Aerosol-generating material and smoking article comprising same

Abstract

The invention relates to an aerosol-generating material and a smoking article comprising the same. The aerosol-generating material comprises at least two plant fibers or a mixture of aerosol-generating materials. The reconstitution material may comprise a combination of extracted cocoa shell fibers and at least one of extracted tobacco fibers, tobacco material, extracted herbaceous plant fibers, and aerosol-generating herbaceous plant material. The reconstituted plant fiber material is capable of generating aerosols, such as smoke, having a very mild and neutral or natural taste without irritant components. The reconstituted plant fiber material is free of nicotine, contains low or no other active compounds, and contains low to non-irritant combustible compounds, such as tar.

Description

[0001] This application is a divisional application of a patent application with application number 202080026753.3, application date February 11, 2020, and invention name “Filler containing a mixture of aerosol generating materials”.

[0002] Related Applications

[0003] This application is based upon and claims priority to U.S. Provisional Patent Application Serial No. 62 / 803,886, filed on February 11, 2019, which is incorporated herein by reference. Technical Field

[0004] The present disclosure relates to the field of plant materials, in particular to aerosol-generating materials and smoking articles containing the same. Background Art

[0005] Conventional smoking articles burn materials at a temperature that releases an active compound, which is inhaled through a mainstream aerosol. The mainstream aerosol delivered to the user not only has a unique, pleasant taste, but also can deliver the active compound to the user, which is absorbed into the blood through the lungs, which can provide a pleasant and calming effect to the smoker. However, in the past, it was difficult to control the amount of active compound, such as nicotine, delivered to the user by the article, and it was even more difficult to maintain good sensory properties, such as taste and smell, while changing the amount of active compound contained in the article.

[0006] Various methods have been proposed to control active agents, such as nicotine. For example, one method of removing nicotine from tobacco is by chemical extraction. For example, nicotine can be removed from tobacco using a relatively harsh solvent extraction method similar to the removal of caffeine from coffee beans. However, this extraction method not only removes nicotine, but also removes various other components of the tobacco material. For example, the nicotine extraction method also removes flavoring agents and may be detrimental to the taste of the tobacco. The extraction method is also relatively expensive and time consuming.

[0007] In addition to solvent extraction, genetically modified tobacco plants have recently been developed that inherently have low nicotine levels. However, genetically modified tobacco plants are not only expensive to grow and harvest, but are also easily contaminated by crossbreeding with conventional tobacco plants. For example, cross-pollination may reverse the low nicotine effects of genetically modified plants. Therefore, genetically modified plants must be planted in areas that are completely isolated from other tobacco crops.

[0008] Furthermore, there is also a lack of blends and varieties that can be used in aerosol-generating articles, as it has proven difficult to control the taste and active material content in reconstitution materials. In particular, there is a lack of blends that use two or more aerosol-generating materials to form a combustible article that retains good organoleptic properties, such as a pleasing or natural taste and smell, and that can also demonstrate control over the active compounds contained in the smoking article.

[0009] In view of the above, there is a need for a combustible material or aerosol generating material combining fibers or aerosol generating materials from two or more plant sources or materials. It is also beneficial to provide a combustible material or aerosol generating material combining fibers or aerosol generating materials from two or more plants that controls or minimizes at least one active compound contained in the aerosol generating material. In addition, it is also advantageous to provide an aerosol generating material that minimizes one or more active compounds, but also maintains natural or pleasing organoleptic properties. Summary of the invention

[0010] In general, the present disclosure relates to an aerosol-generating material comprising a reconstituted plant material comprising a mixture of at least two different plant fibers. The reconstituted plant material comprises: extracted cocoa husk fibers in combination with: (a) extracted tobacco fibers, including tobacco leaves, tobacco stems, tobacco extraction byproducts, or mixtures thereof, (b) extracted herbaceous plant fibers, or (c) mixtures thereof.

