Patent Publication Number: US-2023144274-A1

Title: An article for use with an apparatus for heating an aerosol generating agent

Description:
PRIORITY CLAIM 
     The present application is a Divisional Application of U.S. Application No. 16/492,652, filed Sep. 10, 2019, which is a National Phase entry of PCT Application No. PCT/EP2018/058195, filed Mar. 29, 2018, which claims priority from GB Patent Application No. 1705152.5, filed Mar. 30, 2017, which are all hereby fully incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to an article for use with an apparatus for heating aerosol generating agent. 
     BACKGROUND 
     Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these smoking articles by creating products that release compounds without actually combusting and hence which do not create smoke or an aerosol as a result of degradation of, for example, tobacco by combustion or the process of burning. Examples of such products are so-called heat-not-burn products, tobacco heating products or tobacco heating devices, which release compounds, which may form an aerosol, by heating, but not burning, aerosol generating material. The aerosol generating material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. 
     SUMMARY 
     In accordance with some embodiments described herein, there is provided an article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the article comprising a support layer having a first surface, wherein at least a portion of the first surface is rough; and an aerosol generating agent on the portion of the first surface that is rough. Providing the aerosol generating agent on the portion of the first surface that is rough, heat transfer from a heater to the article will be improved. 
     In an exemplary embodiment, the portion of the first surface that is rough comprises a plurality of protuberances. 
     In an exemplary embodiment, the portion of the first surface is embossed. Embossing the first surface is an efficient and easily repeatable way to obtain the rough surface. 
     In accordance with some embodiments described herein, there is provided an article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the article comprising a first substrate of paper having a first inner surface; and an aerosol generating agent on at least a portion of the first inner surface of the first sheet. 
     In accordance with some embodiments described herein, there is provided a system comprising an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent; and an article for use with the apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the article comprising a support layer having a first surface, wherein at least a portion of the first surface is rough; and an aerosol generating agent on the portion of the first surface that is rough. 
     In accordance with some embodiments described herein, there is provided a kit comprising an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent; and an article for use with the apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the article comprising a support layer having a first surface, wherein at least a portion of the first surface is rough; and an aerosol generating agent on the portion of the first surface that is rough. 
     In accordance with some embodiments described herein, there is provided a method of manufacturing a smoking article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the method comprising providing a support layer having a first surface, wherein at least a portion of the first surface is rough; and providing an aerosol generating agent on the portion of the first surface that is rough. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG.  1    shows a schematic side view of an article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. 
         FIG.  2    shows a schematic perspective view of the article of  FIG.  1   . 
         FIG.  3    shows a schematic perspective view of the first example of an apparatus for heating an aerosol generating material. 
         FIGS.  4 A and  4 B  show an example of delamination between an aerosol forming agent and a substrate. 
         FIG.  5    shows a further example of delamination between an aerosol forming agent and a substrate. 
         FIG.  6    shows a further example of delamination between an aerosol forming agent and a substrate. 
         FIGS.  7 A and  7 B  shows a schematic plan and perspective view of the first example of support layer with a rough first surface for receiving an aerosol generating agent. 
         FIG.  7 C  shows a schematic perspective view of a first example of article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. 
         FIG.  8    shows a schematic perspective view of a support layer of the article with score lines. 
         FIG.  9    shows a schematic perspective view of a second example of an article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. 
         FIG.  10    shows a schematic view of an article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. 
     
    
    
