Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
  • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
  • A24C5/01—Making cigarettes for simulated smoking devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
  • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
  • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
  • B05B12/20—Masking elements, i.e. elements defining uncoated areas on an object to be coated
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C21/00—Accessories or implements for use in connection with applying liquids or other fluent materials to surfaces, not provided for in groups B05C1/00 - B05C19/00
  • B05C21/005—Masking devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C3/00—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material
  • B05C3/18—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material only one side of the work coming into contact with the liquid or other fluent material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C3/00—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material
  • B05C3/20—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material for applying liquid or other fluent material only at particular parts of the work
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
  • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
  • B05C1/14—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a travelling band
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
  • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
  • B05C1/16—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length only at particular parts of the work
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/32—Processes for applying liquids or other fluent materials using means for protecting parts of a surface not to be coated, e.g. using stencils, resists
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D2252/00—Sheets
  • B05D2252/02—Sheets of indefinite length

Definitions

• the present invention relates to an aerosol generating material product, a method of manufacturing an aerosol generating material product, and apparatus for manufacturing an aerosol generating material product.
• Aerosol generating material products are used in aerosol provision systems which generate an aerosol for a user to inhale. Aerosol provision systems which generate an aerosol for a user to inhale are well known in the art. Such systems are generally battery powered and contain an aerosol provision device comprising the battery and an aerosol generator, and an article which includes aerosol generating material. Such an article is sometimes known as a consumable. The article may comprise an aerosol generating material product, or be formed from part of an aerosol generating material product.
• the aerosol can be generated in a variety of ways.
• the aerosol may be generated by heating a substrate that includes or is formed from an aerosol generating material to form a vapour which subsequently condenses in passing air so to form a condensation aerosol.
• the aerosol might be generated by mechanical means, vibration etc., so that the substrate becomes dispersed in passing air so as to form an aerosol.
• an apparatus for use in the manufacture of a product in which the product comprises aerosol generating material supported on a first surface of a support, in which the apparatus is configured to provide a path along which the support may travel in a first direction and which comprises in order in the first direction a converging position, an application position, and a diverging position;
• a stencil for use in the manufacture of a product in which the product comprises aerosol generating material supported on a first surface of a support, in which the stencil comprises a sheet material and defines one or more apertures, in which one or more apertures are configured to produce a desired shape of aerosol generating material supported on a first surface of a support.
• a method of manufacturing a product which comprises an aerosol generating material supported on a first surface of a support in which the method comprises
• a method of manufacture of an article which comprises aerosol generating material for use in an aerosol provision device in which the method comprises providing a product manufactured according to the method of the third aspect of the present disclosure, and cutting the product into an appropriate size for use in an article.
• an apparatus for use in the manufacture of a product in which the product comprises aerosol generating material supported on a first surface of a support, in which the apparatus is configured to provide a path along which the support may travel in a first direction and which comprises in order in the first direction a converging position, an application position, and a diverging position;
• the apparatus is configured to cause the stencil to move toward and into contact with the first surface of the support at the converging position.
• the apparatus is configured to cause the stencil to move away from and out of contact with the first surface of the support at the diverging position.
• the support is a longitudinally extending support.
• the support is a flexible sheet material suitable for supporting aerosol generating material, and for use in an aerosol provision device as an article or as part of an article.
• the support comprises a susceptor, for example, but without limitation, a metal foil such as aluminum foil.
• the support is a laminate.
• the laminate includes a metal foil and paper.
• the apparatus includes one or more surfaces, rollers and / or other suitable features that, in combination, guide the support along the path at least between the converging position, application position, and diverging position.
• the apparatus is so configured that, when the apparatus is operating, a support is moved along the path in the first direction.
• References herein to upstream and downstream are relative to that first direction and a support or portion of support that travels along the path in the first direction moves from an upstream position to a downstream position.
• the longitudinally extending support is of a sufficient longitudinal dimension that at any given time in the operation of the apparatus, only a portion of the support is moving between the converging and diverging positions.
• the path followed by the support starts at a store of support, for example a roll of support, and terminates downstream of the diverging position.
• the support drive is configured to pull the support along the path from a position downstream of the diverging position.
• the support drive is configured to contact the support to move / drive the support along the path at one or more positions along the path followed by the support.
• the stencil includes a stencil sheet.
• the stencil sheet defines one or more apertures that extend through the stencil sheet between the major surface of the stencil sheet.
• One or more or all of those apertures are each so configured that when the apparatus of present disclosure is in use, the stencil causes the deposition of fluid aerosol generating material trough the apertures and on to the first surface of the support in the desired shape and position or positions.
