RU2811714C2 - Aerosol-generating substrate containing aerosol-generating film - Google Patents

Abstract

FIELD: aerosol generators.

SUBSTANCE: aerosol generating article 10 includes aerosol generating substrate rod 14, wherein aerosol generating substrate rod 14 comprises: aerosol generating film 24 containing at least 25 percent by weight of a polyhydric alcohol and at least 10 percent by weight of a cellulose-based film-forming agent. In this case, the aerosol-generating film is designed in such a way that the open surface area of the aerosol-generating film inside the aerosol-generating substrate is at least 5 square millimeters per milligram of aerosol-generating film. Aerosol generating film 24 has a tobacco content of less than 1 percent by weight.

EFFECT: ability to provide an aerosol generating article having an aerosol generating film with improved stability and a high aerosol generating agent content so that it can be successfully used as an aerosol generating substrate; less impact on the environment.

13 cl, 4 dwg

Description

The present invention relates to an aerosol generating substrate in which an aerosol generating film is formed, and to an aerosol generating article containing such an aerosol generating substrate.

Aerosol-generating products in which an aerosol-generating substrate, such as a nicotine-containing substrate or a tobacco-containing substrate, is heated rather than burned are known in the art. Typically, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separate aerosol-generating substrate or material that may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol.

A number of prior art documents disclose aerosol generating devices for consuming aerosol generating articles. Such devices include, for example, electrically heated aerosol generating devices in which the aerosol is generated by transferring heat from one or more electrical heating elements of the aerosol generating device to an aerosol generating substrate of the aerosol generating article being heated.

In the past, substrates for heated aerosol generating products were often prepared using randomly oriented cut pieces, strands or strips of tobacco material. Alternatively, international patent application WO-A-2012/164009, for example, discloses rods for heated aerosol generating articles formed from assembled sheets of tobacco material.

International patent application WO-A-2011/101164 discloses alternative rods for heated aerosol generating articles formed from strands of homogenized tobacco material, which can be formed by casting, rolling, calendering or extruding a mixture containing bulk tobacco and at least one aerosol-forming agent to form a sheet of homogenized tobacco material. In alternative embodiments, the rods of WO-A-2011/101164 may be formed from strands of homogenized tobacco material obtained by extruding a mixture containing bulk tobacco and at least one aerosol forming agent to form homogenized tobacco material of continuous lengths.

Alternative forms of nicotine-containing substrates have also been disclosed. For example, liquid nicotine-based compositions, often referred to as e-liquids, have been proposed. Such liquid compositions, for example, can be heated through the helical electrically resistive filament of the aerosol generating device.

Substrates of this type may require special care in the manufacture of containers containing the liquid composition to prevent unwanted leakage. To address this issue and simplify the overall manufacturing process, it has also been proposed to provide a nicotine-containing gel composition that generates a nicotine-containing aerosol when heated. For example, WO-A-2018/019543 discloses a thermoreversible gel composition, i.e. a gel that will become fluid when heated to its melting temperature and will set to gel again at the gelling temperature. The gel is contained within the cartridge body, and the cartridge can be discarded and replaced when the gel is used up.

It would be desirable to provide an aerosol generating product having a new aerosol generating film with improved stability. In addition, it would be desirable to provide such an aerosol generating article with an aerosol generating film that has a high content of an aerosol generating agent so that it can be successfully used as an aerosol generating substrate. In particular, it would be desirable to provide an aerosol-generating product that is easier to dispose of after use or has less of an environmental impact. It would further be desirable to provide an aerosol generating article that, when used, optimizes the generation of an aerosol from an aerosol generating substrate.

The present invention relates to an aerosol generating article comprising an aerosol generating substrate rod containing an aerosol generating film. The aerosol generating film may contain at least about 25 percent by weight of a polyhydric alcohol. The aerosol generating film may contain at least about 10 percent by weight of cellulose-based film-forming agent. The aerosol generating film may be configured such that the exposed surface area of the aerosol generating film within the aerosol generating substrate is at least about 5 square millimeters per milligram of aerosol generating film. Alternatively or additionally, the aerosol generating film may be configured such that the bulk density of the aerosol generating film is at least about 100 mg per cubic centimeter of aerosol generating substrate.

According to a first aspect of the present invention, there is provided an aerosol generating article comprising an aerosol generating substrate rod, wherein the aerosol generating substrate rod comprises: an aerosol generating film containing at least 25 percent by weight of a polyhydric alcohol and at least 10 percent by weight weight of the cellulose-based film-forming agent. The aerosol generating film is configured such that the exposed surface area of the aerosol generating film within the aerosol generating substrate rod is at least about 5 square millimeters per milligram of aerosol generating film. The aerosol generating film is preferably substantially free of tobacco.

According to a second aspect of the present invention, there is provided an aerosol generating article comprising an aerosol generating substrate rod, wherein the aerosol generating substrate rod comprises: an aerosol generating film containing at least about 25 percent by weight of a polyhydric alcohol and at least about 10 percent by weight of cellulose-based film-forming agent. The aerosol generating film is configured such that the bulk density of the aerosol generating film is at least about 100 mg per cubic centimeter of aerosol generating substrate rod. The aerosol generating film is preferably substantially free of tobacco.

According to a third aspect of the present invention, there is provided a rod for use as an aerosol generating substrate in an aerosol generating article, the rod comprising: an aerosol generating film containing at least about 25 percent by weight of a polyhydric alcohol and at least about 10 percent by weight weight of the cellulosic film-forming agent, wherein the aerosol generating film is configured such that the exposed surface area of the aerosol generating film within the aerosol generating substrate rod is at least about 5 square millimeters per milligram of aerosol generating film. The aerosol generating film is preferably substantially free of tobacco.

According to a fourth aspect of the present invention, there is provided a rod for use as an aerosol generating substrate in an aerosol generating article, the rod comprising: an aerosol generating film containing at least about 25 percent by weight of a polyhydric alcohol and at least about 10 percent by weight weight of the cellulose-based film-forming agent, wherein the aerosol-generating film is configured such that the bulk density of the aerosol-generating film is at least about 100 mg per cubic centimeter of aerosol-generating substrate rod. The aerosol generating film is preferably substantially free of tobacco.

According to a fifth aspect of the present invention, there is provided an aerosol generating system comprising an aerosol generating article and an electrical aerosol generating device comprising a heating element configured to heat an aerosol generating substrate, an aerosol generating article, wherein: the aerosol generating article , comprises an aerosol generating substrate rod according to the present invention, as defined above in relation to the third and fourth aspects of the present invention. The heater element of the aerosol generating device is a heater plate or a heater pin configured to be inserted into the rod of the aerosol generating substrate to heat the aerosol generating film.

Any references herein to features of an aerosol generating article or aerosol generating substrate according to the present invention should be considered to apply to all aspects of the present invention unless otherwise indicated.

As used herein, the term "aerosol-generating article" refers to an aerosol-generating article for producing an aerosol containing an aerosol-generating substrate that is designed to be heated, rather than burned, to release volatile compounds that can form an aerosol.

As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing, when heated, volatile compounds that can form an aerosol. The aerosol generated from the aerosol generating substrates, aerosol generating articles described herein may be visible or invisible and may contain vapors (e.g., fine particles of substances in a gaseous state that are typically liquid or solid at room temperature) , as well as gases and liquid droplets of condensed vapor.

Substrates for heated aerosol generating products typically contain an "aerosol generating agent", i.e. a compound or mixture of compounds which, when used, facilitates the generation of an aerosol and which is preferably substantially resistant to thermal degradation at the operating temperature of the aerosol generating article. Examples of suitable aerosol-forming substances include: polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; polyhydric alcohol esters such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

The polyhydric alcohol in the aerosol generating film of the aerosol generating articles of the present invention is also an aerosol generating substance within the meaning set forth above.

