CN114945287A

CN114945287A - Formulations for aerosol-generating systems

Info

Publication number: CN114945287A
Application number: CN202080087471.4A
Authority: CN
Inventors: F·斯巴达罗; I·陶里诺
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2019-12-18
Filing date: 2020-12-16
Publication date: 2022-08-26
Also published as: BR112022011593A2; EP4076024A1; WO2021122800A1; JP2023508007A; KR20220117268A; US20230000131A1

Abstract

A formulation (311) for an aerosol-generating system. The formulation (311) comprises: one or more aerosol forming agents; and one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch; wherein the formulation (311) has a melting point between 100 degrees Celsius and 300 degrees Celsius. An aerosol-generating article (300) for use in an aerosol-generating system, the aerosol-generating article (300) comprising the formulation (311). An aerosol-generating system, the aerosol-generating system comprising: the formulation (311); and a nebulizer (322) configured to generate an aerosol from the formulation (311).

Description

Formulations for aerosol-generating systems

Technical Field

The present invention relates to a formulation for an aerosol-generating system. The invention also relates to an aerosol-generating article comprising a formulation for an aerosol-generating system and to an aerosol-generating system comprising a formulation and a nebulizer.

Background

Aerosol-generating systems for delivering an aerosol to a user typically include a nebulizer configured to generate an inhalable aerosol from a formulation. Some known aerosol-generating systems include a thermal atomizer (e.g., an electric heater) configured to heat and vaporize a formulation to produce an aerosol. A typical formulation for an aerosol-generating system is a nicotine formulation, which may be a liquid nicotine formulation comprising an aerosol former such as glycerol and/or propylene glycol.

It would be desirable to provide a formulation which, when used in an aerosol-generating system, exhibits a reduced risk of leakage compared to typical formulations.

Disclosure of Invention

A formulation for an aerosol-generating system is provided. The formulation may comprise one or more aerosol-forming agents. The formulation may comprise one or more polymers. The one or more polymers may be selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch. The formulation may have a melting point between 60 degrees celsius and 300 degrees celsius.

There is provided a formulation for an aerosol-generating system, the formulation comprising: one or more aerosol forming agents; and one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch; wherein the formulation has a melting point between 60 degrees Celsius and 300 degrees Celsius.

There is also provided an aerosol-generating article for use in an aerosol-generating system, the aerosol-generating article containing a formulation comprising: one or more aerosol forming agents; and one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch; wherein the formulation has a melting point between 60 degrees Celsius and 300 degrees Celsius.

There is also provided an aerosol-generating device comprising: a formulation, the formulation comprising: one or more aerosol forming agents; and one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch; wherein the formulation has a melting point between 60 degrees Celsius and 300 degrees Celsius.

There is also provided an aerosol-generating system comprising: a formulation, the formulation comprising: one or more aerosol forming agents; and one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch; wherein the formulation has a melting point between 60 degrees Celsius and 300 degrees Celsius.

As used herein, the term "aerosol-forming substrate" relates to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate or by other means of atomization. The aerosol-forming substrate may be a liquid. The liquid may be, for example, an electronic liquid. The liquid may be a solution. The liquid may be a gel. Colloids can have discrete solid particles dispersed in a continuous liquid. The colloid may have discrete liquid particles dispersed in a continuous liquid. Colloids can have discrete liquid particles dispersed in a continuous solid.

Unless otherwise indicated, the weight percentages of the formulation components described herein are based on the total weight of the formulation.

Given that the melting point of the formulation is between 60 degrees celsius and 300 degrees celsius, the formulation is not a liquid at standard temperature and pressure. At standard temperature and pressure, the formulation may be, for example, a solid or a colloid having a solid continuous phase and a liquid dispersed phase. Thus, at standard temperature and pressure, when the formulation is stored in a reservoir of an aerosol-generating article, aerosol-generating device, or aerosol-generating system, the formulation may not flow readily until the formulation is heated.

Advantageously, due to the melting point of the formulation, the formulation does not readily leak out of the aerosol-generating article, aerosol-generating device or aerosol-generating system before being heated during use of the aerosol-generating article, aerosol-generating device or aerosol-generating system. Thus, the melting point of the formulation may reduce the risk of leakage during transport or storage of, for example, an aerosol-generating article, an aerosol-generating device or an aerosol-generating system containing the formulation. Thus, the formulation may increase the shelf life of the aerosol-generating article, aerosol-generating device or aerosol-generating system.

At least a portion of the formulation may transition or may begin to transition to the liquid phase when the formulation is heated to between 60 degrees celsius and 300 degrees celsius. When the formulation is a liquid, it can flow readily and be evaporated into an aerosol by the heater of the aerosol-generating article, aerosol-generating device or aerosol-generating system.

After use of the aerosol-generating article, aerosol-generating device or aerosol-generating system, the formulation may transform back to a solid or a colloid with a solid continuous phase when the formulation cools to below 60 degrees celsius. Advantageously, this phase change restores the formulation to a state in which it does not readily flow, which means that the risk of the formulation leaking or escaping the aerosol-generating article, aerosol-generating device or aerosol-generating system between heating cycles is reduced.

The formulation may be a solid at standard temperature and pressure.

The formulation may be a gel at standard temperature and pressure. The colloid may have a solid continuous phase at standard temperature and pressure. The colloid may have a liquid dispersed phase at standard temperature and pressure. In one example, the colloid may have a solid continuous phase and a liquid dispersed phase at standard temperature and pressure.

The formulation can have an aerosol former content of greater than or equal to about 10% by weight. The formulation can have an aerosol former content of greater than or equal to about 15% by weight. The formulation can have an aerosol former content of greater than or equal to about 20% by weight. The formulation can have an aerosol former content of greater than or equal to about 25% by weight. The formulation can have an aerosol former content of greater than or equal to about 30% by weight. The formulation can have an aerosol former content of greater than or equal to about 35% by weight. The formulation can have an aerosol former content of greater than or equal to about 40% by weight. The formulation can have an aerosol former content of greater than or equal to about 45% by weight. The formulation can have an aerosol former content of greater than or equal to about 50% by weight. The formulation can have an aerosol former content of greater than or equal to about 55 wt%. The formulation can have an aerosol former content of greater than or equal to about 60% by weight. The formulation can have an aerosol former content of greater than or equal to about 65 wt%. The formulation can have an aerosol former content of greater than or equal to about 70% by weight. The formulation can have an aerosol former content of greater than or equal to about 75% by weight. The formulation can have an aerosol former content of greater than or equal to about 80% by weight.

The formulation may have an aerosol former content of less than or equal to about 90% by weight. The formulation may have an aerosol former content of less than or equal to about 85% by weight. The formulation can have an aerosol former content of less than or equal to about 80% by weight. The formulation may have an aerosol former content of less than or equal to about 75% by weight. The formulation can have an aerosol former content of less than or equal to about 70% by weight. The formulation may have an aerosol former content of less than or equal to about 65 wt%. The formulation may have an aerosol former content of less than or equal to about 60% by weight. The formulation can have an aerosol former content of less than or equal to about 55 wt%. The formulation can have an aerosol former content of less than or equal to about 50% by weight. The formulation may have an aerosol former content of less than or equal to about 45% by weight. The formulation may have an aerosol former content of less than or equal to about 40% by weight. The formulation may have an aerosol former content of less than or equal to about 35% by weight. The formulation can have an aerosol former content of less than or equal to about 30% by weight. The formulation can have an aerosol former content of less than or equal to about 25% by weight.

Preferably, the formulation may have an aerosol former content of between about 20% and about 85% by weight.