[0011] For example, in one embodiment, the reconstructed plant material comprises extracted tobacco fibers. Additionally or alternatively, the reconstructed plant material comprises a combination of extracted cocoa shell fibers and extracted tobacco fibers. Furthermore, in embodiments, the reconstructed plant material comprises extracted cocoa husk fibers. Furthermore, in yet another embodiment, the reconstructed plant material comprises extracted herbal fiber, wherein the extracted herbal fiber is obtained from: coffee, tea, liana, ginger, ginkgo, chamomile, tomato, ivy, mate, rooibos tea, cucumber, cereals, turmeric, cloves, liquorice, sandalwood, cinnamon, mint, coriander, fennel, thyme or a mixture thereof.

[0012] Additionally or alternatively, in one embodiment, the reconstructed plant material may also include web building fibers. Furthermore, the web building fibers may include flax fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or mixtures thereof. In embodiments where web building fibers are used, the web building fibers are present in the reconstructed plant material in an amount greater than about 3% by weight, such as in an amount greater than about 5% by weight, such as in an amount greater than about 8% by weight, and in an amount less than about 40% by weight.

[0013] In one embodiment, the reconstructed plant material has been treated with a wetting agent. In embodiments where a wetting agent is used, the wetting agent comprises glycerol, propylene glycol, or a mixture thereof. Furthermore, in embodiments where a wetting agent is used, the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or less, and / or the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or more, such as in an amount of about 10% by weight or more, such as in an amount of about 15% by weight or more, and in an amount of about 50% or less.

[0014] In another embodiment, the aerosol generating material includes an aerosol delivery composition applied to the reconstruction plant material, wherein the aerosol delivery composition includes an aerosol delivery agent. In the embodiment including the aerosol delivery composition, the aerosol delivery agent can include medicine or edible flavoring. In other embodiments, the aerosol delivery agent can include oil or solid, and in another embodiment, the aerosol delivery agent includes nicotine. Additionally or selectively, the aerosol delivery agent includes sugar, licorice extract, honey, coffee extract, maple syrup, tea extract, regional plant (botanical) extract, plant extract, tobacco extract or fruit extract. On the one hand, the aerosol delivery agent can include one or more terpenes. Terpenes that may be added to the reconstituted material include pinene, humulene, b-caryophyllene, isopulegol, guaiacol, neryl acetate, neomenthyl acetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranyl acetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyl alcohol, pinane, neomenthylaceta acetate, and a host of others.

[0015] In embodiments comprising an aerosol delivery composition, the aerosol delivery composition is present on the reconstructed plant material in an amount greater than about 1% by weight, such as greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, such as greater than about 30% by weight, such as greater than about 35% by weight, such as greater than about 40% by weight, and less than about 50% by weight.

[0016] In embodiments according to the present disclosure, the reconstituted plant material has a basis weight of about 40 gsm to about 120 gsm, such as about 55 gsm to about 85 gsm.

[0017] Additionally or alternatively, in embodiments of the present disclosure, the aerosol generating material is in the form of a filler material comprising a strip, a plurality of strips, fragments or a mixture thereof of reconstituted plant material.

[0018] Generally, the present disclosure also includes smoking articles. The smoking article includes an outer wrapper surrounding a smokeable rod, wherein the smokeable rod includes an aerosol generating material according to any of the above embodiments. In one embodiment, the wrapper includes a plurality of discrete deceleration combustion zones spaced apart axially along the smoking article, and the deceleration combustion zones have a diffusion rate of less than about 0.5 cm / s at 23°C. In an embodiment including a plurality of deceleration combustion zones, a plurality of deceleration combustion zones are formed by applying a deceleration combustion composition to the wrapper. In another embodiment, when the smoking article is tested according to ASTM test E2187-09, at least 75% of the smoking articles are self-extinguishing.

[0019] Generally, the present disclosure may also include a smoking article comprising a heating means and a chamber containing an aerosol generating material as defined in any one of the embodiments described above. The heating means is positioned to facilitate heating the aerosol generating material to produce an inhalable aerosol without burning the aerosol generating material.

[0020] In addition, the present disclosure generally relates to an aerosol-generating material comprising a reconstituted plant material. The reconstituted plant material comprises: extracted cocoa shell fibers. The reconstituted plant material is mixed with: (a) extracted tobacco fibers, including tobacco leaves, tobacco stems, tobacco extraction byproducts, or mixtures thereof, (b) extracted herbaceous plant fibers, or (c) mixtures thereof.