As used herein, the term "rod" refers to a generally cylindrical element with a substantially polygonal cross-section and preferably a circular, oval or elliptical cross-section.

As used herein, the term "film" describes a solid laminar element having a thickness that is less than its width or length.

The film can be self-supporting. In other words, the film may have cohesion and mechanical properties such that the film, even if formed by casting a film-forming composition onto a support surface, can be released from the support surface.

Alternatively, the film may be placed on a support or sandwiched between other materials. This can improve the mechanical stability of the film.

The "thickness" of the aerosol generating film of the aerosol generating articles of the present invention corresponds to the minimum distance measured between opposing, substantially parallel surfaces of the film.

The thickness of the aerosol-generating film may substantially correspond to the thickness to which the corresponding film-forming composition is cast or extruded, since the cast or extruded film-forming composition is substantially not in contact during drying despite loss of water.

The "weight" of the aerosol generating film of the aerosol generating articles of the present invention will generally correspond to the weight of the components of the corresponding film-forming composition minus the weight of water evaporated during the drying step. If the film is self-supporting, the film itself may be weighed. If the film is placed on a support, the film and support may be weighed, and the weight of the support, measured before the film is deposited, is subtracted from the total weight of the film and support.

Unless otherwise specified, the percentages by weight of aerosol generating film components given herein are based on the total weight of the aerosol generating film.

As used herein, the term “longitudinal” refers to the direction corresponding to the major longitudinal axis of the aerosol generating article that extends between the upstream and downstream ends of the aerosol generating article. During use, air is drawn longitudinally through the aerosol-generating product. The term "transverse" refers to a direction that is perpendicular to the longitudinal axis.

Any reference to a “cross-section” of an aerosol-generating article or component of an aerosol-generating article refers to a cross-section unless otherwise noted. As used herein, the term "length" refers to the dimension of a component in the longitudinal direction, and the term "width" refers to the dimension of the component in the transverse direction.

As used herein, the terms "upstream" and "downstream" describe the relative positions of elements or parts of elements of an aerosol generating article with respect to the direction in which the aerosol is transported during use through the aerosol generating article.

As described above, the present invention provides an aerosol generating article having a novel aerosol generating substrate in which an aerosol generating film is formed. When heated, the aerosol generating film generates an aerosol, which is released into the aerosol generating article and can be drawn into the mouth of the consumer through the aerosol generating article. Instead of or in addition to any other aerosol generating substrate, an aerosol generating film may be provided in the aerosol generating article.

In many embodiments of the present invention, the aerosol generating film can be configured such that it forms a self-supporting rod and no additional support structures are required within the aerosol generating substrate. In many cases, the aerosol generating substrate rod can be formed from an aerosol generating film using existing apparatus and methods.

The aerosol generating substrate rod containing the aerosol generating film can be easily incorporated into existing aerosol generating article designs without the need for significant modification, and therefore the aerosol generating articles of the present invention can potentially be manufactured at high speed using existing devices and manufacturing methods.

The composition of the aerosol generating film can be selected such that most of the components of the film evaporate upon heating during use of the aerosol generating article, leaving a minimum amount of residue. This can advantageously provide an aerosol-generating product that is easier to dispose of and has less impact on the environment.

The properties and composition of the aerosol generating film can be easily tailored to control the resulting aerosol generated when the film is heated. The use of an aerosol generating film also makes it possible to provide the consumer with a highly stable aerosol.

The aerosol generating articles of the present invention are particularly suitable for use in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater element for heating the aerosol generating substrate rod, as described in more detail below. For example, the aerosol generating articles of the present invention find particular application in aerosol generating systems comprising an electrically heated aerosol generating device having an internal heater plate that is adapted to be inserted into the aerosol generating article near an aerosol generating substrate rod. Aerosol-generating products of this type are described in the prior art, for example in European patent application EP-A-0822670.

The aerosol generating films described herein are particularly suitable for internal heating within an aerosol generating article. When heated by the internal heating element, the aerosol generating film may decrease in volume on the inner surface of the tubular support element, which may advantageously bring the aerosol generating film closer to the surfaces of the heating element, thereby optimizing heating of the aerosol generating film.

As used herein, the term “aerosol generating device” refers to a device comprising a heating element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

Alternatively, the aerosol generating article of the present invention may include a combustible carbon heat source for heating during use of the aerosol generating substrate. Aerosol-generating products of this type are described in the prior art, for example in international patent application WO-A-2009/022232.

According to the present invention, the aerosol generating film is configured to maximize the total exposed surface area of the aerosol generating film within the aerosol generating substrate rod. By maximizing the exposed surface area, it is possible to improve the efficiency of aerosol release from a given volume of aerosol-generating substrate. The "exposed" surface area of the aerosol generating film corresponds to the total area of surfaces that are not covered or obstructed within the aerosol generating substrate rod and from which volatile components can be freely released when the aerosol generating film is heated. During use, the exposed surfaces of the aerosol generating film may become exposed to gaseous air flow through the aerosol generating article.

According to the present invention, the total exposed surface area of the aerosol generating film within the aerosol generating substrate rod can be maximized by increasing the exposed surface area per unit weight of the aerosol generating film. Thereby, the release efficiency of the aerosol from the aerosol generating film of a certain weight can be improved. Therefore, it may be possible to reduce the total weight of the aerosol generating film required to produce the desired amount of aerosol from the aerosol generating substrate rod during the heating cycle of the aerosol generating device.

The exposed surface area of the aerosol generating film is preferably at least about 5 square millimeters per milligram of aerosol generating film, more preferably at least about 10 square millimeters per milligram of aerosol generating film, and most preferably at least about 20 square millimeters per milligram of aerosol generating film. millimeters per milligram of aerosol-generating film.

The exposed surface area of the aerosol generating film is preferably no more than about 40 square millimeters per milligram of aerosol generating film, more preferably no more than about 30 square millimeters per milligram of aerosol generating film. For example, the exposed surface area of the aerosol generating film may be from about 5 square millimeters to about 40 square millimeters per milligram of aerosol generating film, or from about 10 square millimeters to about 30 square millimeters per milligram of aerosol generating film, or from about 20 square millimeters to approximately 30 square millimeters.

Alternatively or additionally, the total exposed surface area of the aerosol generating film can be maximized by increasing the bulk density of the aerosol generating film within the aerosol generating substrate rod so that more film can be provided per unit volume of the aerosol generating substrate rod and therefore , potentially large exposed surface area. The efficiency of aerosol release from a given volume of aerosol-generating substrate can thereby be improved. Therefore, it may be possible to obtain the desired amount of aerosol with a reduced size of the aerosol-generating substrate.

The bulk density of the aerosol generating film within the aerosol generating substrate rod is preferably at least about 100 mg per cubic centimeter of aerosol generating substrate rod, more preferably at least about 200 mg per cubic centimeter of aerosol generating substrate rod, more preferably at least about 300 mg per cubic centimeter of aerosol generating substrate rod, most preferably at least about 400 mg per cubic centimeter.

The bulk density of the aerosol generating film within the aerosol generating substrate rod is preferably no more than about 1000 mg per cubic centimeter of aerosol generating substrate rod, more preferably no more than about 850 mg per cubic centimeter, more preferably no more than about 750 mg per cubic centimeter centimeter, most preferably no more than about 600 mg per cubic centimeter. For example, the bulk density of the aerosol generating film within the aerosol generating substrate rod may be from about 100 mg to about 1000 mg per cubic centimeter, or from about 200 mg to about 8500 mg per cubic centimeter, or from about 300 mg to about 750 mg per cubic centimeter, or approximately 400 mg per cubic centimeter to approximately 600 mg per cubic centimeter.