The formulation may have an aerosol former content of between about 20% and about 80% by weight. The formulation may have an aerosol former content of between about 20% and about 75% by weight. The formulation may have an aerosol former content of between about 20% and about 70% by weight. The formulation may have an aerosol former content of between about 20% and about 65% by weight. The formulation may have an aerosol former content of between about 20% and about 60% by weight. The formulation may have an aerosol former content of between about 20% and about 55% by weight. The formulation may have an aerosol former content of between about 20% and about 50% by weight. The formulation may have an aerosol former content of between about 20% and about 45% by weight. The formulation may have an aerosol former content of between about 20% and about 40% by weight. The formulation may have an aerosol former content of between about 20% and about 35% by weight. For example, the formulation may have an aerosol former content of between about 20% and about 25% by weight.

The formulation may have an aerosol former content of between about 25% and about 85% by weight. The formulation may have an aerosol former content of between about 30% and about 85% by weight. The formulation may have an aerosol former content of between about 35% and about 85% by weight. The formulation may have an aerosol former content of between about 40% and about 85% by weight. The formulation may have an aerosol former content of between about 45 wt% and about 85 wt%. The formulation may have an aerosol former content of between about 50 wt% and about 85 wt%. The formulation may have an aerosol former content of between about 55% and about 85% by weight. The formulation may have an aerosol former content of between about 60% and about 85% by weight. The formulation may have an aerosol former content of between about 20% and about 65% by weight. The formulation may have an aerosol former content of between about 70% and about 85% by weight. The formulation may have an aerosol former content of between about 75% and about 85% by weight. For example, the formulation may have an aerosol former content of between about 80% and about 85% by weight.

The formulation may have an aerosol former content of between about 25% and about 80% by weight. The formulation may have an aerosol former content of between about 25% and about 75% by weight. The formulation may have an aerosol former content of between about 30% and about 70% by weight. The formulation may have an aerosol former content of between about 30% and about 65% by weight. The formulation may have an aerosol former content of between about 35% and about 60% by weight.

Preferably, the formulation may have an aerosol former content of between about 35% and about 55% by weight. The formulation may have an aerosol former content of between about 40% and about 55% by weight. The formulation may have an aerosol former content of between about 40% and about 50% by weight. The formulation may have an aerosol former content of between about 45% and about 50% by weight.

The formulation may comprise one or more aerosol-formers selected from the group consisting of: 1, 3-butylene glycol, glycerol, propylene glycol, triethylene glycol and sorbitol. The glycerol may comprise vegetable glycerol.

In some preferred embodiments, the one or more aerosol-forming agents comprise a major amount of glycerin. It has been found that glycerol-based formulations can provide better, harder solid materials. It has also been found that the inclusion of a small amount of propylene glycol in a glycerin-based formulation can provide a less rigid or less brittle solid than a glycerin-based composition that does not contain propylene glycol.

The use of sorbitol as at least one of the aerosol-forming agents is advantageous because sorbitol is less hygroscopic than other aerosol-forming agents, which can result in the formulation absorbing less water from the environment and being more stable in humid conditions.

Advantageously, the inclusion of propylene glycol in the formulation results in a solid or colloidal formulation that is less rigid, less brittle, and more prone to plug formation. These characteristics improve subsequent processing and handling of the formulation during manufacture.

Advantageously, both glycerol and sorbitol can be less volatile than propylene glycol, which can evaporate under warm conditions.

The one or more aerosol-formers may comprise a combination of glycerin and propylene glycol. The one or more aerosol-former may comprise a combination of vegetable glycerin and propylene glycol.

As discussed below, the inclusion of propylene glycol in the formulation may improve evaporation of the formulation, which may result in more aerosol being produced for a given heating cycle.

By including propylene glycol in a nicotine-containing glycerol-based formulation, the nicotine content of the aerosol may also be improved due to more efficient evaporation of nicotine due to the lower boiling point (188 ℃) of propylene glycol compared to glycerol (290 ℃). However, if there is a large amount of propylene glycol in the formulation, the nicotine content of the aerosol will be reduced because the propylene glycol can evaporate during the heating cycle. Thus, it may be advantageous to have a limited amount of propylene glycol in the nicotine formulation.

The ratio of the weight percent glycerin content to the weight percent propylene glycol content of the formulation can be greater than or equal to about 1. The ratio of the weight percent glycerin content to the weight percent propylene glycol content of the formulation can be greater than or equal to about 1.5. The ratio of the weight percent glycerin content to the weight percent propylene glycol content of the formulation can be greater than or equal to about 2. The ratio of the weight percent glycerin content to the weight percent propylene glycol content of the formulation can be greater than or equal to about 2.5. The ratio of the weight percent glycerin content to the weight percent propylene glycol content of the formulation can be greater than or equal to about 3.

It has been found that such compositions can provide a balance of hardness and rigidity or brittleness to provide an optimal seal in addition to the advantageous evaporation properties discussed herein.

The one or more aerosol-formers may comprise one or more polyols. The one or more polyols may include one or more water-miscible polyols. As used herein, the term "water-miscible polyol" describes a polyol that is a liquid at 20 ℃ and is mixed with water in any proportion to form a homogeneous solution.

The polyethylene may be a low density polyethylene.

Preferably, the one or more polymers are selected from the group consisting of: polyvinyl alcohol, polyethylene glycol, polypropylene glycol and starch.

More preferably, the one or more polymers are selected from the group consisting of: polyvinyl alcohol, polyethylene glycol and polypropylene glycol.

Even more preferably, the one or more polymers are selected from the group consisting of: polyvinyl alcohol and polyethylene glycol.

Most preferably, the one or more polymers consist of polyvinyl alcohol.

All starches are composed of amylose and amylopectin in different ratios. The selection of a particular starch for use in the formulation may be based on the ratio of amylose to amylopectin, depending on the desired functionality of the starch. The starch may be corn starch or wheat starch. Preferably, the starch is wheat starch.

Advantageously, the use of polyvinyl alcohol in formulations comprising nicotine provides more consistent nicotine delivery to the user compared to wheat starch and corn starch.

Advantageously, the use of wheat starch in a nicotine-containing formulation provides more consistent nicotine delivery to the user than corn starch.

The formulation can have a polymer content of greater than or equal to about 0.1 wt%. The formulation can have a polymer content of greater than or equal to about 0.5 wt%. The formulation can have a polymer content greater than or equal to about 1 wt%. The formulation can have a polymer content of greater than or equal to about 2 wt%. The formulation can have a polymer content of greater than or equal to about 3 wt%. The formulation can have a polymer content of greater than or equal to about 4 wt%. The formulation can have a polymer content of greater than or equal to about 5 wt%. The formulation can have a polymer content of greater than or equal to about 6 wt%. The formulation can have a polymer content of greater than or equal to about 7 wt%.

The formulation can have a polymer content of less than or equal to about 10 wt%. The formulation can have a polymer content of less than or equal to about 7 wt%. The formulation can have a polymer content of less than or equal to about 6 wt%. The formulation can have a polymer content of less than or equal to about 5 wt%. The formulation can have a polymer content of less than or equal to about 4 wt%. The formulation can have a polymer content of less than or equal to about 3 wt%. The formulation can have a polymer content of less than or equal to about 2 wt%. The formulation can have a polymer content of less than or equal to about 1 wt%.

The formulation may have a polymer content between about 0.5 wt% and about 7 wt%. The formulation may have a polymer content between about 0.5 wt% and about 6 wt%. The formulation may have a polymer content between about 0.5% and about 5% by weight. The formulation may have a polymer content between about 0.5 wt% and about 4 wt%. The formulation may have a polymer content between about 0.5% and about 3% by weight. The formulation may have a polymer content between about 0.5 wt% and about 2 wt%. The formulation may have a polymer content between about 0.5 wt% and about 1 wt%.