[0021] For example, in one embodiment, the reconstructed plant material comprises extracted cocoa shell fibers. Additionally or alternatively, the reconstructed plant material is mixed with tobacco material. Furthermore, in yet another embodiment, the reconstructed plant material comprises extracted herbal fiber, wherein the extracted herbal fiber is obtained from: coffee, tea, liana, ginger, ginkgo, chamomile, tomato, ivy, mate, rooibos tea, cucumber, cereals, turmeric, cloves, liquorice, sandalwood, cinnamon, mint, coriander, fennel, thyme or a mixture thereof.

[0022] Additionally or alternatively, in one embodiment, the reconstructed plant material may also include web building fibers. Furthermore, the web building fibers may include flax fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or mixtures thereof. In embodiments where web building fibers are used, the web building fibers are present in the reconstructed plant material in an amount greater than about 3% by weight, such as in an amount greater than about 5% by weight, such as in an amount greater than about 8% by weight, and in an amount less than about 40% by weight.

[0023] In one embodiment, the reconstructed plant material has been treated with a wetting agent. In embodiments where a wetting agent is used, the wetting agent comprises glycerol, propylene glycol, or a mixture thereof. Furthermore, in embodiments where a wetting agent is used, the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or less, and / or the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or greater, such as in an amount of about 10% by weight or greater, such as in an amount of about 15% by weight or greater, and in an amount of about 50% by weight or less.

[0024] In yet another embodiment, the aerosol generating material comprises an aerosol delivery composition applied to the reconstructed plant material, wherein the aerosol delivery composition comprises an aerosol delivery agent. In the embodiment comprising the aerosol delivery composition, the aerosol delivery agent may include a medicine or a flavoring. In another embodiment, the aerosol delivery agent may include oil or a solid, and in yet another embodiment, the aerosol delivery agent includes nicotine. Additionally or selectively, the aerosol delivery agent includes sugar, licorice extract, honey, coffee extract, maple syrup, tea extract, regional plant extract, plant extract, tobacco extract or fruit extract. On the one hand, the aerosol delivery agent may include one or more terpenes. Terpenes that can be added to the reconstructed plant material include: pinene, humulene, b-caryophyllene, isopulegol, guaiacol, neryl acetate, neomenthyl acetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranyl acetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyl alcohol, pinane, neomenthylaceta acetate and a large number of others.

[0025] In embodiments comprising an aerosol delivery composition, the aerosol delivery composition is present on the reconstructed plant material in an amount greater than about 1% by weight, such as greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, such as greater than about 30% by weight, such as greater than about 35% by weight, such as greater than about 40% by weight, and less than about 50% by weight.

[0026] In embodiments according to the present disclosure, the reconstituted plant material has a basis weight of about 40 gsm to about 120 gsm, such as about 55 gsm to about 85 gsm.

[0027] Additionally or alternatively, in embodiments of the present disclosure, the aerosol generating material is in the form of a filler material comprising a strip, a plurality of strips, fragments or mixtures thereof of reconstituted plant material.

[0028] Typically, the present invention also includes smoking articles. The smoking article includes an outer wrapper surrounding a smokeable rod, wherein the smokeable rod includes an aerosol-generating material according to any of the above embodiments. In one embodiment, the wrapper includes a plurality of discrete deceleration combustion zones spaced apart axially along the smoking article, and the deceleration combustion zone has a diffusion rate of less than about 0.5 cm / s at 23°C. In an embodiment including a plurality of deceleration combustion zones, the plurality of deceleration combustion zones are formed by applying a deceleration combustion composition to the wrapper. In another embodiment, when the smoking article is tested according to ASTM test E2187-09, at least 75% of the smoking articles are self-extinguishing.

[0029] Generally, the present invention may also include a smoking article comprising a heating means and a chamber containing an aerosol generating material as defined in any one of the embodiments described above. The heating means is positioned to heat the aerosol generating material to produce an inhalable aerosol without burning the aerosol generating material.

[0030] Other features and aspects of the disclosure are discussed in greater detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The full and enabling disclosure of the present disclosure is more particularly set forth in the remainder of the present disclosure, including with reference to the accompanying drawings, in which:

[0032] Figure 1 is a perspective view of one embodiment of a smoking article incorporating a wrapper of the present disclosure; and

[0033] Figure 2 yes Figure 1 An exploded view of the smoking article is shown.