The bulk density of the aerosol generating film corresponds to the ratio of the total weight of the film provided in the aerosol generating substrate rod (in mg), not including the weight of any support material, to the total volume of the rod (in cubic centimeters).

The present invention embraces a number of different aerosol generating film configurations to provide increased total exposed surface area.

In certain preferred embodiments, the aerosol generating substrate rod comprises a plurality of stacked layers of aerosol generating film.

As used herein, the term “stacked” refers to the arrangement of multiple layers of aerosol generating film one above the other. In the present invention, "stacked" layers may be placed one above the other with a space between adjacent layers. Alternatively, adjacent layers may be at least partially in contact with each other such that the layers are spaced apart in some regions, while in other regions the distance between adjacent layers may approach zero. As used herein, the term “stacked” is used regardless of the orientation of the stacked layers.

Providing multiple stacked layers of aerosol generating film advantageously provides a relatively large exposed surface area of the film since the surface of the aerosol generating film on both sides of each layer can be exposed. The exposed surface area can be easily increased by increasing the number of layers in the stack.

The ordered arrangement of the plurality of layers advantageously provides a rod with a constant distribution of the aerosol-generating film and a constant tightening resistance. The tightening resistance of the rod can be easily controlled by adjusting the distance between layers and the thickness of layers. The ordered arrangement of the plurality of layers may also optimize the transfer of heat from the heating element that is in contact with the rod through the rod during use.

Multiple layers of aerosol generating film may be stacked on top of each other such that each layer extends in the longitudinal direction of the aerosol generating article. Preferably, the layers are spaced apart laterally to allow air to flow through the rod during use. This arrangement of layers with a transverse distance between adjacent layers can facilitate insertion of a heating element, such as a heater plate, into the rod.

In such embodiments having a plurality of longitudinally extending layers, preferably at least about 80 percent of the plurality of layers, more preferably at least about 90 percent of the plurality of layers, and more preferably at least about 95 percent of the plurality of layers extend substantially the entire length of the rod . Particularly preferably, each layer of the plurality of layers extends substantially along the entire length of the rod. The layer that extends substantially the entire length of the rod extends substantially the entire length from the upstream end to the downstream end of the rod. This arrangement provides better control of the rod's tightening resistance and therefore aerosol delivery. The relative widths of the plurality of layers may vary to provide varying arrangements of stacked layers. For example, at least two layers may have different widths. Alternatively, the plurality of layers have a substantially constant width.

In such embodiments having multiple longitudinally extending layers, the plurality of layers are preferably arranged substantially parallel to each other to provide a substantially constant transverse distance between the layers along the length of the rod. The transverse spacing between layers can be adjusted to provide the desired level of airflow and therefore the desired resistance to rod tightening. Preferably, the layers are spaced apart laterally by at least about 10 microns, more preferably by at least about 20 microns, and most preferably by at least about 50 microns. Preferably, the layers are preferably spaced laterally from each other by no more than about 300 microns, more preferably by no more than about 200 microns, and most preferably by no more than about 150 microns.

Alternatively, multiple layers of aerosol generating film may be stacked on top of each other such that each layer extends in a transverse direction of the aerosol generating article. Therefore, the stack of layers runs along the length of the rod. Preferably, the transverse layers of the aerosol generating film are adapted to allow air to flow longitudinally through the rod during use. For example, each of the layers may be provided with one or more holes or slits through the layer.

In such embodiments having multiple transverse layers of aerosol generating film, the layers are preferably spaced apart from each other in the longitudinal direction to maximize the exposed surfaces of the layers. In this case, the layers are preferably spaced apart from each other by at least about 50 microns, more preferably by at least about 100 microns, and most preferably by at least about 150 microns. Preferably, the layers are preferably spaced apart from each other in the longitudinal direction by no more than about 1500 microns, more preferably by no more than about 800 microns, and most preferably by no more than about 600 microns. Alternatively, the layers may be stacked on top of each other such that adjacent layers are at least partially in contact with each other with essentially no longitudinal distance between them.

The following further discussion of embodiments of the present invention containing multiple stacked layers of aerosol generating film applies to all layer arrangements as described above.

The number of layers of aerosol generating film stacked on top of each other within the rod may vary depending on the thickness of the layers and the length of the rod. The number of layers can be increased to increase the total exposed surface area of the aerosol generating film. Preferably, the rod contains from about 2 to about 50 stacked layers of aerosol generating film.

The plurality of layers of aerosol generating film may have substantially the same thickness. Alternatively, the plurality of layers may include layers with at least two different thicknesses.

In certain preferred embodiments of the present invention, a plurality of stacked layers of aerosol generating film are secured within a tubular support member, such as a paper tube or cardboard tube. In alternative embodiments, the plurality of stacked layers are defined by a wrapper. By providing stacked layers within a tubular support layer or wrapper, the aerosol generating film can be more conveniently combined with other components to form an aerosol generating article.

In alternative embodiments of the present invention, the aerosol generating substrate rod comprises one or more assembled layers of aerosol generating film. As used herein, in relation to the present invention, the term “assembled” describes a sheet that is rolled, folded, or otherwise compressed or tapered in a direction substantially transverse to the longitudinal axis of the aerosol generating article.

The use of one or more assembled layers of aerosol generating film is an alternative way of providing a relatively large exposed surface area within the aerosol generating substrate rod. The exposed surface area of the aerosol generating film and also the bulk density of the aerosol generating film within the rod can be easily controlled by adjusting the degree of turn or folding of the layers.

Preferably, one or more assembled layers of aerosol generating film are defined by the wrapper. Preferably, one or more assembled layers of aerosol generating film extend along substantially the entire length of the rod and substantially throughout the cross-sectional area of the rod.

In further alternative embodiments of the present invention, the aerosol generating substrate rod comprises a plurality of strips or pieces of aerosol generating film. For example, the rod may be formed from a plurality of strips of aerosol generating film that are longitudinally aligned and brought together and wrapped to form a rod of aerosol generating substrate. Alternatively, the strips of aerosol generating film may be randomly oriented in the rod. The use of multiple strips or pieces is an additional method by which the total exposed surface area of the aerosol generating film can be increased. The exposed surface area of the aerosol generating film and also the bulk density of the aerosol generating film within the rod can be easily controlled by adjusting the number of strips in the volume of the rod.

In such embodiments, the aerosol generating film strips preferably have a length of from about 10 millimeters to about 20 millimeters, more preferably from about 12 millimeters to about 18 millimeters, more preferably from about 14 millimeters to about 16 millimeters, more preferably about 15 millimeters. Alternatively or additionally, the aerosol generating film strips preferably have a width of from about 0.4 millimeters to about 0.8 millimeters.

In further embodiments of the present invention, the aerosol generating substrate rod may comprise a plurality of hollow beads formed from the aerosol generating film, such as a plurality of spherical beads. The use of multiple beads is an additional method by which the total exposed surface area of the aerosol-generating film can be increased. The exposed surface area of the aerosol generating film and also the bulk density of the aerosol generating film inside the rod can be easily controlled by adjusting the number of beads inside the rod and the packing density of the beads.

The aerosol generating substrate rod may contain from about 2 to about 30 beads of aerosol generating film. A plurality of balls are preferably provided in the cavity of the tubular support member so that they can be contained within the aerosol generating substrate.