The formulation may have a polymer content between about 0.1 wt% and about 7 wt%. The formulation may have a polymer content between about 1% and about 7% by weight. The formulation may have a polymer content between about 2 wt% and about 7 wt%. The formulation may have a polymer content between about 3 wt% and about 7 wt%. The formulation may have a polymer content between about 4 wt% and about 7 wt%. The formulation may have a polymer content between about 5 wt% and about 7 wt%. The formulation may have a polymer content between about 6 wt% and about 7 wt%.

The one or more polymers can have a weight average molecular weight (M) greater than or equal to 6000g/mol _w ). The one or more polymers can have a weight average molecular weight greater than or equal to 60000 g/mol. The one or more polymers may have a weight average molecular weight greater than or equal to 100000 g/mol. The one or more polymers can have a weight average molecular weight greater than or equal to 140000 g/mol. The one or more polymers may have a weight average molecular weight greater than or equal to 200000 g/mol.

The one or more polymers can have a weight average molecular weight less than or equal to 8000000 g/mol. The one or more polymers can have a weight average molecular weight of less than or equal to 5000000 g/mol. The one or more polymers may have a weight average molecular weight of less than or equal to 2000000 g/mol. The one or more polymers may have a weight average molecular weight of less than or equal to 1000000 g/mol. The one or more polymers can have a weight average molecular weight of less than or equal to 500000 g/mol. The one or more polymers may have a weight average molecular weight of less than or equal to 200000 g/mol. The one or more polymers can have a weight average molecular weight of less than or equal to 190000 g/mol.

The one or more polymers may have a weight average molecular weight between 6000g/mol to 8000000 g/mol. The one or more polymers may have a weight average molecular weight between 60000g/mol and 500000 g/mol. The one or more polymers may have a weight average molecular weight between 100000g/mol and 200000 g/mol. The one or more polymers may have a weight average molecular weight of between 140000g/mol and 190000 g/mol.

The formulation may have a melting point greater than or equal to 60 degrees celsius. The formulation can have a melting point greater than or equal to 80 degrees celsius. The formulation can have a melting point greater than or equal to 100 degrees celsius. The formulation may have a melting point greater than or equal to 120 degrees celsius. The formulation can have a melting point greater than or equal to 140 degrees celsius. The formulation may have a melting point greater than or equal to 160 degrees celsius. The formulation may have a melting point greater than or equal to 180 degrees celsius. The formulation can have a melting point greater than or equal to 200 degrees celsius. The formulation can have a melting point greater than or equal to 220 degrees celsius. The formulation may have a melting point greater than or equal to 240 degrees celsius. The formulation can have a melting point greater than or equal to 260 degrees celsius. The formulation can have a melting point greater than or equal to 270 degrees celsius. The formulation can have a melting point greater than or equal to 280 degrees celsius. The formulation may have a melting point greater than or equal to 300 degrees celsius.

The formulation may have a melting point of less than or equal to 300 degrees celsius. The formulation may have a melting point of less than or equal to 280 degrees celsius. The formulation may have a melting point of less than or equal to 270 degrees celsius. The formulation may have a melting point less than or equal to 260 degrees celsius. The formulation can have a melting point of less than or equal to 240 degrees celsius. The formulation may have a melting point of less than or equal to 220 degrees celsius. The formulation may have a melting point less than or equal to 200 degrees celsius. The formulation may have a melting point less than or equal to 180 degrees celsius. The formulation may have a melting point less than or equal to 160 degrees celsius. The formulation may have a melting point of less than or equal to 140 degrees celsius. The formulation may have a melting point of less than or equal to 120 degrees celsius. The formulation may have a melting point less than or equal to 100 degrees celsius. The formulation may have a melting point of less than or equal to 80 degrees celsius. The formulation may have a melting point of less than or equal to 60 degrees celsius.

The formulation may have a melting point between 60 degrees celsius and 280 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 260 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 240 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 220 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 200 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 180 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 160 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 140 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 120 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 100 degrees celsius. The formulation may have a melting point between 60 degrees celsius and 80 degrees celsius.

The formulation may have a melting point between 80 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 100 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 120 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 140 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 160 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 200 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 220 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 240 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 260 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 270 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 280 degrees celsius and 300 degrees celsius.

The formulation may have a melting point between 180 degrees celsius and 300 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 280 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 260 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 240 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 220 degrees celsius. The formulation may have a melting point between 180 degrees celsius and 200 degrees celsius.

The formulation may have a melting point between 80 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 100 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 120 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 140 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 160 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 200 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 220 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 240 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 260 degrees celsius and 270 degrees celsius.

The formulation may have a melting point between 190 degrees celsius and 270 degrees celsius. The formulation may have a melting point between 190 degrees celsius and 260 degrees celsius. The formulation may have a melting point between 200 degrees celsius and 260 degrees celsius. The formulation may have a melting point between 200 degrees celsius and 250 degrees celsius. The formulation may have a melting point between 210 degrees celsius and 250 degrees celsius. The formulation may have a melting point between 210 degrees celsius and 240 degrees celsius. The formulation may have a melting point between 220 degrees celsius and 240 degrees celsius. The formulation may have a melting point between 220 degrees celsius and 230 degrees celsius.

The formulation may have a boiling point greater than or equal to 180 degrees celsius. The formulation can have a boiling point greater than or equal to 200 degrees celsius. The formulation can have a boiling point greater than or equal to 220 degrees celsius. The formulation may have a boiling point greater than or equal to 240 degrees celsius. The formulation can have a boiling point greater than or equal to 260 degrees celsius. The formulation can have a boiling point greater than or equal to 270 degrees celsius. The formulation can have a boiling point greater than or equal to 280 degrees celsius. The formulation may have a boiling point greater than or equal to 300 degrees celsius.

The formulation can have a boiling point less than or equal to 300 degrees celsius. The formulation can have a boiling point less than or equal to 280 degrees celsius. The formulation may have a boiling point less than or equal to 270 degrees celsius. The formulation can have a boiling point less than or equal to 260 degrees celsius. The formulation can have a boiling point less than or equal to 240 degrees celsius. The formulation may have a boiling point of less than or equal to 220 degrees celsius. The formulation can have a boiling point less than or equal to 200 degrees celsius. The formulation can have a boiling point less than or equal to 180 degrees celsius.

The formulation may have a boiling point between 180 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 200 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 220 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 240 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 260 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 270 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 280 degrees celsius and 300 degrees celsius.

The formulation may have a boiling point between 180 degrees celsius and 300 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 280 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 270 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 260 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 240 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 220 degrees celsius. The formulation may have a boiling point between 180 degrees celsius and 200 degrees celsius.

The formulation may have a boiling point between 180 degrees celsius and 270 degrees celsius. The formulation may have a boiling point between 200 degrees celsius and 270 degrees celsius. The formulation may have a boiling point between 220 degrees celsius and 270 degrees celsius. The formulation may have a boiling point between 240 degrees celsius and 270 degrees celsius. The formulation may have a boiling point between 260 degrees celsius and 270 degrees celsius.

The formulation may be heat treated after formation.

The formulation may be heat treated at a temperature of greater than or equal to about 50 degrees celsius. The formulation may be heat treated at a temperature of greater than or equal to about 75 degrees celsius. The formulation may be heat treated at a temperature of greater than or equal to about 100 degrees celsius. The formulation may be heat treated at a temperature of greater than or equal to about 125 degrees celsius. The formulation may be heat treated at a temperature of greater than or equal to about 150 degrees celsius.

The formulation may be heat treated at a temperature of less than or equal to about 200 degrees celsius. The formulation may be heat treated at a temperature of less than or equal to about 175 degrees celsius. The formulation may be heat treated at a temperature of less than or equal to about 150 degrees celsius. The formulation may be heat treated at a temperature of less than or equal to about 125 degrees celsius. The formulation may be heat treated at a temperature of less than or equal to about 100 degrees celsius.