[0034] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0035] definition

[0036] As used herein, "reconstructed plant material" refers to a material formed by the following method, wherein a plant raw material, such as cocoa husk, tobacco or reconstructed tobacco, herb, is extracted, for example, with a solvent to form an extract of solubles, such as water-soluble substances, and an insoluble portion or residue containing a fibrous material extracted. The extracted and insoluble fibrous material is then formed into a sheet or web by any suitable method, and the extract can be discarded or reapplied to the formed sheet. Before being recombined with the fibrous material, the extract can be fed by a variety of methods to concentrate the extract and optionally remove or add a variety of components. In the present disclosure, the reconstructed cocoa material is formed by extracted plant fibers, optionally combined with web-building fibers such as cellulose fibers. The soluble extract obtained from the plant fibers is optionally reapplied to the sheet.

[0037] As used herein, "aerosol-generating material" is intended to include both combustible materials that undergo combustion in smoking articles and aerosol-generating materials that are heated but not burned to form an inhalable aerosol. Combustible smoking articles may include cigarettes, cigarillos, and cigars. In cigarettes, the aerosol-generating material is usually surrounded by a wrapping material to form a smokeable rod, but may also be contained in the wrapping material itself. Aerosol-generating devices for generating aerosols include, for example, devices in which aerosols are generated by electrical heating or by transferring heat from a combustible fuel element or a heat source to heat but not burn an aerosol-generating material that releases volatile compounds. When the released compounds cool, they condense to form an aerosol that is inhaled by a consumer.

[0038] As used herein, "extracted plant fiber" generally refers to plant fiber that has been subjected to an extraction process, wherein the plant fiber has been contacted with an aqueous solution to remove water-soluble components contained in the plant fiber. The extraction process is different from the delignification process and the bleaching treatment.

[0039] As used herein, "extracted tobacco fiber" refers to tobacco fiber that has undergone an extraction process, wherein tobacco components, such as stalks, handles, and optional leaves, have been contacted with an aqueous solution to remove water-soluble components contained in the tobacco components. The extraction process is different from the delignification process and the bleaching process.

[0040] As used herein, "extracted herb fiber" refers to herb fiber that has been subjected to an extraction process, wherein the herb fiber has been contacted with an aqueous solution to remove water-soluble components contained in the herb fiber. The extraction process is different from the delignification process and the bleaching treatment.

[0041] As used herein, "extracted byproducts" refers to biomass that has undergone an extraction process to remove selected components without removing a large amount of water-soluble components. The extracted byproducts can refer to biomass produced by an extraction process, wherein the extractant is a solvent such as ethanol, a supercritical fluid such as carbon dioxide, a lipid such as a vegetable oil, etc. According to the present disclosure, the extracted byproducts can undergo a second extraction process to remove water-soluble components during the preparation of a reconstructed material. Extraction byproducts that are very suitable for the present disclosure include those containing water-soluble components in an amount greater than about 8% by weight, such as an amount greater than about 12% by weight, such as an amount greater than about 18% by weight, such as an amount greater than about 24% by weight.

[0042] As used herein, "extracted cocoa fiber" and / or "extracted cocoa husk fiber" refers to cocoa fiber or cocoa husk fiber that has been subjected to an extraction process, wherein the cocoa or cocoa husk has been contacted with an aqueous solution to remove water-soluble components contained in the cocoa. The extraction process is distinct from the delignification process and the bleaching treatment.

[0043] As used herein, "delignified" cellulosic fibers (eg, pulp fibers) refer to fibers that have undergone a pulping or delignification process by which the cellulosic fibers are separated from plant material by chemical means, mechanical means, or by a combination of chemical and mechanical means.

[0044] As used herein, the term "refining" is used to refer to mechanical treatment of plant material that modifies the fibers of the material so that they are more suitable for forming a fibrous sheet or substrate. Refining can be accomplished using a cone refiner or a disc refiner or a valley beater. The mechanical process exerts an abrasive and abrasive effect on the plant material, causing the plant material to deform and decluster. Refining is a process different from delignification and pulping.