• the major surfaces of the stencil sheet are the surfaces that have the largest surface area and which are separated from each other by the material that forms the stencil sheet.
• an advantage of the use of the stencil is that the apertures in the stencil are the size of the desired aerosol generating material that is to be left on the support sheet. This is in contract to normal screen printing techniques in which the aerosol generating material would be forced through the mesh of the screen. This allows the aerosol generating material to include constituents, for example shreds or flakes of tobacco, that would not pass through the mesh used in screen printing techniques.
• the stencil is formed from a flexible sheet material.
• the stencil is longitudinally extending.
• the thickness of the stencil is less than or equal to 2.0 mm.
• the thickness of the stencil is less than or equal to 1.0 mm.
• the thickness of the stencil is less than or equal to 0.9 mm.
• the thickness of the stencil is less than or equal to 0.8 mm.
• the thickness of the stencil is less than or equal to 0.7 mm.
• the thickness of the stencil is less than or equal to 0.6 mm.
• the thickness of the stencil is less than or equal to 0.5 mm.
• the thickness of the stencil is less than or equal to 0.4 mm.
• the thickness of the stencil is less than or equal to 0.3 mm.
• the thickness of the stencil is less than or equal to 0.2 mm.
• the thickness of the stencil is selected to provide a desired thickness of the fluid aerosol generating material deposited on the first surface of the support. It is an advantage that the stencil allows accurate control of the thickness of the fluid aerosol generating material deposited on the first surface of the support.
• the stencil includes a stainless steel.
• the stencil is formed from a stainless steel. It is an advantage to use stainless steel because of its low reactivity with the fluid aerosol generating material. It is a further advantage that the stencil will have a desirable length of working life because of the resistance of stainless steel to damage.
• the stencil is a continuous loop. That is the stencil is formed from a portion of flexible material that extends between a first and a second end, and the first and second ends are joined to each other to form a continuous loop of stencil.
• the apparatus is so configured that when the stencil is a continuous loop, a portion of the loop follows the same path as the support between the converging and diverging positions. The rest of the loop follows a stencil path that takes a portion of the stencil from the diverging position to the converging position along a loop return path.
• the apparatus includes a stencil cleaning means, and the stencil cleaning means cleans the stencil as it follows at least a portion of the loop return path.
• the cleaning includes removal of any aerosol generating material adhering to the stencil.
• the stencil is longitudinally extending and the apparatus is configured to have the stencil follow a path which extends from an initial stencil store, for example a roll of stencil, along a path that includes following the same path as the support between the converging and diverging positions, and to a second stencil store.
• an initial stencil store for example a roll of stencil
• the stencil includes one or more apertures. One or more or all of those apertures are so configured that when the apparatus of present disclosure is in use, the stencil causes the deposition of fluid aerosol generating material gel on the first surface of the support in the desired shape and position or positions.
• the apparatus comprises a stencil drive, in which the stencil drive is configured to move at least a portion of the stencil along the path in the first direction from the converging position to the diverging position.
• the stencil is moved along the path between the converging and diverging positions by the support drive.
• the stencil has a first and a second surface, and the first and second surfaces are the major surfaces of the stencil.
• the first surface of the stencil is in contact with the first surface of the support when the stencil overlies the support as the support travels along the path between the converging and diverging positions.
• the fluid aerosol generating material application means includes a fluid aerosol generating material reservoir and an application means.
• the application means may be any suitable known application means.
• the application means is configured to apply fluid aerosol generating material to the second surface of the stencil and, through one or more apertures in the stencil, the first surface of the support and as the support and stencil pass through the application position on the path.
• the application means comprises a doctor blade.
• the doctor blade both scrapes fluid aerosol generating material off the second surface of the stencil, and helps to ensure that the volume defined by the first surface of the support and the edges of the stencil that define each aperture in the stencil are filled with the fluid aerosol generating material. That filling is up to and level with the second surface of the stencil.
• the apparatus comprises a support bed, and the support bed is configured to at least partially provide support to the support and stencil as they travel along the path between the application position and the divergent position.
• the support bed is configured to accelerate the gelification of the fluid aerosol generating material.
• the apparatus comprises an indexing means configured to maintain the same speed for the support and the stencil as the support and stencil travel along the path from the converging position to the diverging position.
• the indexing means comprises index apertures in the support and stencil which are physical linked whilst the the support and stencil travel along the path from the converging position to the diverging position.