The formulation may be heat treated at a temperature between about 75 degrees celsius and 200 degrees celsius. The formulation may be heat treated at a temperature between about 75 degrees celsius and 175 degrees celsius. The formulation may be heat treated at a temperature between about 75 degrees celsius and 150 degrees celsius. The formulation may be heat treated at a temperature between about 75 degrees celsius and 125 degrees celsius. The formulation may be heat treated at a temperature between about 75 degrees celsius and 100 degrees celsius.

The formulation may be heat treated at a temperature between about 50 degrees celsius and 175 degrees celsius. The formulation may be heat treated at a temperature between about 100 degrees celsius and 175 degrees celsius. The formulation may be heat treated at a temperature between about 125 degrees celsius and 175 degrees celsius. The formulation may be heat treated at a temperature between about 150 degrees celsius and 175 degrees celsius.

The formulation may be heat treated in an oven. The formulation may be heat treated in a vented oven.

Advantageously, heat treatment after the formulation has been formed can reduce swelling of the formulation. Thermal treatment of the formulation may improve the cross-linking between the one or more polymers and the one or more aerosol-forming agents.

The formulation may comprise one or more organic acids. In some embodiments, the one or more organic acids may be water soluble organic acids. As used herein with reference to the present invention, the term "water-soluble organic acid" describes an organic acid having a water solubility at 20 ℃ of greater than or equal to about 100mg/ml, preferably greater than or equal to about 500mg/ml, more preferably greater than or equal to about 750mg/ml, most preferably greater than or equal to about 1000 mg/ml.

Unless otherwise indicated, the water solubility values described herein are water solubilities measured based on the following preliminary tests: OECD (1995), Test No.105: Water Solubility, OECD Guidelines for the Testing of Chemicals, section 1, OECD Publishing, Paris, https:// doi.org/10.1787/9789264069589-en. In a stepwise procedure, increasing volumes of distilled water were added to 0.1g of sample (solid matter must be crushed) in a 10ml glass plug cylinder at 20 ℃. However, when the substance is an acid, the sample is added to distilled water in a first step. After each addition of a certain amount of water, the mixture was shaken for 10 minutes and visually inspected for undissolved parts in the sample. If the sample or part thereof has not dissolved after the addition of 10ml of water, the experiment is continued in a 100ml graduated cylinder. Table 1 below gives the approximate solubility in the volume of water in which the sample was completely dissolved.

When the solubility is low, it may take a long time to dissolve the substance, at least 24 hours should be allowed. If after 24 hours the material has not dissolved, the cylinder is placed in the ultrasonic bath at 40 ℃ for 15 minutes and allowed to stand for a further 24 hours (up to 96 hours). If the substance is not yet dissolved, the solubility is considered to be below the limit or insoluble.

TABLE 1

Advantageously, when the formulation comprises nicotine, the inclusion of an organic acid in the formulation may improve delivery of nicotine to the user.

Advantageously, the inclusion of an organic acid in the formulation may provide a plasticizing effect within the formulation, which may improve the mechanical properties of the formulation.

The formulation can have an organic acid content of greater than or equal to about 0.1 wt%. The formulation can have an organic acid content of greater than or equal to about 0.5 wt%. The formulation can have an organic acid content greater than or equal to about 1% by weight. The formulation can have an organic acid content greater than or equal to about 1.5 wt%. The formulation can have an organic acid content of greater than or equal to about 2 wt%. The formulation can have an organic acid content of greater than or equal to about 2.5 wt%. The formulation can have an organic acid content of greater than or equal to about 3 wt%. The formulation can have an organic acid content of greater than or equal to about 3.5 wt%. The formulation can have an organic acid content of greater than or equal to about 4 wt%. The formulation can have an organic acid content of greater than or equal to about 4.5 wt%. The formulation can have an organic acid content of greater than or equal to about 5 wt%.

The formulation can have an organic acid content of less than or equal to about 10 wt%. The formulation can have an organic acid content of less than or equal to about 5 wt%. The formulation can have an organic acid content of less than or equal to about 4.5 wt%. The formulation can have an organic acid content of less than or equal to about 4 wt%. The formulation can have an organic acid content of less than or equal to about 3.5 wt%. The formulation can have an organic acid content of less than or equal to about 3 wt%. The formulation can have an organic acid content of less than or equal to about 2.5 wt%. The formulation can have an organic acid content of less than or equal to about 2 wt%. The formulation can have an organic acid content of less than or equal to about 1.5 wt%. The formulation can have an organic acid content of less than or equal to about 1 wt%. The formulation can have an organic acid content of less than or equal to about 0.5 wt%.

The formulation may have an organic acid content of between about 0.1 wt% and about 5 wt%. The formulation may have an organic acid content between about 0.5 wt% and about 5 wt%. The formulation may have an organic acid content of between about 1% and about 5% by weight. The formulation may have an organic acid content of between about 1.5 wt% and about 5 wt%. The formulation may have an organic acid content of between about 2 wt% and about 5 wt%. The formulation may have an organic acid content of between about 2.5 wt% and about 5 wt%. The formulation may have an organic acid content of between about 3% and about 5% by weight. The formulation may have an organic acid content of between about 3.5 wt% and about 5 wt%. The formulation may have an organic acid content of between about 4% and about 5% by weight. The formulation may have an organic acid content of between about 4.5 wt% and about 5 wt%.

The formulation may have an organic acid content of between about 0.1 wt% and about 8 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 5 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 4.5 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 4 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 3.5 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 3 wt%. The formulation may have an organic acid content of between about 0.1 wt% and about 2.5 wt%. The formulation may have an organic acid content of between about 0.1% and about 2% by weight. The formulation may have an organic acid content between about 0.1 wt% and about 1.5 wt%. The formulation may have an organic acid content between about 0.1 wt% and about 1 wt%. The formulation may have an organic acid content between about 0.1 wt% and about 0.5 wt%.

The formulation may have an organic acid content of between about 0.5 wt% and about 4.5 wt%. The formulation may have an organic acid content of between about 1 wt% and about 4.5 wt%. The formulation may have an organic acid content of between about 1.5 wt% and about 4.5 wt%. The formulation may have an organic acid content of between about 1.5 wt% and about 4 wt%. The formulation may have an organic acid content of between about 2% and about 4% by weight. The formulation may have an organic acid content of between about 2 wt% and about 3.5 wt%. The formulation may have an organic acid content of between about 2.5 wt% and about 3.5 wt%. The formulation may have an organic acid content of between about 2.5 wt% and about 3 wt%.

The one or more organic acids may include one or more polycarboxylic acids, one or more monocarboxylic acids, or a combination of monocarboxylic acids and polycarboxylic acids.

The one or more organic acids may be selected from the group consisting of: malonic acid, citric acid, 2-ethylbutyric acid, acetic acid, adipic acid, benzoic acid, butyric acid, cinnamic acid, cycloheptane-carboxylic acid, fumaric acid, glycolic acid, caproic acid, lactic acid, levulinic acid, malic acid, myristic acid, caprylic acid, oxalic acid, propionic acid, pyruvic acid, succinic acid, and undecanoic acid.

In some embodiments, the one or more organic acids are selected from the group consisting of: malonic acid, citric acid, lactic acid, benzoic acid, levulinic acid, fumaric acid and acetic acid.

In some embodiments, the one or more organic acids are selected from the group consisting of: malonic acid, citric acid, lactic acid, fumaric acid and acetic acid

Most preferably, the one or more organic acids consist of lactic acid.

The formulation may comprise one or more metal salts.

The bonding between the one or more metal salts and the one or more aerosol-formers in the formulation may increase the boiling point of the one or more aerosol-formers. When the formulation comprises nicotine, this may advantageously enhance the efficiency of evaporation of nicotine from the formulation when used in an aerosol-generating system compared to a typical liquid nicotine formulation which does not comprise one or more metal salts.