[0045] As used herein, the "amount of water-soluble extract present in a substrate or reconstituted plant material or aerosol-generating material is determined by placing 5 grams of the sample in boiling distilled water for 10 minutes to obtain an extract containing water-soluble components. The dry matter weight of the extract soluble in the solvent is calculated by the difference between the dry weight of the sample and the dry weight of the sample after extraction. The difference in dry weight is then used to determine the percentage of water-soluble extract in the sample.

[0046] As used herein, the term "culm" is used to refer to the main structural part of the plant that remains after the leaves have been removed.

[0047] As used herein, the term "petiole" is used herein to refer to the structural part of a plant that connects a leaf or blade to a stalk and also to a vein or rib extending through the leaf. The term "petiole" does not include the term "stalk", and vice versa.

[0048] Those skilled in the art will appreciate that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present disclosure.

[0049] The present disclosure generally relates to aerosol-generating materials, which include fibers or aerosol-generating materials from two or more plant sources or materials. For example, the present disclosure unexpectedly found that a reconstructed plant material comprising a mixture of at least two different plant fibers or aerosol-generating materials can be prepared to maintain good sensory properties, such as a pleasant and / or natural taste, and can also control an aerosol-generating material that maintains one or more active compounds contained in at least one plant (the plant fiber and / or aerosol-generating material is derived from the plant). For example, in one embodiment, the amount of nicotine may be reduced compared to a naturally occurring product, or a certain amount of nicotine can be eliminated from the aerosol-generating material. However, the present disclosure has found that by using a mixture of extracted cocoa fibers and at least one combination of extracted tobacco fibers, tobacco materials, extracted herbal plant fibers, and aerosol-generating herbal plant materials to form a reconstructed plant material, an aerosol-generating material that maintains good sensory properties while controlling the active compounds can be produced. For example, aerosol-generating materials according to the present invention may have a pleasant, neutral or natural taste or smell, and may also regulate the amount of nicotine delivered to a user when the material is incorporated into an aerosol-generating article such as a smoking article, or a heat but not burn aerosol generating device.

[0050] In one embodiment, the aerosol generating material comprises a reconstructed plant material comprising a mixture of at least two different plant fibers, wherein a kind of plant fiber comprises extracted cocoa fiber, and another kind of plant fiber comprises at least one of extracted tobacco and extracted herbal plant fiber. Additionally or alternatively, the aerosol generating material can comprise a reconstructed plant material formed by extracted plant fiber, and then the reconstructed plant material can be mixed with at least one of tobacco material and herbal material. In any case, in one embodiment, the reconstructed plant material can be cut or chopped to form a loose filler material, which is designed to produce an aerosol when heated or burned.

[0051] The reconstructed plant material of the present invention provides many advantages and benefits. For example, the reconstructed material can be nicotine-free, which means that the aerosol produced by the material when heated or burned contains undetectable nicotine levels. In addition, the reconstructed plant material can produce tar at a lower level than conventional tobacco fillers. In addition, when burned or heated, the reconstructed plant material has a very natural or neutral taste, and in some embodiments can include a pleasant, neutral and / or natural herbal taste. For example, the mainstream smoke or aerosol generated by the reconstructed plant material produces a pleasant smoking or aerosol experience, with a pleasant and natural or neutral taste, without any stimulating components at all.

[0052] Because the reconstructed plant material has a natural flavor when sucking and can be nicotine-free, the reconstructed plant material can be used to prepare a nicotine-free smoking article. In addition, the reconstructed material is very suitable for combining with other aerosol-generating fillers and / or topical additives. For example, the reconstructed plant material can be combined with tobacco material to form an aerosol-generating filler with the tobacco flavor that the user wants while reducing the nicotine level. For example, when combined with tobacco material, the ratio of the reconstructed plant material of the present disclosure can be increased or reduced to control the nicotine level. When combined with tobacco material, the reconstructed plant material of the present disclosure does not cover the taste of tobacco material in any way due to its natural characteristics, and in fact, except reducing the nicotine level, smoking or aerosol experience can be enhanced by diluting and reducing irritants.

[0053] I. Plant Fiber

[0054] As noted above, the reconstituted plant material of the present disclosure is generally formed from extracted cocoa, and optionally extracted tobacco and / or extracted herbal plant material.

