An Aerosol-Generating Material in the Form of One or More Non-Linear Strands

The present invention relates to aerosol-generating materials, aerosol-generating compositions comprising the aerosol-generating material; consumables for use within a non-combustible aerosol provision system, the consumables comprising the aerosol-generating composition; and non-combustible aerosol provision systems. The invention also relates to methods for producing the aerosol-generating material, and aerosol-generating materials obtainable by the methods of the invention.

Smoking consumables such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of consumables release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking consumables or aerosol generating assemblies.

One example of such a product is a heating device which releases compounds by heating, but not burning, a solid aerosol-generating material. This solid aerosol-generating material may, in some cases, contain a botanical material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known.

As another example, there are hybrid devices. These contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

According to a first aspect of the present invention, there is provided an aerosol-generating material in the form of one or more non-linear strands, wherein each non-linear strand has a number of contact points with other non-linear strands, the average number of contact points per non-linear strand being less than about 5.

The aerosol-generating material may comprise an aerosol-generating agent; a crosslinked binder; optionally one or more fillers; and optionally an active and/or flavourant and/or an acid.

In some aspects, the aerosol-generating material may comprise an aerosol-generating agent; a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota-carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof; optionally one or more fillers; and optionally an active and/or flavourant and/or an acid.

In another aspect, there is provided an aerosol-generating composition comprising the aerosol-generating material of the invention.

According to a further aspect of the present invention, there is provided a method of forming an aerosol-generating material in the form of one or more non-linear strands, the method comprising:

According to a further aspect of the present invention, there is provided a method of forming an aerosol-generating material in the form of non-linear strands, the method comprising:

The method then further comprises:

According to a further aspect of the present invention, there is provided a consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating composition as defined herein.

According to a further aspect of the present invention, there is provided a non-combustible aerosol provision system comprising the consumable as defined herein and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device configured to (or arranged to) generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

According to a further aspect of the invention, there is provided the use of an aerosol-generating composition as defined herein in a consumable for use in a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol-generation device arranged to generate aerosol from the consumable when the consumable is used with the non-combustible aerosol provision device.

According to a further aspect of the invention, there is provided the use of an aerosol-generating material or an aerosol-generating composition as defined herein for generating an aerosol.

According to a further aspect, the invention provides an aerosol-generating material obtainable by, or obtained by, a method of the invention.

According to a further aspect of the present invention, there is provided a method of generating an aerosol using a non-combustible aerosol provision system as described herein, the method comprising heating the aerosol-generating material. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of less than or equal to 350° C. In some embodiments, the method comprises heating the aerosol-generating material to a temperature of from about 220° C. to about 280° C.

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

The aerosol-generating materials/compositions described herein are materials/compositions that are capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating composition comprises an aerosol-generating material. The aerosol-generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating composition may for example comprise from about 50 wt %, 60 wt % or 70 wt % of aerosol-generating material, to about 90 wt %, 95 wt % or 100 wt % of aerosol-generating material. In some cases, the aerosol-generating composition consists of the aerosol-generating material. In other cases, the aerosol-generating composition comprises from about 40 to about 60 wt % of the aerosol-generating material. The remainder of the composition may be formed from other components as described below, for example tobacco material.

As described hereinabove, the invention provides an aerosol-generating material in the form of one or more non-linear strands, wherein each non-linear strand has a number of contact points with other non-linear strands, the average number of contact points per non-linear strand being less than about 5. The aerosol-generating material may comprise:

In some embodiments, the aerosol-generating material may comprise:

The aerosol-generating material described herein is in the form of one or more non-linear strands, such as 2 or more, 3 or more, 4 or more, 5 or more, 10 or more, 15 or more or 20 or more strands.

The aerosol-generating material may also optionally comprise one or more fillers, an active and/or a flavourant and/or an acid.

The aerosol-generating material is in the form of non-linear strands, which may alternatively be described as non-linear gel fibers. That is, the aerosol-generating material is in the form of strands or gel fibers, wherein each strand or fiber is non-linear across its length. The strands or fibers may alternatively be described as being curly, noodle-like or kinked. Each strand may therefore be thought of as being similar in shape to a noodle, whilst a number of the strands or gel fibers together can be thought of as being similar in shape to a collection of multiple noodles, where the individual strands may overlap and interlink randomly with each other. As used herein, the term “non-linear strands” is also intended to encompass the alternative terms described herein, such as “non-linear gel fibers”, “curly strands”, “curly gel fibers”, “noodle-like strands”, “noodle-like gel fibers”, “kinked strands”, etc.