• the apparatus is configured to cause the period of time for the stencil and support to travel between the application position and the diverging position is sufficient for fluid aerosol generating material applied to the first surface of the support to cure sufficiently that when the stencil moves away from the support at the diverging position the fluid aerosol generating material is dimensionally stable.
• the speed at which a given position on the support and stencil travel between the application position and the diverging position is selected to result in the time taken for that movement of the position to take a predetermined period of time.
• the ambient conditions to which a given position on the support and stencil is exposed whilst travelling between the application position and the diverging position are selected to result in the fluid aerosol generating material achieving a predetermined amount of dimensional stability during the time taken for that position to move from the application position to the diverging position.
• the ambient conditions surrounding the support and stencil may be one or more of the temperature, humidity, or exposure to electromagnetic radiation in one or more ranges in the electromagnetic spectrum, for example microwave or infrared radiation.
• a stencil for use in the manufacture of a product in which the product comprises aerosol generating material gel supported on a first surface of a support, in which the stencil comprises a sheet material and defines one or more apertures, in which one or more apertures are each configured to produce a desired shape of fluid aerosol generating material gel supported on a first surface of a support.
• the stencil is one or both of longitudinally extending, and formed from a flexible sheet material.
• the thickness of the stencil is less than or equal to 2.0 mm.
• the thickness of the stencil is less than or equal to 1.0 mm.
• the thickness of the stencil is less than or equal to 0.9 mm.
• the thickness of the stencil is less than or equal to 0.8 mm.
• the thickness of the stencil is less than or equal to 0.7 mm.
• the thickness of the stencil is less than or equal to 0.6 mm.
• the thickness of the stencil is less than or equal to 0.5 mm.
• the thickness of the stencil is less than or equal to 0.4 mm.
• the thickness of the stencil is less than or equal to 0.3 mm.
• the thickness of the stencil is less than or equal to 0.2 mm.
• the stencil includes a stainless steel.
• the stencil is formed from a stainless steel.
• the stencil is a continuous loop. That is the stencil is formed from a portion of flexible material that extends between a first and a second end, and the first and second ends are joined to each other to form a continuous loop of stencil.
• a method of manufacturing a product which comprises an aerosol generating material gel supported on a first surface of a support in which the method comprises
• the stencil is one or both of longitudinally extending, and formed from a flexible sheet material.
• the thickness of the stencil is less than or equal to 2.0 mm.
• the thickness of the stencil is less than or equal to 1.0 mm.
• the thickness of the stencil is less than or equal to 0.9 mm.
• the thickness of the stencil is less than or equal to 0.8 mm.
• the thickness of the stencil is less than or equal to 0.7 mm.
• the thickness of the stencil is less than or equal to 0.6 mm.
• the thickness of the stencil is less than or equal to 0.5 mm.
• the stencil is formed from a stainless steel.
• the article comprises aerosol generating material.
• the article may comprise an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
• Non-combustible aerosol provision systems release compounds from an aerosol generating material without combusting the aerosol generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol generating materials.
• a "non-combustible" aerosol provision system is one where a constituent aerosol generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
• the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
• the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not a requirement.
• END electronic nicotine delivery system
• the non-combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system.
• a heat-not-burn system is a tobacco heating system.
• the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol generating materials, one or a plurality of which may be heated.
• Each of the aerosol generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.
• the hybrid system comprises a liquid or gel aerosol generating material and a solid aerosol generating material.
• the solid aerosol generating material may comprise, for example, tobacco or a non-tobacco product.
• the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
• the disclosure relates to consumables comprising aerosol generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
• the non-combustible aerosol provision system may comprise a power source and a controller.
• the power source may, for example, be an electric power source or an exothermic power source.
• the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol generating material or to a heat transfer material in proximity to the exothermic power source.
• the article for use with the non-combustible aerosol provision device may comprise aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
• Aerosol generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
• the aerosol generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
• the aerosol generating material may comprise or be in the form of an aerosol generating film.
• the aerosol generating film may comprise a binder, such as a gelling agent, and an aerosol former.
• a substance to be delivered and/or filler may also be present.
• the aerosol generating film may be substantially free from botanical material.
• the aerosol generating material is substantially tobacco free.
• the aerosol generating film may have a thickness of about 0.015 mm to about 1 mm.
• the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.
• the aerosol generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol generating film.
• a binder such as a gelling agent
• a solvent such as water
• an aerosol-former such as one or more other components, such as one or more substances to be delivered
• the slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
• the aerosol generating material may comprise or be an "amorphous solid".