[0055] The cocoa material used in the present disclosure is obtained from Theobroma cacao, which is also called the cocoa tree. The cocoa tree belongs to the evergreen family and originates from tropical regions. The cocoa tree bears fruit, called cocoa pods. The cocoa pods are typically yellow to orange in color and can weigh more than 1 pound when mature. The pods contain about 10 to about 80 cocoa beans, which are used to make chocolate, juice, jelly, etc. After the beans are removed from the cocoa pods, the cocoa beans are dried and air-dried or fermented by exposure to sunlight and / or ultraviolet rays. Each individual bean is covered in a husk or shell. Before using the beans to prepare food, the husk or shell is removed from the beans. The reconstructed plant material of the present invention is made of cocoa husks or husks, but other components of the cocoa pods may also be used.

[0056] Tobacco materials useful in the present disclosure may include, for example, cut tobacco leaves, reconstituted tobacco material, or mixtures thereof, and include tobacco stems, stalks, and optionally leaves and scraps.

[0057] The herbal plant materials used in the plants of the present disclosure include regional plants and trees, including herbs, plants and trees that can be used to form smokeable fibers or smokeable herbal plant products, such as cocoa trees, coffee trees or coffee beans, tea trees or tea leaves, vines, ginger, ginkgo, chamomile, tomato, ivy, yerba mate, rooibos tea, cucumber, mint, grains such as wheat, barley or rye, and other trees such as hardwood trees or resinous trees, and combinations thereof.

[0058] II. Methods of Forming Filler Materials

[0059] Tobacco, cocoa shell and herbaceous plant comprise plant fiber, and the plant fiber, when forming according to the present invention, is very suitable for forming substrate and web material.In one embodiment, plant fiber from at least one of tobacco, cocoa shell and herbaceous plant is optionally classified or ground, then undergoes extraction process to remove water-soluble components.Then the plant fiber extracted can be combined with web construction fiber and form substrate, such as reconstructed sheet.Optionally, substrate can be processed with soluble extract obtained from plant fiber.Selectively, extract obtained from plant fiber can be discarded, and not recombined with water-insoluble fiber and other materials.Then reconstructed material is dried and formed aerosol generating material, such as aerosol generating filler.Then, aerosol generating material can be optionally combined with various other components.For example, material can be processed with various aerosol delivery agents, and / or combined with various other aerosols or smoking fillers, such as tobacco material or other herbal fillers.

[0060] The resulting aerosol-generating materials prepared according to the present disclosure can then be used in many different types of consumer products. For example, in one embodiment, the aerosol-generating materials can be incorporated into smoking articles, such as cigarettes, cigarillos, cigars, etc. In one embodiment, the aerosol-generating materials of the present disclosure can be packaged and sold as loose fill materials for pipes, or to allow consumers to roll their own cigarettes or other smoking articles. In an optional embodiment, the aerosol-generating materials of the present disclosure can be incorporated into a device that heats a material without burning the material to produce an inhalable aerosol. The aerosol-generating material can be cut, shredded, or otherwise processed into a form that is most suitable for a particular application and product.

[0061] In forming the reconstructed plant material of the present disclosure, plant fibers from at least one of tobacco, cocoa shells, and herbs are first collected and optionally reduced in size. For example, in one embodiment, the plant fibers may be subjected to a grinding operation, a milling operation, or a beating operation, which may reduce the size of the plant fibers and / or reduce the plant fibers to individual fibers. For example, in one embodiment, the plant fibers may be fed to a hammer mill that beats the plant fibers against a screen to prepare a fibrous material.

[0062] After the plant fibers are optionally reduced in size, the plant fibers undergo an extraction process to remove water-soluble components. The extraction process can provide a variety of benefits. For example, the extraction process can remove colloids from the plant fibers, which makes it easier to process the plant fibers into a fiber substrate or a reconstructed plant sheet. It is believed that removing colloids from the plant fibers also contributes to the neutral taste of the final product.

[0063] Subjecting the plant fibers to the extraction process also cleans the plant fibers and removes any herbicides or pesticides and microorganisms that may be present on the material.