In any embodiment of the present invention, the aerosol generating film may advantageously be textured over at least a portion of its surface. As used herein, the term “textured” refers to a film that is corrugated, embossed, blind embossed, perforated, or otherwise locally deformed. For example, the film may include a plurality of spaced apart recesses, projections, perforations, or a combination thereof. The texture may be provided on one side of the film or on both sides of the film. In cases where there are multiple stacked layers of aerosol generating film, some or all of the layers may be textured.

Providing texture over at least a portion of the surface of the aerosol generating film is an alternative or additional method by which the exposed surface area of the aerosol generating film can be maximized.

In certain preferred embodiments, the aerosol generating film is corrugated over at least a portion of its surface. As used herein, the term "corrugated" means a film having a plurality of substantially parallel folds or corrugations. Preferably, when the aerosol generating article is assembled, substantially parallel folds or corrugations extend along or parallel to the longitudinal axis of the aerosol generating article.

A single corrugated layer of aerosol generating film may be provided in the aerosol generating substrate rod. In such embodiments, the single corrugated layer is preferably assembled in the manner described above. Alternatively, a plurality of corrugated layers of aerosol generating film may be provided. For example, multiple corrugated layers of aerosol generating film may be stacked on top of each other to form an aerosol generating substrate rod as described above.

The thickness of the aerosol generating film in the aerosol generating articles of the present invention is preferably at least about 0.05 millimeters, more preferably at least about 0.1 millimeters, most preferably at least about 0.15 millimeters. The thickness of the aerosol generating film is preferably no more than about 1.0 millimeters, more preferably no more than about 0.5 millimeters, most preferably no more than about 0.3 millimeters. For example, the film thickness may be from about 0.05 millimeter to about 1.0 millimeter, or from about 0.1 millimeter to about 0.5 millimeter, or from about 0.15 millimeter to about 0.3 millimeter. Therefore, the present invention provides a relatively thin layer of aerosol generating film so that the surface area to weight ratio of the film can be maximized. This improves the efficiency of releasing volatile components from the aerosol generating film when heated. The use of a relatively thin layer of aerosol generating film also allows the weight of the film to be kept low while still maintaining sufficient surface area. This advantageously reduces the thermal inertia of the aerosol generating film to further improve the aerosol generation efficiency.

The weight of the aerosol generating film in the aerosol generating substrate rod can also be adjusted depending on the desired level of aerosol delivery during use. Preferably, the weight of the aerosol generating film is selected such that substantially all of the volatile components of the aerosol generating film are released during the normal heating cycle of the aerosol generating article to minimize waste and maximize the degradability of the aerosol generating substrate rod.

Preferably, the tubular support element provides at least about 20 milligrams of aerosol generating film, more preferably at least about 50 milligrams, more preferably at least about 100 milligrams. Preferably, the tubular support element provides no more than about 300 milligrams of aerosol generating film, more preferably no more than about 200 milligrams. For example, a tubular support member may provide from about 20 milligrams to about 300 milligrams of aerosol generating film, or from about 50 milligrams to about 200 milligrams of aerosol generating film, or from about 100 milligrams to about 200 milligrams of aerosol generating film.

The aerosol generating film preferably has a basis weight of at least about 100 grams per square meter, more preferably at least about 120 grams per square meter, most preferably at least about 140 grams per square meter. Preferably, the aerosol generating film has a basis weight of no more than 300 grams per square meter, more preferably no more than 280 grams per square meter, most preferably no more than 260 grams per square meter. For example, the aerosol generating film may have a basis weight of from about 100 grams per square meter to about 300 grams per square meter, or from about 120 grams per square meter to about 280 grams per square meter, or from about 140 grams per square meter up to approximately 260 grams per square meter.

The aerosol generating substrate rod preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol generating article.

Preferably, the aerosol generating substrate rod has an outer diameter of at least 5 millimeters. The aerosol generating substrate rod may have an outer diameter of from about 5 millimeters to about 12 millimeters, such as from about 5 millimeters to about 10 millimeters, or from about 6 millimeters to about 8 millimeters. In a preferred embodiment, the aerosol generating substrate rod has an outer diameter of approximately 7 millimeters.

The rod of the aerosol generating substrate may have a length of from about 5 millimeters to about 15 mm. In one embodiment, the rod of the aerosol generating substrate may be approximately 10 millimeters in length. In a preferred embodiment, the aerosol generating substrate rod is approximately 12 millimeters in length.

Preferably, the rod of the aerosol generating substrate has a substantially constant cross-section along the length of the rod. Particularly preferably, the rod of the aerosol generating substrate has a substantially circular cross-section.

The aerosol generating film may be incorporated directly into the aerosol generating substrate rod as a single layer substrate. The aerosol generating film, in one layer, can be textured in the manner described above. Alternatively, the aerosol generating film may be applied to a support layer, such as a layer of porous or fibrous sheet material, or the layer may be impregnated with it before being incorporated into the aerosol generating substrate core. Suitable sheet materials for the support layer include, but are not limited to, paper, cardboard and homogenized plant material. The carrier layer bearing the aerosol generating film may be textured as described above.

The aerosol generating film of the aerosol generating articles of the present invention has a composition comprising at least about 25 weight percent polyhydric alcohol, more preferably at least about 30 weight percent polyhydric alcohol, more preferably at least about 35 weight percent polyhydric alcohol. by weight of polyhydric alcohol, more preferably at least about 40 percent by weight of polyhydric alcohol.

Preferably, the aerosol generating film preferably contains less than about 90 weight percent polyhydric alcohol, more preferably less than about 80 weight percent polyhydric alcohol, more preferably less than about 70 weight percent polyhydric alcohol, more preferably less than about 60 weight percent polyhydric alcohol.

For example, the aerosol generating film may contain from about 25 weight percent to about 90 weight percent polyhydric alcohol, or from about 30 weight percent to about 80 weight percent polyhydric alcohol, or from about 35 weight percent to about 70 weight percent polyhydric alcohol. percent by weight of the polyhydric alcohol, or from about 40 percent by weight to about 60 percent by weight of the polyhydric alcohol.

Polyhydric alcohols suitable for use in aerosol generating film include, but are not limited to, propylene glycol, triethylene glycol, 1,3-butanediol and glycerol. Preferably, in the aerosol generating film of the present invention, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, and combinations thereof. In particularly preferred embodiments, the polyhydric alcohol is glycerol.

Thus, the invention advantageously provides a film having a significant polyhydric alcohol content that can be easily cast or extruded and cured starting from a composition having a gel-like texture. Since a significant percentage of polyhydric alcohol, in particular glycerol, can be provided in the form of a film, while at the same time allowing fine control of the geometry of the film, the present invention advantageously provides a film that is particularly suitable for use in an aerosol generating substrate, in an aerosol generating article configured to be heated to release the aerosol.

Preferably, the aerosol generating film further contains at least about 3 weight percent cellulose-based film-forming agent, more preferably at least about 6 weight percent cellulose-based film-forming agent, more preferably at least about 10 weight percent cellulose-based film-forming agent cellulose-based film-forming agent, more preferably at least about 14 percent by weight cellulose-based film-forming agent, more preferably at least about 16 percent by weight cellulose-based film-forming agent, more preferably at least about 18 percent by weight weight of the cellulose-based film-forming agent.

The aerosol generating film may contain up to about 70 percent by weight of cellulose-based film-forming agent. Preferably, the aerosol generating film preferably contains no more than about 26 percent by weight of cellulose-based film-forming agent, more preferably no more than about 24 percent by weight of cellulose-based film-forming agent, more preferably no more than about 22 percent by weight of cellulose-based film-forming agent per based on cellulose.