• the aerosol generating material comprises an aerosol generating film that is an amorphous solid.
• the amorphous solid may be a "monolithic solid".
• the amorphous solid may be substantially non-fibrous.
• the amorphous solid may be a dried gel.
• the amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
• the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
• the amorphous solid may be substantially free from botanical material.
• the amorphous solid may be substantially tobacco free.
• a susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field.
• the susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents.
• the susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor.
• the susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.
• the device that is configured to generate the varying magnetic field is referred to as a magnetic field generator.
• the active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.
• the active substance may for example be selected from nutraceuticals, nootropics, psychoactives.
• the active substance may be naturally occurring or synthetically obtained.
• the active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
• the active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
• flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch,
• the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
• a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
• the aerosol generating material comprises an aerosol generating agent.
• the aerosol generating agent may comprise one or more constituents capable of forming an aerosol.
• the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
• the aerosol generating agent comprises glycerol.
• the aerosol generating agent 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.
• polyhydric alcohols such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin
• esters of polyhydric alcohols such as glycerol mono-, di- or triacetate
• aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
• the aerosol generating material may also comprise a gelling agent.
• the gelling agent comprises a hydrocolloid.
• the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.
• the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
• the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol generating material.
• the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
• the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.
• the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.
• the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.
• 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.
• the non-cellulose based gelling agent is alginate or agar.
• the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
• the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis).
• the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20-35wt% of a gelling agent.
• the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis).
• the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.
• the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB).
• the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).
• the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material.
• the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
• the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material.
• the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
• alginate is comprised in the gelling agent in an amount of from about 5 to 40wt% of the aerosol generating material, or 15 to 40wt%. That is, the aerosol generating material comprises alginate in an amount of about 5 to 40wt% by dry weight of the aerosol generating material, or 15 to 40wt%. In some examples, the aerosol generating material comprises alginate in an amount of from about 20 to 40wt%, or about 15wt% to 35wt% of the aerosol generating material.
• pectin is comprised in the gelling agent in an amount of from about 3 to 15wt% of the aerosol generating material. That is, the aerosol generating material comprises pectin in an amount of from about 3 to 15wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises pectin in an amount of from about 5 to 10wt% of the aerosol generating material.
• guar gum is comprised in the gelling agent in an amount of from about 3 to 40wt% of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10wt% of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40wt% of the aerosol generating material, or from about 20 to 40wt%, or from about 15 to 35wt%.
• the (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry.
• the slurry layer is formed by electrospraying the slurry.
• the slurry layer is formed by casting the slurry.
• the slurry comprises gelling agent, aerosol-former material and active substance.
• the slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material.
• the slurry may comprise (on a dry weight basis):
• the setting the gel (c) may comprise supplying a setting agent to the slurry.
• the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
• supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.
• the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%.
• the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm.
• the slurry solvent consists essentially of or consists of water. In some examples, the slurry comprises from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
• the filler is fibrous.
• the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).
• including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.
• the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.
• the aerosol generating material additionally comprises an active substance.
• the aerosol generating material additionally comprises a tobacco material and/or nicotine.
• the aerosol generating material comprises powdered tobacco and/or nicotine and/or a tobacco extract.
• the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance.
• the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material.
• the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material.
• the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine.
• the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
• the aerosol generating material comprises an active substance such as tobacco extract.
• the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract.
• the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract.
• the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract.
• the tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.
• the aerosol generating material comprises no tobacco material but does comprise nicotine.
• the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine.
• the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
• the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10vnt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
• the aerosol generating composition may comprise one or more active substances.
• the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material.
• the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10vnt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material.
• the active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol generating composition in order to achieve a physiological and/or olfactory response.
• Tobacco material may be present in the aerosol generating composition in an amount of from about 50 to 95wt%, or about 60 to 90wt%, or about 70 to 90wt%, or about 75 to 85wt%.
• the tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol generating composition.
• the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly it has been identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics.
• the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.
• the tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.
• the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
• the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture.
• the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%.
• the emulsifying agent may comprise acacia gum.
• the aerosol generating material is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1wt%, 2wt% or at least about 5wt% of water (WWB).
• the aerosol generating material may have any suitable water content, such as from 1wt % to 15wt%.
• the water content of the aerosol generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.
• 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 material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally an active substance.
• the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally a tobacco material and/or a nicotine source.
• the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.
• the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.