The one or more metal salts may be selected from the group consisting of: metal alginates, metal benzoates, metal cinnamates, metal cycloheptane carboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

Preferably, the one or more metal salts are selected from the group consisting of: metal cinnamates, metal cycloheptane carboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

Preferably, the one or more metal salts are selected from the group consisting of: metal benzoates, metal cinnamates, metal cycloheptane carboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates.

Preferably, the one or more metal salts are selected from the group consisting of: metal cinnamates, metal cycloheptane carboxylates, metal stearates, and metal undecanoates.

The one or more salts may be salts of any suitable metal.

Preferably, the one or more metal salts are alkali metal salts.

More preferably, the one or more metal salts are sodium salts.

Preferably, the evaporable barrier comprises one or more non-saccharide sodium salts.

Metal salts having a high molecular weight may improve the above-mentioned advantages relating to nicotine evaporation efficiency and solid layer formation rate. However, if the molecular weight of the metal salt is too high, properties such as solubility begin to be negatively affected. Advantageously, the inclusion of sodium stearate in the formulation may provide an optimum balance in terms of increasing the evaporation efficiency and rate of solid layer formation of nicotine while maintaining solubility.

More preferably, the formulation comprises one or more sodium salts selected from the group consisting of: sodium benzoate, sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propionate, sodium stearate, and sodium undecanoate.

Preferably, the one or more metal salts are selected from the group consisting of: sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propionate, sodium stearate, and sodium undecanoate.

Preferably, the one or more sodium salts are selected from the group consisting of: sodium benzoate, sodium cinnamate, sodium cycloheptanecarboxylate, sodium levulinate, sodium propionate, sodium stearate, and sodium undecanoate.

Preferably, the one or more metal salts are selected from the group consisting of: sodium cinnamate, sodium cycloheptanecarboxylate, sodium stearate, and sodium undecanoate.

Most preferably, the formulation comprises sodium stearate.

Advantageously, the inclusion of one or more metal stearates in the formulation improves the mechanical properties of the formulation.

Advantageously, the covalent bonding between the one or more metal stearates and the one or more aerosol-forming agents in the formulation can further increase the boiling point of the one or more aerosol-forming agents. When the formulation comprises nicotine, this may advantageously enhance the efficiency of evaporation of nicotine from the formulation when used in an aerosol-generating system compared to a typical liquid nicotine formulation that does not comprise one or more metal stearates.

The formulation can have a metal salt content of greater than or equal to about 0.1 wt%. The formulation may have a metal salt content of greater than or equal to about 0.25 wt%. The formulation may have a metal salt content of greater than or equal to about 0.5 wt%. The formulation may have a metal salt content of greater than or equal to about 0.75 wt%. The formulation can have a metal salt content greater than or equal to about 1% by weight. The formulation may have a metal salt content of greater than or equal to about 1.25 wt%. The formulation can have a metal salt content greater than or equal to about 1.5 wt%. The formulation may have a metal salt content of greater than or equal to about 1.75 wt%.

The formulation may have a metal salt content of less than or equal to about 5 wt%. For example, the formulation may have a metal salt content of less than or equal to about 3 wt%. The formulation may have a metal salt content of less than or equal to about 2 wt%. The formulation can have a metal salt content of less than or equal to about 1.75 wt%. The formulation can have a metal salt content of less than or equal to about 1.5 wt%. The formulation can have a metal salt content of less than or equal to about 1.25 wt%. The formulation can have a metal salt content of less than or equal to about 1% by weight. The formulation may have a metal salt content of less than or equal to about 0.75 wt%. The formulation may have a metal salt content of less than or equal to about 0.5 wt%.

The formulation may have a metal salt content of between about 0.1 wt% and about 5 wt%. The formulation may have a metal salt content of between about 0.1 wt% and about 3 wt%. The formulation may have a metal salt content of between about 0.1 wt% and about 2 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 1.75 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 1.5 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 1.25 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 1 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 0.75 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 0.5 wt%. The formulation may have a metal salt content between about 0.1 wt% and about 0.25 wt%.

The formulation may have a metal salt content of between about 0.25 wt% and about 2 wt%. The formulation may have a metal salt content of between about 0.5 wt% and about 2 wt%. The formulation may have a metal salt content of between about 0.75 wt% and about 2 wt%. The formulation may have a metal salt content of between about 1% and about 2% by weight. The formulation may have a metal salt content of between about 1.25 wt% and about 2 wt%. The formulation may have a metal salt content of between about 1.5 wt% and about 2 wt%. The formulation may have a metal salt content of between about 1.75 wt% and about 5 wt%.

The formulation may comprise nicotine. The formulation may comprise liquid nicotine.

The nicotine may be nicotine base. The nicotine may be a nicotine salt. The formulation may comprise natural nicotine. The formulation may comprise synthetic nicotine.

The nicotine salt may be formed using one or more organic acids. The nicotine salt may comprise one or more organic acids.

The nicotine may be provided as a tobacco extract, which may include other tobacco components, such as tobacco flavor components.

The formulation can have a nicotine content of greater than or equal to about 0.5 wt%. The formulation can have a nicotine content greater than or equal to about 1% by weight. The formulation can have a nicotine content greater than or equal to about 1.5 wt%. The formulation can have a nicotine content of greater than or equal to about 2% by weight. The formulation can have a nicotine content of greater than or equal to about 3% by weight. The formulation can have a nicotine content of greater than or equal to about 5% by weight.

The formulation can have a nicotine content of less than or equal to about 10% by weight. The formulation can have a nicotine content of less than or equal to about 8% by weight. The formulation can have a nicotine content of less than or equal to about 5% by weight. The formulation can have a nicotine content of less than or equal to about 3% by weight. The formulation can have a nicotine content of less than or equal to about 2% by weight. The formulation can have a nicotine content of less than or equal to about 1% by weight.

The formulation may have a nicotine content of between about 0.5% and about 10% by weight. The formulation may have a nicotine content of between about 0.5% and about 8% by weight. The formulation may have a nicotine content of between about 0.5% and about 5% by weight. The formulation may have a nicotine content of between about 0.5% and about 3% by weight. The formulation may have a nicotine content of between about 0.5% and about 2% by weight. The formulation may have a nicotine content of between about 0.5% and about 1% by weight.

The formulation can have a nicotine content of between about 1% and about 5% by weight. The formulation may have a nicotine content of between about 2% and about 5% by weight. The formulation may have a nicotine content of between about 3% and about 5% by weight. The formulation may have a nicotine content of between about 4% and about 5% by weight.

The formulation can have a nicotine content between about 1% and about 2% by weight. The formulation may have a nicotine content of between about 2% and about 3% by weight. The formulation may have a nicotine content of between about 3% and about 5% by weight. The formulation may have a nicotine content of between about 2% and about 4% by weight. The formulation may have a nicotine content of between about 1% and about 4% by weight.

The formulation may comprise water.

The formulation may have a water content of greater than or equal to about 10 wt%. The formulation can have a water content of greater than or equal to about 20 wt%. The formulation can have a water content greater than or equal to about 30 wt%. The formulation can have a water content of greater than or equal to about 40 wt%. The formulation can have a water content greater than or equal to about 50 wt%. The formulation may have a water content of greater than or equal to about 60% by weight.

The formulation may have a water content of less than or equal to about 70% by weight. The formulation may have a water content of less than or equal to about 60% by weight. The formulation may have a water content of less than or equal to about 50% by weight. The formulation may have a water content of less than or equal to about 40 wt%. The formulation can have a water content of less than or equal to about 30 wt%. The formulation may have a water content of less than or equal to about 20 wt%.