     DETAILED DESCRIPTION 
     As used herein, the term “aerosol generating agent” includes agents that provide volatilized components upon heating. “Aerosol generating agent” includes any tobacco-containing material and may, for example, include one or more of tobacco, tobacco derivatives including tobacco extracts, expanded tobacco, reconstituted tobacco or tobacco substitutes. “Aerosol generating agent” may also include other, non-tobacco, products, including for example flavorants, which, depending on the product, may or may not contain nicotine, filler materials such as chalk and/or sorbent materials, glycerol, propylene glycol or triacetin. The aerosol generating agent may also include a binding material, for example, sodium alginate. The aerosol generating agent may include tobacco particles or leaves in solid form within the agent. In one example the aerosol generating agent is an aerosol forming gel. The aerosol generating gel may be a solid, jelly like material. The aerosol generating gel may be a newtonian or non-newtonian gel. In one example the gel is a thermoplastic gel. In one example, the aerosol generating gel has a viscosity of between 0.1 and 100 Ns/m 2 . 
     Referring to  FIGS.  1  to  2   , there is shown an article  100  for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. The article  100  includes a support layer  102  and a layer of aerosol generating agent  104 . The aerosol generating agent  104  is located on a first surface  106  of the support layer  102 . The aerosol generating agent  104  forms a layer of material on the support layer  102  as shown in  FIGS.  1  and  2   , for example the layer of aerosol generating agent  104  is bonded to the support layer  102 . 
     In the examples of the articles  100  shown in  FIGS.  1  to  6   , the support layer  102  has a substantially smooth first surface  106  on which the aerosol generating agent  104  is located. An example of a support layer  102  which has a smooth surface is aluminum foil. 
     The article  100  is designed to be used with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, such as a so-called tobacco heating product, which includes a heater. An example of a heating apparatus is shown in  FIG.  3   . In one example, the apparatus  50  comprises a substantially flat heating surface  52  upon which, in use, the article  100  is placed such that the support layer  102  lies on the heating surface. In other examples, the heater may take the form of a cylindrical heater or a blade heater. In other example, the apparatus may comprise a heater to heat air which will subsequently pass over the surface of the aerosol generating agent to heat it. The heater may comprise a resistive heater, in another example, the heater may be an inductive heater and the article may be placed on a susceptor within the apparatus. In the example of the induction heating, the support layer  102  may be formed of a magnetic material and act as an additional susceptor so that an eddy current is generated when the support layer  102  is subjected to a varying magnetic field. The apparatus  50  is configured to heat the article  100  to volatilize at least one component of the aerosol generating agent. In the example of  FIG.  3   , the apparatus  50  includes a mouthpiece  54  through which the volatilized components may flow. However, in other examples, the apparatus does not include the mouthpiece  54 . 
     In the example of the aerosol forming agent  104  comprising an aerosol forming gel, the aerosol forming gel  104  may be formed by mixing a concentrated tobacco extract with water in a high shear mixer with a binding agent, such as sodium alginate, to form a paste or slurry. An aerosol generating material, such as glycerol, is added and the paste is wet cast on as a thin film on a support layer  102 , such as aluminum or paper. The thin film is then dried by applying heat to remove excess water from the film. In the drying phase, the articles  100  may be subject to a temperature of approximately 60 to 100° C. for approximately 20 minutes to 5 hours. Depending on the chemicals used in the formulation of the thin films, the thin films exhibit a sticky surface that makes handling them in a commercial environment problematic. The thin films may also exhibit poor adhesion to the support layer  102  on which they have been cast, which may lead to problems during the drying phase and also when the article  100  is heated in use in the aerosol generating apparatus, which will be described in more detail below. 
     In one example, the aerosol forming agent  104  has a thickness of between 100 µm and 350 µm. 
     It has been observed that upon heating of the article, the aerosol generating agent  104  tends to become delaminated from the support layer  102 . In addition, when the article  100  is placed on a heating surface  52  of the apparatus, the support layer  102  tends to curl, which results in a separation between the support layer  102  and the heating surface  52 . The consequence of both of these examples is poor heat transfer from the heating surface  52  to the aerosol generating agent  104 , which results in a poor aerosol delivery. 
     A first mechanism for delamination between the aerosol generating agent  104  and the support layer  102  is shown in  FIGS.  4 A and  4 B .  FIG.  4 A  shows an example of the article  100  during heating. The heating process causes water and or other components within the aerosol generating agent  104  to evaporate causing the agent to contract as shown by the arrows in  FIG.  3 A . The support layer  102  may be formed from a solid material, such as aluminum or paper and thus would not contract upon heating. As there is some adhesion between the aerosol generating material  104  and the support layer  102 , the differential contraction between the aerosol generating agent layer  104  and the support layer  102  causes the article  100  to curl as shown in  FIG.  3 A . The self-weight of the support layer  102  causes the support layer  102  to resist the contraction of the aerosol generating agent  104 . As the aerosol generating agent  104  continues to contract, the central part of the aerosol generating agent  104  may separate from the support layer  102  resulting in delamination of the aerosol generating agent  104  and the support layer  102 . The degree of curling versus delamination depends on the level of adhesion between the aerosol generating agent  104  and the support layer  102 , the stiffness of the support layer  102  and the stiffness of the aerosol forming agent  104 . 
