Method of making an amorphous solid for use with a non-combustible aerosol provision system

Abstract

A method of making an amorphous solid is provided. The method comprises: (a) forming a slurry comprising: 0.5-60 wt % of a gelling agent; 5-80 wt % of an aerosol forming material; and 0-60 wt % of an active constituent and/or flavorant; wherein these weights are calculated on a dry weight basis; (b) shaping the slurry; (c) setting the slurry to form a gel; and (d) drying the gel to form an amorphous solid; wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes. Amorphous solids provided by the method, articles comprising the amorphous solids, and non-combustible aerosol provision systems comprising the articles are also provided.

1 . A method of making an amorphous solid comprising:
 (a) forming a slurry comprising:
 0.5-60 wt % of a gelling agent; 
 5-80 wt % of an aerosol forming material; and 
 0-60 wt % of an active constituent and/or flavorant; 
   wherein these weights are calculated on a dry weight basis;   (b) shaping the slurry;   (c) setting the slurry to form a gel; and   (d) drying the gel to form an amorphous solid;   wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes.   
     
     
         2 . A method according to  claim 1 , wherein the drying removes 50-95 wt % of water in the slurry, calculated on a wet weight basis. 
     
     
         3 . A method according to  claim 1 , wherein the resulting amorphous solid comprises from about 1 wt % to about 15 wt % water, calculated on a wet weight basis. 
     
     
         4 . A method according to  claim 1 , wherein shaping the slurry comprises forming a layer of the slurry, wherein the layer is less than about 4 mm thick. 
     
     
         5 . A method according to  claim 4 , wherein the thickness of the layer is in the range of about 1 mm to about 3 mm. 
     
     
         6 . A method according to  claim 4 , wherein the drying results in an amorphous solid which has a thickness that is between about 5% and 20% of the thickness of the layer. 
     
     
         7 . A method according to  claim 1 , wherein the drying comprises flowing air over the gel, wherein the air temperature is in the range of about 80° C. to about 140° C. 
     
     
         8 . A method according to  claim 7 , wherein the air flow speed is in the range of 10 m/s to 30 m/s. 
     
     
         9 . A method according to  claim 1 , wherein the drying comprises heating the gel for a period of less than 20 minutes. 
     
     
         10 . A method according to  claim 1 , wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 110° C. 
     
     
         11 . A method according to  claim 1 , wherein a carrier is provided and the slurry is shaped on the carrier. 
     
     
         12 . A method according to  claim 1 , wherein the slurry comprises 10-60 wt % of the active constituent and/or flavorant. 
     
     
         13 . A method according to  claim 1 , wherein the gelling agent is selected from pectins, alginates and mixtures thereof. 
     
     
         14 . A method according to  claim 1 , wherein the aerosol forming material is selected from erythritol, propylene glycol, glycerol and mixtures thereof. 
     
     
         15 . An amorphous solid, obtainable or obtained by a method comprising:
 (a) forming a slurry comprising:
 0.5-60 wt % of a gelling agent; 
 5-80 wt % of an aerosol forming material; and 
 0-60 wt % of an active constituent and/or flavorant; 
   wherein these weights are calculated on a dry weight basis;   (b) shaping the slurry;   (c) setting the slurry to form a gel; and   (d) drying the gel to form an amorphous solid;   wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes.   
     
     
         16 . An article for use within a non-combustible aerosol provision system, the article comprising an amorphous solid obtainable or obtained by a method comprising:
 (a) forming a slurry comprising:
 0.5-60 wt % of a gelling agent; 
 5-80 wt % of an aerosol forming material; and 
 0-60 wt % of an active constituent and/or flavorant; 
   wherein these weights are calculated on a dry weight basis;   (b) shaping the slurry;   (c) setting the slurry to form a gel; and   (d) drying the gel to form an amorphous solid;   wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes.   
     
     
         17 . A non-combustible aerosol provision system comprising an article and a non-combustible aerosol provision device, the article comprising an amorphous solid obtainable or obtained by a method comprising:
 (a) forming a slurry comprising:
 0.5-60 wt % of a gelling agent; 
 5-80 wt % of an aerosol forming material; and 
 0-60 wt % of an active constituent and/or flavorant; 
   wherein these weights are calculated on a dry weight basis;   (b) shaping the slurry;   (c) setting the slurry to form a gel; and   (d) drying the gel to form an amorphous solid;   wherein the drying comprises heating the gel to a temperature in the range of about 80° C. to about 140° C. for a period of less than 60 minutes and wherein the non-combustible aerosol provision device comprises an aerosol-generation device to generate aerosol from the article when the article is used with the non-combustible aerosol provision device.