The formulation may have a water content between about 20% and about 70% by weight. The formulation may have a water content of between about 20% and about 60% by weight. The formulation may have a water content between about 20% and about 50% by weight. The formulation may have a water content between about 20% and about 40% by weight. The formulation may have a water content of between about 20% and about 30% by weight.

The formulation may have a water content between about 30% and about 60% by weight. The formulation may have a water content between about 40% and about 60% by weight. The formulation may have a water content of between about 50 wt% and about 50 wt%.

The formulation may have a water content between about 10% and about 70% by weight. The formulation may have a water content of between about 30% and about 50% by weight.

The aerosol-generating system may comprise an aerosol-generating article.

The aerosol-generating article may comprise a nebulizer configured to generate an aerosol from the formulation.

The aerosol-generating article may comprise a cartridge.

The cartridge containing the formulation and the atomizer may be referred to as a "cartomiser".

The atomiser may be a thermal atomiser.

As used herein, the term "thermal atomizer" describes an atomizer configured to heat a formulation to generate an aerosol.

The aerosol-generating article may comprise any suitable type of thermal atomiser. For example, the thermal atomizer may comprise a heater. The thermal atomizer may comprise an electric heater. In one example, the thermal atomizer may comprise an electric heater comprising a resistive heating element. In another example, the thermal atomizer may comprise an electric heater comprising an induction heating element.

The heater may comprise a heating element. The heating element may be a grid element. The heating element may be a mesh layer. The heating element may be a mesh element. The heating element may be a mesh layer. In these embodiments, the formulation may flow into interstitial spaces that form a mesh or network.

The atomizer may be a non-thermal atomizer.

As used herein, the term "non-thermal atomizer" describes an atomizer configured to generate an aerosol from an article by means other than heating.

The aerosol-generating article may comprise any suitable type of non-thermal atomiser. For example, the non-thermal atomizer may be an impinging jet atomizer. In another example, the non-thermal atomizer may be an ultrasonic atomizer. In another example, the non-thermal atomizer may be a vibrating mesh atomizer.

The aerosol-generating article may comprise a porous material for containing the formulation. The porous material may be crimped.

The aerosol-generating system may comprise an aerosol-generating device.

The aerosol-generating device may comprise a reservoir for containing the formulation.

The aerosol-generating device may comprise a housing defining a device cavity configured to receive at least a portion of an aerosol-generating article.

The aerosol-generating device may comprise a nebulizer configured to generate an aerosol from the formulation.

The atomiser may be a thermal atomiser.

The aerosol-generating device may comprise any suitable type of thermal atomiser. For example, the thermal atomizer may comprise a heater. The thermal atomizer may comprise an electric heater. In one example, the thermal atomizer may comprise an electric heater comprising a resistive heating element. In another example, the thermal atomizer may comprise an electric heater comprising an induction heating element.

The heater may comprise a heating element. The heating element may be a grid element. The heating element may be a mesh layer. The heating element may be a mesh element. The heating element may be a mesh layer. In these embodiments, the formulation may flow into interstitial spaces that form a grid or mesh.

The aerosol-generating device may comprise a porous material for containing the formulation. The porous material may be crimped.

According to the present invention there is also provided an aerosol-generating system comprising a formulation according to the present invention and a nebuliser configured to generate an aerosol from the formulation.

The atomiser may be a thermal atomiser.

The aerosol-generating system may comprise any suitable type of thermal atomiser.

The thermal atomizer may comprise an electric heater. For example, the thermal atomizer may comprise an electric heater comprising a heating element, which may comprise a resistive heating element or an inductive heating element.

The heating element may be a mesh or mesh element or layer. In these embodiments, the formulation may flow into the interstitial spaces forming the mesh or net-like elements.

An aerosol-generating system may comprise an aerosol-generating article comprising a formulation according to the invention and an aerosol-generating device comprising a housing defining a device cavity configured to receive at least a portion of the aerosol-generating article.

An aerosol-generating system may comprise a consumable aerosol-generating article comprising a formulation according to the invention and a reusable aerosol-generating device comprising a housing defining a device cavity configured to receive at least a portion of the aerosol-generating article.

The aerosol-generating device may comprise a battery and control electronics.

The aerosol-generating system may comprise: an aerosol-generating article according to the invention comprising a formulation and a nebuliser; and an aerosol-generating device comprising a housing defining a device cavity configured to receive at least a portion of an aerosol-generating article.

The aerosol-generating system may comprise: an aerosol-generating article comprising a formulation according to the invention; and an aerosol-generating device comprising a housing defining a device cavity configured to receive at least a portion of an aerosol-generating article; and an atomizer.

The aerosol-generating system may comprise a porous material for containing the formulation. The porous material may be crimped.

For the avoidance of doubt, the above features relating to the formulation may also relate to the aerosol-generating article, the aerosol-generating device and the aerosol-generating system, where appropriate. Similarly, features described above in relation to the aerosol-generating article may also relate to the aerosol-generating device and the aerosol-generating system, and vice versa, where appropriate.

Drawings

Specific embodiments will now be described, by way of example only, with reference to the following examples and the accompanying drawings, in which:

figure 1 schematically shows a cross-sectional side view of an aerosol-generating system comprising an aerosol-generating device and an aerosol-generating article comprising a formulation according to the invention;

figure 2 schematically shows a cross-sectional view of the aerosol-generating system of figure 1, wherein the aerosol-generating article is inserted into an aerosol-generating device;

figure 3 schematically shows a cross-sectional view of an alternative aerosol-generating system comprising an aerosol-generating article comprising a formulation according to the present invention;

figure 4 schematically shows a cross-sectional view of an aerosol-generating article comprising a formulation according to the invention before heating the aerosol-forming substrate;

figure 5 schematically shows a cross-sectional view of an aerosol-generating article comprising a formulation according to the invention during heating of the aerosol-forming substrate;

figure 6 is a graph showing the average aerosolized collection mass (in milligrams per puff) for a series of different aerosol-former compositions;

figure 7 is a graph showing the average nicotine (in mg/puff) for a range of different aerosol-former compositions; and

figure 8 is a graph showing the average nicotine percentage for a range of different aerosol former compositions.

Detailed Description

Aerosol-generating systems for delivery to a user typically include a nebulizer configured to generate an inhalable aerosol from a formulation. Some known aerosol-generating systems include a thermal atomizer (e.g., an electric heater) configured to heat and vaporize a formulation to produce an aerosol. A typical formulation for an aerosol-generating system is a nicotine formulation, which may be a liquid nicotine formulation comprising an aerosol former such as glycerol and/or propylene glycol.

An aerosol-generating system may comprise an aerosol-generating device and an aerosol-generating article containing a formulation. Typical aerosol-generating systems may suffer from undesirable leakage of the formulation from the aerosol-generating article. Leakage of the formulation can occur in many different situations, such as: when there is too much formulation in the reservoir of the aerosol-generating article; when the material forming one or more parts of the aerosol-generating article or system fails to retain the designed formulation; due to pressure variations, for example at high altitude during aircraft transportation; or at high temperatures, for example due to hot weather.

In contrast to typical formulations, it is desirable to provide a formulation that: which reduces the risk of leakage from the aerosol-generating article or system.

Fig. 1 and 2 show an aerosol-generating system comprising an aerosol-generating device 10 and an aerosol-generating article 20. In this example, the aerosol-generating article 20 is a cartridge.

The aerosol-generating device 10 is configured to receive an aerosol-generating article 20 in the cavity 18. The aerosol-generating article 20 comprises a housing 24. The housing 24 defines the reservoir 22. The reservoir 22 has a reservoir opening that can be covered by a removable cap 26. An aerosol-forming substrate is disposed in the reservoir 22. The aerosol-forming substrate in the reservoir 22 may be a formulation according to the invention.