     A second mechanism for delamination between the aerosol generating agent  104  and the support layer  102  is shown in  FIG.  5   .  FIG.  5    shows an example of the article  100  during heating. The heating process causes water and or other components within the aerosol generating agent  104  to evaporate. If the support layer  102  is placed on a heating surface  52  of an apparatus, then the surface of the aerosol generating agent  104  that is proximate to the first surface  106  of the support layer  102  (and hence the heating surface) will be heated faster compared with the surface of the aerosol forming agent  104  that is further from the heating surface  52 . As a result, the surface of the aerosol generating agent  104  that is proximate to the first surface  106  of the support layer  102  will lose more water compared with the surface of the aerosol forming agent that is further from the heating surface and therefore will contract more as shown in  FIG.  5   . 
     A third mechanism for delamination between the aerosol generating agent  104  and the support layer  102  is shown in  FIG.  6   . As the aerosol generating agent  104  is heated, at least one component of the aerosol generating agent  104  is volatilized. If there is not a flow path between the volatilized component and the outer surface of the aerosol generating agent  104 , then a build-up of volatilized components will act to separate the aerosol generating agent  104  from the support layer  102 . There may also be air bubbles that get trapped in the aerosol generating agent  104  during the drying process that will expand upon heating and act to cause a delamination between the aerosol generating agent  104  and the support layer  102 . 
     There is a need to improve heat transfer between a heater of the apparatus  50  and the article  100 , which will improve the generation of volatilized components. Surprisingly, it was found that improving the adhesion sufficiently improves heat transfer for aerosol generating agents and results in a more efficient aerosol generating. One way of improving heat transfer is to improve adhesion between the aerosol generating agent  104  and the support layer  102  to reduce the delamination between the aerosol generating agent  104  and the support layer  102 . One option for improving the adhesion between the aerosol generating agent  104  and the support layer  102  would be through the use of chemical additives to the aerosol generating agent  104  and the support layer  102 . Powdered additives may be used to reduce the stickiness of the aerosol generating agent  104  to improve the handling of the agent. However, the use of additives has a number of drawbacks because components from the additives may be volatilized upon heating and be inhaled by a user, which may be undesirable. Further, the use of additives will increase the costs of creating the article  100 . 
       FIGS.  7 A and  7 B  show an example of a support layer  202  in the form of a substrate having a first surface  206 , wherein at least a portion of the first surface  206  is rough to provide an uneven or irregular surface. The first surface  206  is sufficiently rough to prevent or inhibit the delamination of the aerosol generating agent  204  from the first surface  206  of the support layer  202 . 
     In one example, the first surface  206  is made rough by making a number of holes in the support layer  202 . The holes may be made by penetrating the first surface  206  with a pin or series of pins. 
     The support layer  202  may be formed of any material suitable for receiving and holding the aerosol generating agent  204 . In one example, the support layer  202  is formed from a heat conducting material, for example a metal such as aluminum. The support layer  202  may be, for example a metal foil such as aluminum foil. 
     In the example of the support layer  202  being formed of aluminum, the aluminum can have a thickness of between 5 µm to 25 µm. The aluminum thickness may be 7 µm, 10 µm or 20 µm, such as 6 µm to 8 µm. 
     In other examples, the support layer  202  is formed from a paper material, such as tipping paper, porous plug wrap, cigarette paper or tea bag paper. The paper may be a porous paper. When an aerosol generating gel is used as the aerosol generating agent, the gel may flow into the pores of the porous paper to improve adhesion. In the example of the support layer being formed from a paper material, the paper can have a weight of between 20 gsm and 100 gsm. 
     The aerosol forming agent  204  (not shown) will be located on the first surface  206  of the support layer  202 . In the example shown in  FIGS.  7 A and  7 B , the first surface  206  is rough due to the fact that there is a plurality of protuberances  208 . Protuberances  208  are elements that protrude from the first surface  206  of the support layer  202 . In the example shown in  FIGS.  7 A and  7 B , the protuberances take the form of cylinders, however, any shape that projects from the first surface  206  of the support layer  202  may be used, such as cubes, pyramids and irregular shapes. It is not necessary for the protuberances  208  to be formed of the same shape. The protuberance  208  in  FIGS.  7 A and  7 B  are shown as covering most of the first surface  206  of the support layer  202 , but in other example, the protuberances  208  only cover part of the first surface  206  of the support layer  202 . In one example protuberances  208  may be formed by adding additional material or removing some material from the first surface  206  of the support later. 