Schematic examples of a non-linear strand of the invention are shown as the solid lines in, although it will be appreciated that these figures show a two dimensional representation of a three dimensional structure. In reality, each strand is three dimensional, and may also be non-linear in three dimensions. By “non-linear” in three dimensions it is meant that the stands of the invention are non-linear in the x, y and z directions. A spring or coil is an example of a shape which is non-linear in the x, y and z directions. In contrast, other strands may be non-linear in two dimensions (e.g. the x and y direction), but linear or flat in the third dimension (e.g. the z direction).

Each non-linear strand may have a diameter from about 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm or 0.5 mm to about 3 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.1 mm, 0.8 mm, 0.6 mm or 0.5 mm. In some embodiments, each non-linear strand has a diameter of from about 0.05 mm to about 3 mm, from about 0.3 to about 2.5 mm, from about 0.5 to about 1.5 mm, or from about 0.7 to about 1.1 mm. In some embodiments, each non-linear strand has a diameter of from about 0.1 to about 2 mm, from about 0.2 to about 1.1 mm, from about 0.3 to about 0.6 mm, or from about 0.2 mmm to about 0.4 mm. The diameter, also referred to as the width, is defined as the longest dimension of the cross-section of the strand.

Each non-linear strand may have a circular or substantially circular cross-section. The cross-section is the shape exposed by making a straight cut through the strand at right angles to the length at that point. An example of a circular cross-section of a strand is shown in, with the cross-section being taken at the dotted line on the schematic representation of the strand of the invention as shown in.

However, as will be described below, the shape of the strands are determined by the way in which they are made, and therefore the skilled person would recognise that strands having other cross-sectional shapes (e.g. rectangular, substantially rectangular, triangular or substantially triangular) could also be made.

In some embodiments, the non-linear strands are of the invention are homogenous through the cross-section. That is, some embodiments the composition of the strands is homogeneous.

Each non-linear strand has a number of contact points with other non-linear strands. The contact points are the points at which a non-linear strand contacts or touches another non-linear strand. The average number of contact points per strand can be calculated by measuring the number of contact points for a number of non-linear strands (e.g. 10 or more), and then dividing the number of contact points by the number of non-linear strands.

As will be appreciated, the average number of contact points per non-linear strand is a measure of how tangled the strands are. Essentially, if the non-linear strands are highly tangled, each strand will have a large number of contact points with other non-linear strands. This can make it difficult to handle or process the non-linear strands, as they will form a tangled block of strands which are difficult to separate. Conversely, if the average number of contact points is low, the strands will be less tangled and hence easier to separate. The inventors have also found that it is easier to form a homogeneous mixture with another material (e.g. tobacco) if the non-linear strands are not tangled (i.e. if they have a low average number of contact points). If the number of contact points is reduced to zero, the strands will be completely separated (i.e. each strand will not contact any other strands).

As used herein, the number of contact points includes any contact points between the same non-linear strand. That is, a single strand may still have a number of contact points above 0, if part of the strand contacts or touches another part of the same strand.

The number of contact points can be measured visually, either manually or with the help of suitable image analysis software.

The average number of contact points per non-linear strand is less than about 5, such as less than about 4, less than about 3, less than about 2, less than about 1 or less than about 0.5. In one aspect the average number of contact points per non-linear strand is 0. In one aspect the average number of contact points per non-linear strand ranges from 0 to about 5, such as from about 0.5 to about 4.

In some embodiments, each non-linear strand is orientated in substantially the same direction as the other non-linear strands. For example, the non-linear strands of aerosol-generating material may be aligned such that their free lengths are in substantially parallel alignment with each other. At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the non-linear strands may be arranged such that their free lengths are in substantially parallel alignment with each other.

In some embodiments, a majority of the non-linear strands may be arranged such that their free lengths are in substantially parallel alignment with each other. In some embodiments, about 95% to about 100% of the non-linear strands are arranged such that their free lengths are in substantially parallel alignment with each other.

In some embodiments, substantially all of the non-linear strands are arranged such that their free lengths are in substantially parallel alignment with each other.

By substantially parallel alignment it is meant that the smallest theoretical intersect angle between the free lengths of two non-linear strands is less than 25 degrees, such as less than 20 degrees, less than 10 degrees, less than 5 degrees, less than 1 degree or 0 degrees. By way of example, the intersect angle between two non-linear strands which have completely parallel free lengths is 0 degrees, whilst the intersect angle between two non-linear strands which have completely perpendicular free lengths is 90 degrees. If a majority of a plurality of non-linear strands are arranged such that their free lengths are in substantially parallel alignment with each other this means that if the smallest theoretical intersect angle between every possible combination of the non-linear strands was determined, at least 50% of these angles would be less than 25 degrees.