For example, the aerosol generating film may contain from about 3 weight percent to about 70 weight percent cellulose-based film-forming agent, or from about 6 weight percent to about 26 weight percent cellulose-based film-forming agent, or from about 10 percent by weight to about 24 percent by weight of a cellulose-based film-forming agent, or from about 14 percent by weight to about 24 percent by weight of a cellulose-based film-forming agent, or from about 16 percent by weight to about 22 percent by weight of a film-forming agent based on cellulose-based, or from about 18 percent by weight to about 22 percent by weight cellulose-based film-forming agent.

In the context of the present invention, the term "cellulose-based film-forming agent" is used to describe a cellulosic polymer capable of forming a continuous film, alone or in the presence of an adjuvant thickener.

Preferably, the cellulose-based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylmethylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC) and combinations thereof. In a particularly preferred embodiment, the cellulose-based film-forming agent is HPMC.

Preferably, in the aerosol generating film, the ratio of the weight of cellulose-based film-forming agent to the weight of polyhydric alcohol is at least about 0.1, more preferably at least about 0.2, even more preferably about 0.3. Additionally or alternatively, in the aerosol generating film, the ratio of the weight of the cellulose-based film-forming agent to the weight of the polyhydric alcohol is preferably no more than about 1.

In preferred embodiments, the aerosol generating film has a ratio of the weight of cellulose-based film-forming agent to the weight of polyhydric alcohol from about 0.1 to about 1.

The inventors have surprisingly discovered that aerosol generating films containing at least 6 percent by weight of cellulose-based film-forming agent, and preferably HPMC, are particularly stable. Thus, they essentially retain their shape when exposed to a range of environmental conditions, such as changing relative humidity from 10 percent to 60 percent. Accordingly, aerosol generating films as described above advantageously do not release a liquid phase during storage or transport.

Preferably, the aerosol generating film further contains at least about 1 weight percent non-cellulose thickener, more preferably at least about 2 weight percent non-cellulose thickener, more preferably at least about 3 weight percent non-cellulose thickener. based on cellulose. Preferably, the aerosol generating film preferably contains no more than about 10 percent by weight of a non-cellulose based thickener, more preferably no more than about 8 percent by weight of a non-cellulose based thickener, more preferably no more than about 6 percent by weight of a non-cellulose based thickener . For example, the aerosol generating film may contain from about 1 weight percent to about 10 weight percent non-cellulose-based thickener, or from about 2 weight percent to about 8 weight percent non-cellulose-based thickener, or from about 3 percent by weight to approximately 6 percent by weight of a non-cellulose based thickener.

As used herein in connection with the present invention, the term “non-cellulose thickener” is used to describe a non-cellulosic substance that, when added to an aqueous or non-aqueous liquid composition, increases the viscosity of the liquid composition without substantially changing its other properties. A thickener can increase stability and improve suspension of components in a liquid composition. A thickener may also be called a "thickening agent" or a "rheology modifier".

Preferably, in the aerosol generating film of the present invention, the non-cellulose based thickener is selected from the group consisting of agar, xanthan gum, acacia gum, guar gum, locust bean gum, pectin, carrageenan, starch, alginate and combinations thereof. In preferred embodiments, the non-cellulose based thickener is agar.

Preferably, in the aerosol generating film, the ratio of the weight of the non-cellulose thickener to the weight of the polyhydric alcohol is at least about 0.05, more preferably at least 0.1, even more preferably at least 0.2. Additionally or alternatively, in the aerosol generating film, the ratio of the weight of the non-cellulose based thickener to the weight of the polyhydric alcohol is preferably no more than about 0.5.

In preferred embodiments, the aerosol generating film has a non-cellulose thickener to polyhydric alcohol weight ratio of from about 0.1 to about 0.5.

The inventors have surprisingly discovered that by incorporating a combination of a cellulose-based film-forming agent and a non-cellulose-based thickener into a film together with a polyhydric alcohol, a film having improved stability can be provided that can be produced with high accuracy and repeatability.

Preferably, the aerosol generating film contains less than about 30 percent by weight water. More preferably, the aerosol generating film contains from about 10 percent by weight to about 20 percent by weight water.

In some embodiments, the aerosol generating film further comprises an alkaloid compound or a cannabinoid compound, or both.

As used herein, in relation to the present invention, the term “alkaloid compound” describes any of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Typically, the alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in an alkaloid compound molecule may be active as a base in acid-base reactions. Most alkaloid compounds have one or more nitrogen atoms as part of a cyclic system, such as a heterocyclic ring. In nature, alkaloid compounds are found primarily in plants and are particularly common in certain families of flowering plants. However, some alkaloid compounds are found in animal and fungal species. In the context of the present invention, the term "alkaloid compounds" is used to describe both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

Preferably, the alkaloid compound is selected from the group consisting of nicotine, anatabine, and combinations thereof.

As used herein, in relation to the present invention, the term “cannabinoid compound” describes any of a class of naturally occurring compounds that are found in parts of the cannabis plant, namely the species Cannabis sativa , Cannabis indica and Cannabis ruderalis . Cannabinoid compounds are particularly concentrated in the female flower heads. The cannabinoid compounds found naturally in the hemp plant include tetrahydrocannabinol (THC) and cannabidiol (CBD). In the context of the present invention, the term “cannabinoid compounds” is used to describe both naturally occurring cannabinoid compounds and synthetically manufactured cannabinoid compounds.

Preferably, the cannabinoid compound is selected from the group consisting of: tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ester (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT) and combinations thereof.

In general, the aerosol generating film may contain up to about 10 percent by weight of an alkaloid compound or a cannabinoid compound, or both. The content of the alkaloid compound or cannabinoid compound or both in the film can be increased and adjusted to optimize delivery of the alkaloid compound or cannabinoid compound or both in aerosol form to the consumer. Compared to existing aerosol generating substrates based on the use of plant material, this may advantageously allow for a higher content of alkaloid compound or cannabinoid compound or both per volume of substrate (film) or per weight of substrate (film), which can be desirable from a manufacturing point of view.

Preferably, the aerosol generating film contains at least about 0.5 percent by weight of an alkaloid compound or a cannabinoid compound, or both. Thus, the aerosol generating film preferably contains at least about 0.5 percent by weight of an alkaloid compound or at least 0.5 percent by weight of a cannabinoid compound or at least about 0.5 percent by weight of a combination of an alkaloid compound and a cannabinoid compound. connections.

More preferably, the aerosol generating film contains at least about 1 percent by weight of an alkaloid compound or a cannabinoid compound or both, more preferably at least about 2 percent by weight of an alkaloid compound or a cannabinoid compound or both. The aerosol generating film preferably contains less than about 6 percent by weight of an alkaloid compound or a cannabinoid compound or both, more preferably less than about 5 percent by weight of an alkaloid compound or a cannabinoid compound or both, more preferably less than about 4 percent by weight of an alkaloid compound or a cannabinoid compound or both the weight of the alkaloid compound or cannabinoid compound or both.

For example, the aerosol generating film may contain from about 0.5 weight percent to about 10 weight percent an alkaloid compound or a cannabinoid compound or both, or from about 1 weight percent to about 6 weight percent an alkaloid compound, or a cannabinoid compound or both, or from about 2 percent by weight to about 5 percent by weight an alkaloid compound or a cannabinoid compound or both.

In some embodiments, the aerosol generating film contains one or more of a cannabinoid and an alkaloid compound containing nicotine or anatabine. In some preferred embodiments, the aerosol generating film contains nicotine. As used herein, in connection with the present invention, the term “nicotine” is used to describe nicotine, nicotine base or nicotine salt. In embodiments in which the aerosol generating film contains nicotine base or nicotine salt, the amounts of nicotine given herein mean the amount of nicotine in free base form or the amount of protonated nicotine, respectively.