     In one example the protuberances have a height of between 0.1 mm and 0.2 mm and a width of between 0.2 mm and 0.4 mm, such as a height of 0.15 mm and a width of 0.3 mm. 
     In one example, the first surface  206  of the support layer  202  is embossed to create the surface roughness. The support layer  202  may be embossed by stamping the support layer  202  with a mould to cause the first surface  206  of support layer  202  to have a three-dimensional or raised effect on selected areas. In some examples, the embossing procedure requires the use of two dies: one that is raised and one that is recessed. The dies fit into each other so that when the support layer  202  is pressed between them, the raised die forces the support layer  202  into the recessed die and creates the embossed surface. 
     The protuberances  208  may also be formed by embossing. Embossing the first surface  206  of the support layer  202  is a simple and repeatable way of creating a rough surface. The first surface  202  may be made rough by including one or more ridges, folds, indents, raised sections, holes. 
     The first surface  206  may be embossed using various patterns, such as one or more of spirals, lines; squares; circles; and/or rectangles. 
     The rough first surface  206  of the support layer  202 , as shown in  FIGS.  7 A and  7 B , acts to increase the contact surface area between the aerosol generating agent  204  and the support layer  202 . An example of article  200  formed from the support layer  202  with a rough first surface  206  and aerosol generating agent  204  is shown in  FIG.  7 C . The increased surface area will increase the adhesion between the aerosol forming agent  204  and the support layer  202 , and hence reduce the effects of the first two separation mechanisms described above. In relation to the first mechanism, the increased adhesion means that as the aerosol generating agent  204  contracts, it will be less likely to separate from the support layer  202 . In relation to the second mechanism, the aerosol forming agent  204  is less likely to separate from the inner surface of the heat conducting layer because it will have a stronger adhesion to the inner surface. As the adhesion is increased, the aerosol forming agent  204  is less likely to delaminate from the support layer  202  and therefore when the article  200  is heated by a heating apparatus, more aerosol generating agent  204  will be heated. 
     The article  200  may be manufacturing by providing a support layer  202  having a first surface  206 , wherein at least a portion of the first surface  206  is rough; and providing an aerosol generating agent  204  on the portion of the first surface  206  that is rough. As described above, the first surface  206  may be made rough by one or more of embossing the first surface  206 , providing protuberances  208 , or other means of roughening the surface. 
     In the further example shown in  FIG.  8   , the first surface  306  of the support layer  302  is made rough by having one or more score lines  310  formed in the first surface  306 . The score lines may be formed by known processes such as running a cutting element over the first surface  306  of the support layer  306  to provide one or more cuts or indents in the first surface  306  of the support layer  302 . 
       FIG.  8    shows the support layer  302  with six score lines  310  applied to the first surface  306 , however, in some examples there are fewer score lines and in other examples there are more than six score lines  310  applied to the first surface  306 . As with the protuberances  208  shown in  FIG.  7 B , score lines  310  perform the function of adding a surface roughness to the first surface of the support layer  310 , which increases the adhesion between the aerosol generating agent  304  and the support layer  302 . In one example, the surface roughness of the first surface  306  of the support layer  302  is provided by the score lines  310 . In other examples, the surface roughness of the first surface  306  of the support layer is provided by a combination of one or more of the protuberances  208 , embossment and the score lines  310 . 
     As shown in  FIG.  9   , the score lines  310  may also be applied to the aerosol generating agent  304 . Applying score lines  310  to the aerosol generating agent  304  results in the aerosol generating agent  304  being pooled into one or more separate sections delineated by the score lines  310 . Separating the aerosol generating agent  304  into separate sections provides more flow paths for any volatilized components and the outer surface of the aerosol generating agent  304 . Therefore, the third mechanism of delamination between the aerosol generating agent  304  and the support layer  302  described above is less likely to occur. Further, separating the aerosol generating agent  304  into one or more separate sections helps reduce the curling effect described above. 
     Aerosol generating agents  104 ,  204 ,  304  may be formed from different tobacco extracts, such as Burley, Virgina and Oriental. Aerosol generating agents  204 ,  304  formed from different tobacco extracts may have different properties, for example, agents formed from Burley tobacco is more brittle, whereas agents formed from Virginia and Oriental is more pliable. Providing a first surface  306  of a support later  302 , where at least a portion of the first surface is rough provides the best results when an aerosol generating agent  304  formed from an oriental tobacco is used. 
     T-Peel tests were carried out on a selection of samples. A T-Peel test involves testing the peel strength between the aerosol generating agent  304  and the support layer  302 . Result of the T-Peel Test are shown below: 
     
