerosol provision system to the aerosol is approximately 1.2% per 1 mg of tar or NFDPM, the following calculations can be made. In order to deliver 36 pg sensate in each puff provided by a 1 mg tar cigarette providing 7 puffs, 21 mg of sensate needs to be evenly distributed along the rod of aerosol-generating material. In order to deliver approximately 50 pg sensate in 3 predetermined puffs provided by a 6.1 mg tar cigarette including sensate, 2 mg of sensate needs to be included in a localized manner, for example, as a patch or band positioned at an appropriate position along the rod of aerosol-generating material.

In embodiments where the delivery system is a non-combustible aerosol provision system, the sensate is included in an amount to provide delivery of, on average, at least about 1.5 pg sensate in a puff of aerosol generated by the product under the HCl smoking regime. The HCl smoking regime is based on a 55 mL puff volume, 2 second puff duration, and 30 second puff interval with vents blocked. In some embodiments, the non-combustible aerosol provision system comprises sufficient sensate to provide delivery of, on average, at least 2 pg sensate in a puff of aerosol generated by the non-combustible aerosol provision system under the HCl smoking regime. In some embodiments, the maximum amount of sensate delivered in a puff of aerosol generated by the non-combustible aerosol provision system under the HCl smoking regime is about 100 pg.

In some embodiments, a non-combustible aerosol provision system including a charge of aerosol-generating material that is heated to form an aerosol but is not combusted, includes sufficient sensate to provide delivery of, on average, at least about 1.5 pg sensate in a puff, at least about 2 pg, at least about 2.5 pg, at least about 3 pg, at least about 4 pg, at least about 5 pg, at least about 6 pg, at least about 7 pg, at least about 8 pg, at least about 9 pg, at least about 10 pg, at least about 12 pg, at least about 15 pg, at least about 20 pg, at least about 25 pg, or at least about 30 pg sensate in a puff under the HCl smoking regime. In some embodiments, a non-combustible aerosol provision system includes sufficient sensate to provide delivery of, on average, no more than about 100 pg sensate in a puff, no more than about 95 pg, no more than about 90 pg, no more than about 85 pg, no more than about 80 pg, no more than about 75 pg, no more than about 70 pg, no more than about 65 pg, no more than about 60 pg, no more than about 55 pg, or no more than about 50 pg sensate in a puff under the HCl smoking regime.

Although an aerosol deliver device and/or an aerosol-generating component according to the present disclosure may take on a variety of embodiments, as discussed in detail above, the use of the aerosol delivery device and/or aerosol-generating component by a consumer will be similar in scope. The foregoing description of use of the aerosol delivery device and/or aerosol-generating component is applicable to the various embodiments described through minor modifications, which are apparent to the person of skill in the art in light of the further disclosure provided herein. The description of use, however, is not intended to limit the use of the articles of the present disclosure but is provided to comply with all necessary requirements of disclosure herein.

Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.