The aerosol generating film may contain natural nicotine or synthetic nicotine.

The aerosol generating film may contain one or more monobasic nicotine salts.

As used herein, in connection with the present invention, the term “nicotine monobasic salt” is used to describe the monobasic acid salt of nicotine.

Preferably, the aerosol generating film contains at least about 0.5 percent by weight nicotine. More preferably, the aerosol generating film contains at least about 1 percent by weight nicotine. Even more preferably, the aerosol generating film contains at least about 2 percent by weight nicotine. Additionally or alternatively, the aerosol generating film preferably contains less than about 10 percent by weight nicotine. More preferably, the aerosol generating film contains less than about 6 percent by weight nicotine. Even more preferably, the aerosol generating film contains less than about 5 percent by weight nicotine. For example, the aerosol generating film may contain from about 0.5 weight percent to about 10 weight percent nicotine, or from about 1 weight percent to about 6 weight percent nicotine, or from about 2 weight percent to about 5 weight percent nicotine. percent by weight of nicotine.

In some preferred embodiments, the aerosol generating film contains a cannabinoid compound. Preferably the cannabinoid compound is selected from CBD and THC. More preferably, the cannabinoid compound is CBD.

The aerosol generating film may contain up to about 10 percent by weight CBD. Preferably, the aerosol generating film contains at least about 0.5 weight percent CBD, more preferably at least about 1 weight percent CBD, more preferably at least about 2 weight percent CBD. Preferably, the aerosol generating film preferably contains less than about 6 percent by weight CBD, more preferably less than about 5 percent by weight CBD, more preferably less than about 4 percent by weight CBD.

For example, the aerosol generating film may contain from about 0.5 percent by weight to about 10 percent by weight CBD, more preferably from about 1 percent by weight to about 6 percent by weight CBD, even more preferably from about 2 percent by weight to approximately 5 percent by weight CBD.

The aerosol generating film may be a substantially tobacco-free aerosol generating film.

As used herein, in relation to the present invention, the term “substantially tobacco-free aerosol generating film” describes an aerosol generating film having a tobacco content of less than 1 percent by weight. For example, the aerosol generating film may have a tobacco content of less than about 0.75 percent by weight, less than about 0.5 percent by weight, or less than about 0.25 percent by weight.

The aerosol generating film may be a tobacco-free aerosol generating film.

As used herein, in relation to the present invention, the term “tobacco-free aerosol generating film” describes an aerosol generating film having a tobacco content of 0 percent by weight.

In some embodiments, the aerosol generating film contains tobacco material or non-tobacco plant material or plant extract. For example, the aerosol generating film may contain tobacco particles, such as tobacco blade particles, as well as particles of other plants, such as cloves and eucalyptus. In cases where the aerosol generating film contains tobacco, the tobacco content is preferably no more than about 70 weight percent, more preferably no more than about 50 weight percent, more preferably no more than about 30 weight percent, and most preferably no more than about 10 percent by weight.

In preferred embodiments, the aerosol generating film contains an acid. More preferably, the aerosol generating film contains one or more organic acids. Even more preferably, the aerosol generating film contains one or more carboxylic acids. In particularly preferred embodiments, the acid is lactic acid or levulinic acid.

The inclusion of acid is particularly preferred in embodiments of an aerosol generating film containing nicotine, as it has been observed that the presence of acid can stabilize dissolved compounds in the film-forming composition, such as with nicotine and other plant extracts. Without being limited by theory, it is understood that the acid can react with the nicotine molecule, especially in cases where the nicotine is provided in the form of a salt, and this essentially prevents the nicotine from evaporating during the drying operation. In this way, nicotine loss during film production can be minimized and a higher, better controlled delivery of nicotine to the consumer can advantageously be provided.

Preferably, the aerosol generating film contains at least about 0.25 percent by weight acid. More preferably, the aerosol generating film contains at least about 0.5 percent by weight acid. Even more preferably, the aerosol generating film contains at least about 1 percent by weight acid. Additionally or alternatively, the aerosol generating film preferably contains less than about 3.5 percent by weight acid. More preferably, the aerosol generating film contains less than about 3 percent by weight acid. Even more preferably, the aerosol generating film contains less than about 2.5 percent by weight acid.

For example, the aerosol generating film may contain from about 0.25 weight percent to about 3.5 weight percent acid, or from about 0.5 weight percent to about 3 weight percent acid, or from about 1 weight percent acid. weight to approximately 2.5 percent by weight acid.

The aerosol generating film may optionally contain a fragrance. In some embodiments, the aerosol generating film may contain up to about 2 percent by weight of flavorant. For example, the aerosol generating film may contain one or more of the following: menthol, terpenes, terpenoids, eugenol and eucalyptol.

An aerosol-generating film can be produced by forming a film-forming composition from film components, preferably an aqueous film-forming composition, casting or extruding the film-forming composition onto a support surface, allowing the film-forming composition to gel, and then drying the film-forming composition to form an aerosol-generating film. The film can then be separated from the support surface and incorporated into an aerosol generating substrate for an aerosol generating article. Alternatively, the film may be included in the aerosol generating substrate along with the support surface.

It was found that when heated, most of the components of the aerosol-generating film evaporate. In fact, it has been observed that only some residue of the cellulose-based film-forming agent, if any, usually remains after use. Thus, aerosol-generating articles including substrates containing aerosol-generating film as described can be more easily disposed of, and their environmental impact can be improved.

During use, the aerosol generating film may be heated to a temperature of from about 180 degrees Celsius to about 250 degrees Celsius to generate an aerosol. The inventors have surprisingly discovered that when the aerosol generating film is heated in the aerosol generating device, it can release the polyol without substantially releasing the liquid phase.

The aerosol generating articles of the present invention preferably comprise one or more elements in addition to an aerosol generating substrate rod, the rod and one or more elements being assembled within a substrate wrap or within a tubular support member.

Preferably, the aerosol generating article further comprises a flow restriction element downstream of the aerosol generating substrate rod. A flow restriction element may advantageously be included for the purpose of providing the aerosol generating article with an acceptable level of resistance to draw (RTD). Suitable flow restriction elements to provide the desired level of RTD are known to one skilled in the art. In some embodiments, the flow restriction element may have a constriction, such as one or more holes having a diameter that is less than the diameter of the internal cavity. In preferred embodiments, the flow restriction element comprises one or more inserts of fibrous filter material, such as one or more inserts of cellulose acetate.

The RTD of the aerosol generating article after insertion of the heating element is preferably from about 40 mmH2O. to about 140 mm water column, more preferably from about 80 mm water column. up to approximately 120 mm water column.

In the context of this document, tightening resistance is expressed in units of pressure “mmWg.” or "millimeters of water" and is measured in accordance with ISO 6565:2002.

The flow restriction element may extend to a downstream end of the aerosol generating article. Alternatively, a hollow cavity may be provided downstream of the flow restriction element at the mouth end.

The flow restriction element preferably extends longitudinally from about 15 millimeters to about 25 millimeters along the aerosol generating article.

Preferably, the flow restriction element is spaced from the aerosol generating substrate rod in the longitudinal direction such that the flow restriction element and the aerosol generating substrate rod are separated by a hollow space or cavity. This separation of components advantageously provides space for aerosol generation in the aerosol generating article. Preferably, the longitudinal distance between the flow restriction element and the aerosol generating film is at least about 10 percent of the length of the aerosol generating article, more preferably at least about 20 percent of the length. Preferably, the length of the space between the aerosol generating film and the flow restriction element is at least 50 percent of the length of the aerosol generating substrate rod.