• the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:
• the aerosol generating material comprising:
• the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:
• the aerosol generating material comprises:
• the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance.
• the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour.
• the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.
• the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).
• gelling agent preferably comprising alginate
• tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%
• aerosol generating agent preferably comprising glycerol
• the aerosol generating material comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).
• the "thickness" of the aerosol generating material describes the shortest distance between a first surface and a second surface.
• the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet.
• the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1.5mm or 0.05mm to about 1.0mm.
• the thickness may be in the range of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.
• the aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m 2 to 350 g/m 2 .
• the sheet may have a mass per unit area of 50-250 g/m 2 , or from about 70 to 210 g/m 2 , or from about 90 to 190 g/m 2 , or suitably about 100 g/m 2 (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate).
• the sheet may have a mass per unit area of about 30 to 70 g/m 2 , 40 to 60 g/m 2 , or 25-60 g/m 2 and may be used to wrap an aerosolisable material such as tobacco.
• the roll holder 6 is configured to support an axle (not shown) upon which a roll 10 of support 8 is mounted above the bed surface 12 by a distance sufficient to allow the roll 10 to be able to rotate about the axle and the support 8 to unroll from the roll 10.
• the support 8 is caused to unroll from roll 10 and travel in the direction 14 by a drive means 40 which includes a pair of driven rollers 42, 44.
• the driven rollers 42, 44 are each configured to rotate about their axis, and the axes of the rollers are parallel with each other.
• the rollers 42, 44 are driven (by means not shown) so that the roller 42 rotates in a clockwise direction as seen in Figure 1 , and roller 44 rotates in an anti-clockwise direction as seen in Figure 1 .
• each of the rollers 42, 44 are so configured that each roller is respectively in contact with a portion of the first or second surface 46, 48 of the support 8 adjacent the lateral edges 60, 62 of support 8.
• the apparatus 2 further includes a stencil system 16.
• the stencil system 16 includes a stencil 18, and a pair of stencil rollers 20, 22.
• the stencil 18 is formed from an endless loop of a flexible stainless steel sheet material.
• the flexible stainless steel sheet material is of uniform thickness. In the illustrated example the thickness is less than 1.0 mm. In other non-illustrated the thickness may be less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, or less than 0.5 mm.
• the stencil 18 includes a plurality of groups 32 of apertures 34 (for clarity not all of apertures 34 are labelled).
• the apertures 34 extend through the stencil 18 between an outer surface 52 of the endless loop and an inner surface 54 of the endless loop.
• each of the groups 32 of apertures 34 the apertures 34 are positioned relative to each other in a predetermined pattern.
• the apertures 34 are laid out in a square lattice pattern.
• the apertures 34 of each group 32 are also positioned on the stencil 18 in the same position relative to the lateral edges of the stencil 18.
• the volume of the or each aperture 34 is the volumes bounded by the edge or edges of the stencil that define the aperture and the planes of the inner and outer surfaces 52, 54 of the stencil.
• the volume is dependent on both the dimensions of the aperture in the plane of the inner and outer surfaces 52, 54 of the stencil and the thickness of the stencil and determines the quantity of fluid aerosol generating material that may be retained in an aperture 34.
• the apertures may be of other shapes, for example, but without limitation, triangles, squares, rectangles, or other polygons, or other shapes as desired.
• the stencil 18 may be considered to be comprised of a plurality of finite elements each of which extend between the lateral edges 56, 58 of the stencil 18 and extend a distance x in the direction 14 when the apparatus 2 is in use.
• the stencil 18 is mounted on the pair of rollers 20, 22.
• the rollers 20, 22 are each configured to rotate about their respective axis, and the axes of the rollers 20, 22 are parallel with each other and perpendicular to the direction 14.
• At least one of the rollers is configured to be driven by a drive means (not shown).
• Driving of one or both of the rollers 20, 22 causes the stencil 18 to follow a closed loop path that passes from roller 20 to roller 22, around the portion of roller 22 not facing the roller 20, back to roller 20, and around the portion of roller 20 not facing the roller 22.
• the rollers 20, 22 are each positioned relative to the bed surface 12 so that the minimum distance between the radially outer surface of the roller and the bed surface 12 is equal to or closely equal to the cumulative thickness of the stencil 18 (the distance between the inner and outer surfaces 52, 54 of the stencil 18) and the support 8 (the distance between the first and second surfaces 46, 48 of the support 8).
• the position along the bed surface 12 at which the roller 22 is closest to the bed surface 30 may be termed the converging position 26, and the position along the bed surface 12 at which the roller 20 is closest to the bed surface 12 may be termed the diverging position 30.