       
         
           
               
               
               
               
             
               
                 Agent type 
                 Support Layer Thickness 
                 Unembossed 
                 Embossed 
               
             
            
               
                 Burley 
                 20 µm 
                 4.5+/- 0.8 N/mm 
                 6.4+/- 0.6 N/mm 
               
               
                 Oriental 
                 10 µm 
                 2.3 +/- 0.3 N/mm 
                 3.9 +/- 0.8 N/mm 
               
            
           
         
       
     
     In a yet further example, the support layer  402  may be formed from paper, such as tipping paper, porous plug wrap, cigarette paper or tea bag paper. As paper is a fibrous substrate, the surface of the paper will be irregular. When an aerosol generating agent is applied to the surface of the paper, the aerosol generating agent will contact the irregular surface and will adhere to a first surface of the paper substrate. The inventors found that surprisingly, the aerosol generating agent  404  did not weaken the thin paper support and upon casting, the paper retained its integrity and after drying, the thin film adhered strongly to the paper substrate. This makes an article  400  that uses a paper substrate as the support layer an ideal system for use in a heating apparatus because the paper is thin enough not to act as a significant “insulation layer” so heat transfer is acceptable. 
     In one example, the apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent may be sold in a kit, together with the article according to any of the examples described above. 
     The examples above show an aerosol generating agent on a first surface of a support layer, however, in other examples the support layer may include a first surface and a second surface, wherein at least a portion of the first surface is rough; and at least a portion of the second surface is rough. The second surface may be arranged on the opposite side of the support layer to the first surface. An aerosol generating agent is applied to the portion of the first surface that is rough and to the portion of the second surface that is rough. This arrangement enables more aerosol generating agent to be held by the support layer. Alternatively, the article may comprise a second support layer, such that the aerosol generating agent is located in between the first and second support layers. As with the first support layer the second support layer may comprise a first and/or second surface that are rough. 
       FIG.  10    shows an example of an article according to any of the example above, wherein the article  500  is in the form of a cartridge that can be inserted into the apparatus  50  for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent. The article  500  includes a support layer having a first surface (not shown) wherein at least a portion of the first surface is rough. An aerosol generating agent is be applied to the portion of the first surface that is rough. 
     The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.