Preferably, the aerosol generating article further comprises an upstream sealing element covering the upstream end of the aerosol generating substrate rod. Sealing the upstream end advantageously reduces the penetration of air and water into the aerosol generating substrate rod prior to use. This helps maintain the freshness of the aerosol generating film during storage to optimize aerosol delivery when heated. In addition, compacting the upstream end of the aerosol generating substrate rod can reduce the loss of volatile components of the aerosol generating film during storage so that delivery of these components to the consumer can be maximized.

The upstream sealing element may take any suitable shape, but is preferably in the form of a sheet of material that covers the upstream face of the aerosol generating substrate rod. Preferably, the sheet of material is substantially impermeable. The upstream sealing element may be formed from any suitable sheet material, including, but not limited to, paper, aluminum, polymer, or combinations thereof.

Preferably, a fragile upstream sealing element is provided. The sealing element is fragile such that it may be pierced by a heating element or other piercing means when the aerosol generating article is inserted into the aerosol generating device. A support element, such as an insert of fibrous filter material, may be provided immediately behind the frangible upstream seal element, if necessary, to facilitate piercing of the frangible upstream seal element by a heater element or other piercing means.

Alternatively, or in addition to the upstream sealing element, the aerosol generating article may further comprise a downstream sealing element at its downstream end. The downstream sealing element may have the same shape as the upstream sealing element or a different shape. In cases where a downstream sealing element is provided, it may be removable such that it can be removed from the aerosol generating article prior to use.

Alternatively, or in addition to providing an upstream sealing member, a tubular support member may be provided at the upstream end of the aerosol generating article upstream of the rod of the aerosol generating substrate. For example, upstream of the aerosol generating substrate rod, a hollow acetate tube may be provided at the upstream end of the aerosol generating article. The tubular support member can advantageously minimize the risk of any aerosol generating film being lost in the aerosol generating article prior to use. In addition, the tubular support member may facilitate insertion of the internal heater element into and removal from the aerosol generating article during use of the aerosol generating article in the aerosol generating device. Additionally, the tubular support member may be used to direct or control air flow through the aerosol generating article.

As defined above, the third and fourth aspects of the present invention provide rods for use as an aerosol generating substrate for an aerosol generating article, wherein the rod comprises an aerosol generating film. The aerosol generating substrate rod and the aerosol generating film may have any of the features or properties described above with respect to the first and second aspects of the present invention.

The aerosol generating substrate rods according to the third aspect of the present invention as described above can be produced using the method of the present invention as defined below. The method of the present invention includes a first step of providing an aqueous film-forming composition containing a polyhydric alcohol and a cellulose-based film-forming agent and a second step of providing sheet material. In the third step, the aqueous film-forming composition is applied to the surface of the sheet material to form a film layer, and in the fourth step, the film layer is dried to form an aerosol-generating film having at least 25 percent by weight of polyhydric alcohol and at least 10 percent by weight of film-forming agent based on cellulose. In a fifth step, the film layer is configured to form a rod of aerosol generating substrate such that the exposed surface area of the aerosol generating film is at least about 5 square millimeters per milligram of aerosol generating film.

The aerosol generating substrate rods according to the fourth aspect of the present invention as described above can be produced using the method of the present invention as defined below. The method of the present invention includes a first step of providing an aqueous film-forming composition containing a polyhydric alcohol and a cellulose-based film-forming agent and a second step of providing sheet material. In the third step, the aqueous film-forming composition is applied to the surface of the sheet material to form a film layer, and in the fourth step, the film layer is dried to form an aerosol generating film having at least about 40 weight percent polyhydric alcohol and at least about 10 weight percent cellulose-based film-forming agent. In a fifth step, the film layer is configured to form an aerosol generating substrate rod such that the bulk density of the aerosol generating film is at least about 100 mg per cubic centimeter of aerosol generating substrate rod.

In any of the methods of the present invention, the configuration step will depend on the desired configuration of the aerosol generating film within the aerosol generating substrate rod. For example, in cases where it is desired to form a rod of aerosol generating substrate comprising a plurality of stacked layers of aerosol generating film as described above, the step of configuring the aerosol generating film may include the step of forming the plurality of layers of aerosol generating film and stacking multiple layers on top of each other to form a rod. Alternatively, the step of configuring the aerosol generating film may include assembling the aerosol generating film to form a rod. Alternatively, the step of configuring the aerosol generating film may include cutting a plurality of strips from the film layer and forming a core of the plurality of strips.

As described above, the present invention further provides an aerosol generating system comprising an aerosol generating article containing an aerosol generating substrate rod according to the present invention in combination with an electrical aerosol generating device which is adapted to receive the aerosol generating article, and which has a heating element configured to heat the aerosol generating film, the aerosol generating substrate rod. The aerosol generating article contains an aerosol generating substrate according to the third or fourth aspects of the present invention, as described in detail above.

Preferably, the heating element is configured to heat the aerosol generating film to a temperature of from about 120 degrees Celsius to about 350 degrees Celsius, more preferably to a temperature of from about 200 degrees Celsius to about 220 degrees Celsius.

The electrical aerosol generating device may be configured to heat the aerosol generating article from the outside. An elongated heating chamber is provided which is adapted to accommodate an aerosol generating article, and a heating element is provided circumferentially around the heating chamber to partially or completely surround the aerosol generating article within the chamber for heating the aerosol generating substrate rod.

Alternatively, the electrical aerosol generating device may be configured to be heated from within the aerosol generating article in the tubular support member. A heater element in the form of an elongated heater plate or pin is provided which is adapted to be inserted into the rod of the aerosol generating substrate to heat the aerosol generating film.

In any of the aerosol generating systems of the present invention, the heater element may have any suitable shape for transferring heat. The aerosol generating system may be an electrical aerosol generating system comprising an induction heating device. Induction heating devices typically include an induction source configured to be connected to a current collector. The induction source generates an alternating electromagnetic field, which induces magnetization or eddy currents in the pantograph. The pantograph may heat up as a result of hysteresis losses, or induced eddy currents heat the pantograph through ohmic or resistive heating.

Electrical aerosol generating systems that include an induction heating device may also include an aerosol generating article having an aerosol generating film and a current collector in thermal proximity to the aerosol generating film. The pantograph is heated by hysteresis losses or induced eddy currents, which in turn heats the aerosol-generating film. Typically, the pantograph is in direct contact with the aerosol-generating film, and heat is transferred from the pantograph to the aerosol-generating film mainly through conduction. Examples of electrical aerosol generating systems containing induction heating devices and aerosol generating products containing current collectors are described in WO-A1-95/27411 and WO-A1-2015/177255.

The invention will now be further described with reference to the drawings, in which:

in fig. 1 is a schematic longitudinal cross-sectional view of an aerosol generating article according to a first embodiment of the present invention;

in fig. 2 is a schematic longitudinal sectional view of the aerosol generating article shown in FIG. 1, in combination with an internal heating element of the aerosol generating device;

in fig. 3 is a schematic longitudinal sectional view of the aerosol generating article shown in FIG. 1, in combination with an external heater element of the aerosol generating device; And

in fig. 4 is a schematic longitudinal sectional view of an aerosol generating article according to a second embodiment of the present invention.

The aerosol generating article 10 shown in FIG. 1 includes a tubular support element 12, an aerosol generating substrate rod 14, and a flow restriction element 16.

The tubular support element 12 is made in the form of a paper tube having a length of approximately 12 millimeters and an outer diameter of approximately 7 millimeters. The tubular support element 12 is cylindrical in shape and defines a longitudinally extending internal cavity 18 extending from the upstream end 20 of the tubular support element 12 to the downstream end 22.