When the non-linear strands are orientated in substantially the same direction, they will also be untangled and hence easier to separate and to form into a homogeneous mixture with another material (e.g. tobacco).

Thus, in one aspect the invention provides an aerosol-generating material in the form of one or more non-linear strands, wherein a majority of the non-linear strands are arranged such that their free lengths are in substantially parallel alignment with each other.

Each non-linear strand may have a thickness of from about 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm or 0.5 mm to about 3 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.1 mm, 0.8 mm, 0.6 mm or 0.5 mm. In some embodiments, each non-linear strand has a thickness of from about 0.05 mm to about 3 mm, from about 0.3 to about 2.5 mm, from about 0.5 to about 1.5 mm, or from about 0.7 to about 1.1 mm. In some embodiments, each non-linear strand has a thickness of from about 0.1 to about 2 mm, from about 0.2 to about 1.1 mm, from about 0.3 to about 0.6 mm, or from about 0.2 mm to 0.4 mm. As used herein, the term “thickness” is the dimension of the cross-section which is perpendicular to the diameter or width.

When the cross-section of the non-linear strand is a circle, the ratio of the diameter to the thickness of the non-linear strand will be 1. Each non-linear strand may have a diameter to thickness ratio of from about 1:2 to about 2:1, such as from about 3:2 to about 2:3, such as about 1:1.

Each non-linear strand may have an overall length (also referred to herein as the total length) of from about 8 mm, 10 mm, 15 mm, 20 mm or 30 mm to about 200 mm, 100 mm, 75 mm or 50 mm. The overall or total length of each strand is also referred to herein as the uncoiled length, and is defined as the theoretical length if the strand was extended to be straight. For example, the overall length of the strand shown inis the total length of the strand, i.e. the length of the solid black line if this was straightened out.

In some embodiments, each non-linear strand has an overall length of from about 10 mm to about 200 mm, such as from about 20 mm to about 100 mm, or from about 30 mm to about 50 mm.

Each non-linear strand may have an a free-length of from about 3 mm, 5 mm, 8 mm or 11 mm to about 25 mm, 22 mm, 20 mm or 18 mm. The term “free length” as used herein is intended to mean the shortest (linear) length between the furthest ends of the strand in its natural non-linear (or curly) state (e.g. the distance between the ends of the strand “as the crow flies”). This is also referred to herein as the coiled length. For example, inthe free-length or coiled length of the strand is shown by the dashed line. Non-linear strands with a free-length outside of the ranges disclosed herein may clump together more readily than non-linear strands having a free-length as defined herein.

In some embodiments, each non-linear strand has a free or coiled length of from about 2 mm to about 35 mm, such as from about 3 mm to about 25 mm, from about 6 to about 23 mm, from about 8 mm to about 22 mm, or from about 11 mm to about 20 mm.

The total or uncoiled length is greater than the free or coiled length. In some embodiments, the ratio between the total length and the free length of each non-linear strand (i.e. the total length divided by the free length) is at least about 1.2, such as at least about 1.3, at least about 1.5 or at least about 2. In some embodiments, the ratio between the total length and the free length of each non-linear strand is less than about 10, less than about 8 or less than about 6. In some embodiments, the ratio between the total length and the free length of each non-linear strand is from about 1.2 to about 10, such as from about 1.5 to about 5, or from about 2 to about 5.

In some embodiments, the aspect ratio of the non-linear strands (i.e. the total length divided by the diameter) ranges from about 5 to about 200, such as from about 10 to about 100 or about 20 to about 50.

In some embodiments, the tensile strength of each strand ranges from about 0.1 N, 0.2 N, 0.3 N or 0.4 N to about 3.0 N, 2.0 N, 1.5 N or 1.0 N. In some embodiments, the tensile strength of each strand ranges from about 0.1 N to about 3.0 N, from about 0.2 N to about 2.0 N, or from about 0.3 N to about 1.0 N.

The tensile strength of the non-linear strands of the present invention may be determined by measuring the tensile force needed to break the strand. A suitable test procedure is set out in ISO 527-3:1995. As used herein, the tensile strength is essentially the force needed to break the strand, and is given as a force (in Newtons) per strand. The force needed to break the strand may be determined using an appropriate machine, for example a tensile testing machine from Instron, model 68TM-5. Before measuring the tensile strength, the samples should be conditioned at 22° C.±1° C. and a relative humidity (RH) of (60±2) % for at least 48 hours. The atmospheric pressure should be within the range 96 kPa±10 kPa.