In the example shown in fig. 1 and 2, the aerosol-generating article 20 comprises an atomizer configured to generate an aerosol from the formulation in the reservoir 22. The atomiser may be a thermal atomiser. In the example shown in fig. 1 and 2, the atomizer is an electric heater 30. In other examples, the nebulizer may be another type of nebulizer, such as a non-thermal nebulizer.

In the example of fig. 1 and 2, the aerosol-generating article 20 contains an aerosol-forming substrate and an atomizer, and may therefore be referred to as a "cartridge atomizer".

When the aerosol-forming substrate provided in the reservoir 22 is depleted, the user may replace the aerosol-generating article 20.

Figure 1 shows an aerosol-generating article 20 prior to insertion into an aerosol-generating device 10. The arrow 1 in fig. 1 indicates the direction of insertion of the aerosol-generating article 20 into the aerosol-generating device 10.

The aerosol-generating device 10 is portable and has a size comparable to a conventional cigar or cigarette. The aerosol-generating device 10 comprises a body 11 and a mouthpiece portion 12. The body 11 contains a battery 14 (e.g., a lithium iron phosphate battery), control electronics 16, and a cavity 18.

The mouthpiece portion 12 is connected to the body 11 by a hinged connection 21 and is movable between an open position as shown in figure 1 and a closed position as shown in figure 2. The mouthpiece portion 12 is placed in an open position to allow insertion and removal of the aerosol-generating article 20, and in a closed position when the aerosol-generating system is to be used to generate an aerosol.

The mouthpiece portion 12 comprises a plurality of air inlets 13 and outlets 15. In use, the user sucks or sucks on the outlet 15 to draw air from the air inlet 13, through the mouthpiece portion to the outlet 15 and then into the mouth or lungs of the user. An internal baffle 17 is provided to force air flowing through the mouthpiece portion 12 through the aerosol-generating article 20.

The housing 24 comprises a capillary material soaked in an aerosol-forming substrate. The capillary tubing material in this example is positioned adjacent to the electric heater 30.

The cavity 18 has a circular cross-section and is sized to receive a housing 24 of the aerosol-generating article 20. Electrical connectors 19 are provided at the sides of the cavity 18 to provide electrical connections between the control electronics 16 and the battery 14 and corresponding electrical contacts on the aerosol-generating article 20. This arrangement allows power to be supplied to the electric heater 30.

Figure 2 shows an aerosol-generating article 20 inserted into the cavity 18 of the aerosol-generating device 10. In this position, the electrical connectors 19 rest on corresponding electrical contacts on the aerosol-generating article 20. The lid 26 has been completely removed and the mouthpiece portion 12 has been moved to the closed position.

The mouthpiece portion 12 is held in the closed position by a clasping mechanism (not shown). It will be apparent to those skilled in the art that other suitable mechanisms for retaining the mouthpiece in the closed position may be used, such as a snap fit or magnetic snap open.

The mouthpiece portion 12 in the closed position holds the aerosol-generating article 20 in electrical contact with the electrical connector 19 so that a good electrical connection is maintained in use regardless of the orientation of the aerosol-generating system.

In use, when the aerosol-generating device 10 is actuated by a user, the electric heater 30 melts and aerosolizes at least a portion of the aerosol-forming substrate in the reservoir 22. When the user sucks or sucks on the outlet 15, air flows through the air inlet 13 and through the electric heater 30 and capillary material. Air flowing through the electric heater 30 and the capillary material entrains the volatilized aerosol components from the evaporated aerosol-forming substrate. The air with entrained aerosol-forming substrate then flows out through the outlet 15 and towards the user. This gas flow pattern is shown in figure 2.

Fig. 3 shows an alternative embodiment of an aerosol-generating system comprising an aerosol-generating article 200. In this example, the aerosol-generating article 200 is a "lipstick" push mechanism aerosol-generating article 200. The aerosol-generating article 200 comprises a body 212. The body 212 defines the reservoir 210. The reservoir 210 has a reservoir opening 215. An aerosol-forming substrate 211 is disposed in the reservoir 210. The heater 222 is disposed proximate the reservoir opening 215. In this example, the body 212 includes a ring or rotating element 251 coupled to the moveable rigid base 213. The ring or rotating element 251 converts the rotational motion into a lateral motion by means of the helical or spiral groove 214. Pins (not shown) connect the rigid base 213 to the spiral or helical groove 214 to provide lateral movement of the aerosol-forming substrate 211. The aerosol-forming substrate 211 is a formulation according to the invention that can flow into and through the mesh layer of the heater 222.

In an alternative embodiment (not shown), the aerosol-generating system may comprise an automated mechanism to move or advance the aerosol-forming substrate 211 towards the heater 222. In such an alternative embodiment, the controller 253 of the aerosol-generating device 200 may activate an actuator or advancing mechanism to advance the aerosol-forming substrate 211 and the rigid base 213 towards the heater 222 upon detecting that the heater 222 is not in contact with the aerosol-forming substrate 211. An actuator or propulsion mechanism may be provided on the aerosol-generating article 200.

Figures 4 and 5 are schematic cross-sectional views of an alternative aerosol-generating article 300. Figure 4 shows the aerosol-generating article 300 before use by a user. The aerosol-generating article 300 includes a body 312 defining a reservoir 310 having a reservoir opening 315. An aerosol-forming substrate 311 is disposed in the reservoir 310. The aerosol-generating article 300 comprises a heater 322 positioned across the reservoir opening 315. In this example, the heater 322 has a heating element in the form of a mesh layer 323. The aerosol-generating article 300 further comprises a transfer element 324. The transfer member 324 is preferably formed of a porous material. In the example of fig. 4, the transfer element 324 is formed from a layer of fiberglass. The transfer element 324 controls the flow of the aerosol-forming substrate 311 from the reservoir 310 to the mesh layer 313 of the heater 322. In this example, the aerosol-forming substrate 311 is a formulation according to the invention.

Examples

One formulation according to the invention (example a) was prepared having the composition shown in table 1. The formulation of example a is a solid at standard temperature and pressure.

TABLE 2

The formulation of example a was prepared by:

(1) heating one or more aerosol formers to a temperature between about 100 degrees celsius and about 120 degrees celsius using a heated plate stirrer;

(2) adding one or more polymers to the one or more aerosol-formers while continuing to stir, and then continuing to heat the mixture to a temperature between about 85 ℃ and about 95 ℃ until the mixture is clear;

(3) adding water to the clarified mixture;

(4) reducing the heating temperature of the mixture to about 50 ℃ and adding the organic acid and nicotine to the mixture while continuing to stir; and

(5) the heated mixture is poured into a mold, and the mixture is then allowed to cool and solidify to form the formulation.

An example of using a formulation according to the invention as an aerosol-forming substrate will now be described with reference to the formulation of example a when used as an aerosol-forming substrate 311 in an aerosol-generating article 300 shown in figures 4 and 5.

Figure 4 shows the aerosol-forming substrate 311 at standard temperature and pressure. Figure 5 shows the aerosol-forming substrate 311 at an elevated temperature when heated by the heater 322.

In the example of fig. 4 and 5, the aerosol-forming substrate 311 is a solid at standard temperature and pressure, as the melting point of the aerosol-forming substrate 311 is between 60 degrees celsius and 300 degrees celsius. In another example, the aerosol-forming substrate 311 is a colloid at standard temperature and pressure. Colloids can have a solid continuous phase and a liquid dispersed phase.

Thus, the aerosol-forming substrate 311 is in the solid phase prior to activation of the heater 322.

The aerosol-generating article 300 is inserted into the aerosol-generating device 10 shown in figure 1

The user then activates the aerosol-generating device 300. Activation of the aerosol-generating device 10 involves activation of the heater 322 of the aerosol-generating article 300. Activation of the heater 322 causes a portion of the aerosol-generating substrate 311 contained within the transfer element 324 to be heated. In this example, the heater 322 was activated at 0.8 watts for a period of six minutes. In one example, the heaters 322 may be activated at different power levels. In another example, the heater 322 may initiate different time periods.