The aerosol generating substrate rod 14 contains a plurality of layers 24 of aerosol generating film. As shown in FIG. 1, each of the plurality of layers 24 extends longitudinally along the entire length of the rod 14. Although not shown in FIG. 1, the layers 24 are spaced apart from each other in the transverse direction. Each of the layers 24 has a thickness of approximately 0.25 millimeters and a length of approximately 10 millimeters. The core contains approximately 30 sheets. The total amount of aerosol generating film in rod 14 is approximately 200 mg.

The exposed surface area of the aerosol generating film layers 24 is greater than 5 square millimeters per milligram of aerosol generating film.

The bulk density of the aerosol generating film in rod 14 is greater than 100 mg per cubic centimeter of rod 14.

The aerosol-generating film 14 has the following composition:

Composition of aerosol-generating film
(weight percent) 19.3%HPMC
4.8% agar
1.4% nicotine
48% glycerin
2.1% levulinic acid
24.4% water

The flow restriction element 16 includes one segment of cellulose acetate rod, which is provided in the internal cavity 18 of the tubular support element 12, at the downstream end 22. The flow restriction element 16 has a length of approximately 20 millimeters and an outer diameter corresponding to the diameter of the internal cavity 18 of the tubular support element. element 12. The flow restriction element 16 is located downstream of the aerosol generating film 14 and is spaced from the aerosol generating film 14 such that an empty space is formed within the tubular support element 12 between the downstream end of the film 14, generating the aerosol, and the end of the flow restriction element 16 located upstream of the flow.

The upstream end 20 of the tubular support element 12 is sealed by an upstream sealing element 26 which includes a sheet of aluminum provided over the end of the tubular support element 12 to seal the upstream end of the internal cavity 18.

The aerosol generating article 10 shown in FIG. 1 is suitable for use with an electrical aerosol generating device including a heater for heating the aerosol generating film 14.

In fig. 2 is a schematic view of an aerosol generating article 10 heated in an aerosol generating device 50 having a heater plate 52. The aerosol generating article is inserted into the aerosol generating device 50 such that the heater plate 52 pierces through a previously located along the flow, the sealing element 24 is inserted into the rod of the aerosol generating substrate 14 between the layers of the aerosol generating film 24.

During use, the heater plate 52 heats the aerosol generating film layers 24 to a temperature sufficient to generate an aerosol from the aerosol generating film. The aerosol is drawn through the flow restriction element 16 and pulled out through the downstream end 22 of the tubular support element.

In fig. 3 is a schematic view of an aerosol generating article 10 being heated in an alternative aerosol generating device 60 having a heating chamber 62 into which the upstream end of the aerosol generating article is inserted such that the outer heater element 64 surrounds the upstream end of the aerosol generating article. along the flow, a part of the tubular supporting element 12, including a substrate rod 14 that generates an aerosol. The heating element 64 heats the aerosol generating film layers 24 in the aerosol generating substrate rod 14 circumferentially from the outside of the tubular support element 12.

The aerosol generating device 60 further includes a piercing element 66 that pierces the upstream sealing element 24 as the aerosol generating article 10 is inserted into the heating chamber 62.

In fig. 4 shows an aerosol generating article 70 according to a second embodiment of the present invention, which is similar in structure to the aerosol generating article 10 shown in FIG. 1 but includes an aerosol generating substrate rod 74 having a different aerosol generating film configuration.

The rod 74 contains multiple layers 76 of aerosol generating film. As shown in FIG. 4, each of the aerosol generating film layers 76 extends in a transverse direction. The layers 76 are parallel to each other and stacked on top of each other such that adjacent layers are in contact with each other without any longitudinal distance between them. The layers 76 are circular in shape and have a diameter substantially corresponding to the diameter of the inner cavity 18 of the tubular support member 12. Each of the layers 76 has a thickness of approximately 0.25 millimeters, and the rod contains approximately 45 layers. The length of the rod 74 is approximately 5 millimeters. The total amount of aerosol generating film in rod 74 is approximately 200 mg.

The exposed surface area of the aerosol generating film layers 76 is greater than 5 square millimeters per milligram of aerosol generating film.

The bulk density of the aerosol generating film in rod 74 is greater than 100 mg per cubic centimeter of rod 74.

Each of the layers 76 includes a plurality of air flow holes (not shown) located along the surface, which provide the layers 76 with sufficient porosity to allow air flow through the rod 74 during use.

The aerosol generating article 70 may be heated in the aerosol generating device as described above with respect to the aerosol generating article 10.

It should be understood that the aerosol generating articles 10 shown in FIG. 1 may also be suitable for use with other types of aerosol generating devices.

Claims (17)

1. An aerosol-generating article comprising an aerosol-generating substrate rod, wherein the aerosol-generating substrate rod contains: an aerosol-generating film containing at least 25 percent by weight of a polyhydric alcohol and at least 10 percent by weight of a cellulose-based film-forming agent, wherein the aerosol-generating film is configured such that the open surface area of the aerosol-generating film is within of aerosol generating substrate is at least 5 square millimeters per milligram of aerosol generating film, and wherein the aerosol generating film has a tobacco content of less than 1 percent by weight. 2. The aerosol-generating product according to claim 1, characterized in that the aerosol-generating substrate rod contains a plurality of stacked layers of aerosol-generating film. 3. The aerosol generating product according to claim 2, characterized in that a plurality of layers of aerosol generating film are stacked on top of each other in such a way that each layer extends in the transverse direction of the aerosol generating product. 4. The aerosol-generating product according to claim 2, characterized in that a plurality of layers of aerosol-generating film are stacked on top of each other in such a way that each layer extends in the longitudinal direction of the aerosol-generating product. 5. An aerosol-generating product according to any one of claims. 2-4, characterized in that the aerosol-generating substrate contains a tubular support element forming a longitudinally extending internal channel, and a plurality of stacked layers are provided in the internal channel. 6. An aerosol-generating product according to any one of claims. 2-5, characterized in that the plurality of stacked layers of aerosol-generating film contain from 2 to 50 stacked layers. 7. The aerosol generating product according to claim 1, wherein the aerosol generating substrate rod comprises one or more assembled layers of aerosol generating film. 8. The aerosol generating product according to claim 1, wherein the aerosol generating substrate rod contains a plurality of aerosol generating film strips. 9. An aerosol-generating product according to any of the previous paragraphs, characterized in that the thickness of the aerosol-generating film is from 0.1 millimeter to 0.5 millimeter. 10. An aerosol generating product according to any of the preceding claims, characterized in that the aerosol generating film is textured, preferably corrugated. 11. An aerosol generating article according to any of the previous claims, characterized in that an aerosol generating film is provided on at least one surface of the carrier layer, preferably the paper layer. 12. A rod for use as an aerosol generating substrate in an aerosol generating article, the rod comprising: an aerosol generating film containing at least 25 percent by weight of a polyhydric alcohol and at least 10 percent by weight of a cellulosic film-forming agent, wherein the aerosol generating film is configured such that the exposed surface area of the aerosol generating film is within the substrate, aerosol generating film is at least 5 square millimeters per milligram of aerosol generating film, and wherein the aerosol generating film has a tobacco content of less than 1 percent by weight. 13. An aerosol-generating system containing an aerosol-generating product and an electrical aerosol-generating device containing a heating element configured to heat the aerosol-generating substrate, the aerosol-generating product, wherein: the aerosol generating product comprises an aerosol generating substrate rod according to claim 12; And wherein the heating element is a heater plate or a heater pin configured to be inserted into the rod of the aerosol generating substrate to heat the aerosol generating film.