• the drive means (not shown) for one or both of the rollers 20, 22 is configured to drive the or each roller in a clockwise direction as seen in Figure 2 with the result that the finite elements of the stencil 18 in the portion 36 of the stencil 18 that is closest to the support 8 move in direction 14.
• the rollers 20, 22 are positioned relative to each other at a distance that ensures that the stencil 18 extending between the rollers is taut, that is there is no slack in the stencil 18. This has the effect, that the portion 36 of the stencil 18 overlies and remains in contact with the first surface 46 of the support 8 as the finite elements of the stencil 18 in portion 36 of the stencil move from the converging position 26 to the diverging position 30.
• the drive means (not shown) for one or both of the rollers 20, 22 is further configured so that the or each roller is driven to rotate at a rotational speed that causes the finite elements of the stencil 18 to travel from the roller 20 to the roller 22 at the same speed as the finite elements of the support 8 move along the bed surface 12 with the result that at the converging position 26 a finite element of the stencil 18 and support 8 are positioned next to and in contact with each other, and that pair of finite elements moves in the direction 14 without relative movement between the pair of finite elements until that pair of finite elements reach the diverging position 30.
• the apparatus 2 further comprises an application system 24 which is adapted to apply a fluid aerosol generating material to the inner surface 54 of the stencil 18.
• the application system 24 includes an applicator 64 and a doctor blade 66.
• the application system 24 is held at an application position 28 along the bed surface 12.
• the application position 28 is, in the direction 14, between the converging position 26 and the diverging position 30. In some examples the application position 28 is closer to the converging position 24 than the diverging position 30.
• the fluid aerosol generating material that remains in an aperture 34 after that aperture 34 has passed the doctor blade 66 may be termed a discrete portion 74 of fluid aerosol generating material.
• the heater element 68 is configured to heat the portion of the bed surface 12 adjacent to the heater element.
• the heater element 68 is configured to heat the bed surface 12, and hence the support 8 and the discrete portions 74 of fluid aerosol generating material, to a temperature that accelerates the gelification of the fluid aerosol generating material. That is, the temperature is a temperature that enhances the rate at which the fluid aerosol generating material of the discrete portions 74 becomes a gel that is sufficiently viscous that the gel of the discrete portions 74 will not flow or change dimension or position when the stencil 18 moves away from the support 8 as the stencil 18 passes around the roller 30.
• the applicator 64 applies fluid aerosol generating material to the surface 54 of the finite element of the stencil 18 and the first surface 46 of the finite element of the support 8 via any apertures or parts of apertures 34 that are included in the finite element of the stencil 18.
• the pair of finite elements pass between the doctor blade 66 and the bed surface 12.
• the doctor blade 66 scrapes the fluid aerosol generating material off the surface 54 of the finite element of the stencil 18 and either directs the fluid aerosol generating material into a collection system for excess fluid aerosol generating material, or directs the fluid aerosol generating material into any aperture 34 or part of an aperture 34 that is between the doctor blade 66 and the first surface 46 of support 8.
• the first surface 46 of the support 8 now has the general appearance shown in Figure 4 . It is noted that, for clarity, not all of the discrete portions 74 of fluid aerosol generating material are labelled.
• the finite element of the support 8 subsequently continues to travel in the direction 14, through the drive means 40 and to the cutting position 70 where the cutting system 70 cuts the support 8 into a plurality of products.
• Each product including at least one group 32 of discrete portions 74 of aerosol generating material.
• the features of the apparatus 2 are as described in connection with Figures 1 to 4 above with the exception as follows:
• One or both of the rollers 20, 22 of the stencil system 16 are provided with a plurality of indexing teeth 76 (for clarity, not all of the indexing teeth 76 are labelled).
• the indexing teeth 76 are configured to engage with indexing holes 78 (again for clarity, not all of the indexing holes 78 are labelled) in the support 8.
• the engagement of the indexing teeth 76 and holes 78 assists in maintaining the relative positions of the support 8 and the stencil 18 (not shown in Figure 5 ) as the support 8 and stencil 18 travel along the bed surface 12 from the converging position 26 to the diverging position 30.
• the indexing teeth 76 and holes 78 ensure that the support 8 and the stencil 18 maintain the same speed in direction 14.

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• 2024
  • 2024-03-22 EP EP24165700.6A patent/EP4620336A1/de active Pending
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  • 2025-03-17 WO PCT/EP2025/057262 patent/WO2025195988A1/en active Pending

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