Activating the heater 322 at 0.8 watts for six minutes increases the temperature of the mesh layer 323 to approximately 200 degrees celsius.

Heating of the aerosol-forming substrate 311 contained within the transfer element 324 increases the temperature of at least a portion of the aerosol-forming substrate 311, which melts the heated portion of the aerosol-generating substrate 311 into a liquid.

Figure 5 shows an example in which the entire aerosol-forming substrate 311 has been converted to a liquid by heating of the aerosol-forming substrate 311 by the heater 322. In another example, at least a portion, or only a portion, of the aerosol-forming substrate 311 melts into a liquid when the heater 322 is activated. For example, a portion of the aerosol-forming substrate 311 adjacent to the heater 322 may melt to a liquid, but the remainder of the aerosol-forming substrate 311 may remain solid.

The temperature of the aerosol-forming substrate 311 is increased until at least a portion of the molten aerosol-forming substrate 311 contained within the transfer element 324 is evaporated into an aerosol.

The aerosol can then be inhaled by the user through the outlet 15.

After the first heating cycle of the heater 322 is complete, the aerosol-forming substrate 311 cools down. As shown in fig. 4, the aerosol-forming substrate 311 reforms into a solid.

The aerosol-generating article 300 may be used several times before the aerosol-generating substrate 311 contained in the reservoir 310 is completely consumed. Accordingly, the aerosol-generating article 300 may undergo multiple heating cycles. Thus, in use, the aerosol-forming substrate may undergo multiple phase changes.

Advantageously, the aerosol-forming substrate 311 is stored within the reservoir 310 as a solid or substantially solid colloid. Since the aerosol-forming substrate 311 is stored in solid form, it is much less likely to leak or escape from the reservoir 310 than a liquid aerosol-forming substrate 311. In view of this, an aerosol-generating article, an aerosol-generating device or an aerosol-generating system comprising an aerosol-forming substrate 311 consisting of a formulation according to the invention has an improved shelf life.

Furthermore, an aerosol-forming substrate 311 consisting of a formulation according to the invention melts into a liquid when heated during a normal heating cycle of an aerosol-generating article, aerosol-generating device or aerosol-generating system. This means that the aerosol-forming substrate flows as a normal liquid aerosol-forming substrate and can normally evaporate into an aerosol. As discussed herein, depending on the specific design of the aerosol-generating article, aerosol-generating device or aerosol-generating system, a portion of the aerosol-forming substrate or the entire aerosol-forming substrate may melt during the heating cycle.

Furthermore, when the aerosol-forming substrate 311 consisting of a formulation according to the invention cools down after a heating cycle, it will freeze back to a solid and is therefore no longer able to flow out of the reservoir 310. This prevents the aerosol-forming substrate 311 from leaking during use of the aerosol-generating article, aerosol-generating device or aerosol-generating system.

Figure 6 shows the average aerosolized collection mass (in milligrams per puff) for a range of different aerosol former compositions as the weight percent of Propylene Glycol (PG) was varied relative to the weight percent of Vegetable Glycerin (VG). For example, the data for "25% PGvsVG" is for a formulation comprising an aerosol former composition containing 25% by weight propylene glycol and 75% by weight vegetable glycerin.

Figure 7 is a graph showing the average nicotine (in milligrams per puff) for a series of different aerosol former compositions as the weight percent of Propylene Glycol (PG) was varied relative to the weight percent of Vegetable Glycerin (VG). For example, the data for "25% PGvsVG" is for a formulation comprising an aerosol former composition containing 25% by weight propylene glycol and 75% by weight vegetable glycerin.

Fig. 8 is a graph showing the average nicotine percentage for a range of different aerosol former compositions as the weight percentage of Propylene Glycol (PG) was varied relative to the weight percentage of Vegetable Glycerin (VG). For example, the data for "25% PGvsVG" is for a formulation comprising an aerosol former composition containing 25% by weight propylene glycol and 75% by weight vegetable glycerin.

The data in the figures indicate that the nicotine content of the aerosol is improved by incorporating propylene glycol as the aerosol former in a nicotine-containing formulation, as discussed above. For example, the highest weight percent nicotine is at 5% propylene glycol by weight in the aerosol former. This improvement may be due to the higher evaporation efficiency of nicotine, since propylene glycol has a lower boiling point (188 ℃) compared to glycerol (290 ℃).

However, if there is a significant amount of propylene glycol in the formulation (e.g., 25% by weight propylene glycol), the nicotine content of the aerosol will be reduced because the propylene glycol can evaporate during the heating cycle. Therefore, it is advantageous to have a limited amount of propylene glycol in a nicotine formulation.

The above-described exemplary embodiments are not intended to limit the scope of the claims. Other embodiments consistent with the above exemplary embodiments will be apparent to those skilled in the art. Features described with respect to one embodiment may also be applicable to other embodiments.

Claims

1. A formulation for an aerosol-generating system, the formulation comprising:

one or more aerosol forming agents; and

one or more polymers selected from the group consisting of: polyvinyl acetate, polyvinyl alcohol, polyethylene glycol, polyglycolic acid, polylactic acid, polydioxanone, polycaprolactone, polyethylene, polypropylene glycol, and starch;

wherein the formulation has a melting point between 100 degrees Celsius and 300 degrees Celsius.

2. The formulation of claim 1, wherein the formulation has a melting point between 180 degrees celsius and 270 degrees celsius.

3. The formulation according to claim 1 or claim 2, wherein the formulation has an aerosol former content of between 20 and 85 wt.%.

4. The formulation of claim 3, wherein the formulation has an aerosol former content of between 35% and 55% by weight.

5. A formulation according to any one of claims 2 to 4, wherein the one or more aerosol-former comprises one or more water-miscible polyols.

6. The formulation of claim 5, wherein the one or more water-miscible polyols are selected from the group consisting of: vegetable glycerin, propylene glycol and sorbitol.

7. The formulation of any one of the preceding claims, comprising one or more organic acids.

8. The formulation of claim 7, wherein the formulation has an organic acid content of less than 10% by weight.

9. The formulation according to claim 7 or claim 8, wherein the one or more organic acids are selected from the group consisting of: malonic acid, citric acid, 2-ethylbutyric acid, acetic acid, adipic acid, benzoic acid, butyric acid, cinnamic acid, cycloheptane-carboxylic acid, fumaric acid, glycolic acid, caproic acid, lactic acid, levulinic acid, malic acid, myristic acid, caprylic acid, oxalic acid, propionic acid, pyruvic acid, succinic acid, and undecanoic acid.

10. The formulation of claim 9, wherein the one or more organic acids are selected from the group consisting of: malonic acid, citric acid, lactic acid, benzoic acid, levulinic acid, fumaric acid and acetic acid.

11. The formulation of any one of the preceding claims, wherein the formulation has a polymer content of greater than or equal to about 0.5 wt%.

12. The formulation of any one of the preceding claims, comprising one or more metal salts.

13. The formulation of claim 12, wherein the one or more metal salts are selected from the group consisting of: metal alginates, metal cinnamates, metal cycloheptane carboxylates, metal levulinates, metal propionates, metal stearates, and metal undecanoates, preferably the one or more metal salts are selected from the group consisting of: metal cinnamates, metal cycloheptane carboxylates, metal stearates, and metal undecanoates.

14. An aerosol-generating article for use in an aerosol-generating system, the aerosol-generating article comprising a formulation according to any one of claims 1 to 13.

15. An aerosol-generating system, comprising:

the formulation of any one of claims 1 to 13; and

a nebulizer configured to generate an aerosol from the formulation.