[0064] In the extraction process, the plant fiber is contacted with a solvent to remove water-soluble components. In one embodiment, the solvent comprises only water. In selectable embodiments, various water-miscible solvents, such as alcohols (e.g., ethanol) and / or suitable oils and fats, can be combined with water to form an aqueous solvent. In some cases, the water content of the aqueous solvent is greater than 50wt.% of the solvent, particularly greater than 90wt.% of the solvent. Deionized water, distilled water or tap water can be used. The amount of the solvent in the suspension can vary widely, but is generally added in an amount of about 50%w / w to about 99%w / w of the suspension, in some embodiments about 60%w / w to about 95%w / w, and in some embodiments about 75%w / w to about 91%w / w. However, the amount of the solvent can vary with the nature of the solvent, the temperature at which the extraction is performed, and the type of the plant ingredients.

[0065] After forming the solvent / plant fiber mixture, some or all of the soluble portion of the mixture can be separated from the insoluble portion of the mixture. The solvent / plant fiber mixture can be agitated by stirring, shaking or otherwise mixing the mixture to increase the dissolution rate. Typically, the method is performed for about half an hour to about 6 hours. The process temperature range can be about 10°C to about 100°C, for example, about 40°C to about 90°C.

[0066] After the plant fiber is soaked in the extractant, a press can be used to mechanically separate the insoluble plant fiber material from the soluble plant fiber mixture in the extract. Once the soluble fraction is separated from the insoluble fraction, the soluble fraction can be discarded or further processed, for example, by concentration. Any known type of concentrator, such as a vacuum evaporator, can be used to concentrate the soluble fraction. In one embodiment of the present disclosure, the soluble fraction can be highly concentrated. In one embodiment, for example, the soluble fraction can be evaporated to have a final brix of about 5% to about 70%, such as about 15% to about 60%.

[0067] The resulting concentrated soluble fraction may be used in a separate process, or may be later applied to the reconstituted plant material of the present disclosure, as will be described in more detail below.

[0068] The water-insoluble fraction obtained is usually in an unrefined state and comprises particles and fibers. In one embodiment, the insoluble portion can undergo a refining process. For example, the extracted insoluble plant fiber material can be fed by any suitable refining device, such as a conical refiner or a disc refiner. Other refining devices that can be used include a beater, such as a Valley beater, a conical refiner or a disc refiner. After the cocoa material is wetted or combined with water, it can be refined. For example, in one embodiment, when the consistency of the plant fiber material is less than about 10%, for example, less than about 5%, for example, less than about 3%, it can be refined.

[0069] According to the present disclosure, the plant fiber material extracted can be optionally combined with web construction fibers to form a fiber substrate, such as a reconstructed plant material. For example, the plant fiber extracted can be combined with water or an aqueous solution to form a slurry, or alternatively, the extracted fiber can be combined in a solution to form a slurry without incorporating the web construction fiber. In some embodiments, the web construction fiber can increase the tensile strength of the sheet of the reconstructed plant material. When the web is used to construct the fiber, the web construction fiber, such as delignified cellulose fiber, can be combined with the plant fiber material to form a slurry. Whether or not the web is used to construct the fiber, the fiber slurry is then used to form a continuous reconstructed sheet. For example, in one embodiment, the fiber slurry is fed to a papermaking process, which may include a forming wire, a gravity drain, a suction drain, a felt press, and a dryer, such as a Yankee dryer, a drum dryer, etc. For example, in one embodiment, the fiber slurry forms a continuous sheet on a fourdrinier paper machine. One advantage of combining extracted plant fibers with cellulosic fibers is that the resulting fiber furnish can be more easily processed on conventional papermaking equipment, however, it should be noted that in some embodiments, reconstructed plant materials according to the present disclosure may be well suited for use with papermaking equipment without the addition of web building fibers.

[0070] In one embodiment, the fiber slurry is spread onto a porous forming surface and formed into a sheet. Excess water is removed by a gravity drain and / or a suction drain. In addition, various presses can be used to facilitate water removal. The formed sheet can be dried and further processed.

[0071] Various other different methods can also be used to prepare the reconstructed plant material substrate. For example, in one embodiment, the extracted plant fibers and optional web building fibers can be extruded into a reconstructed material. In one embodiment, the reconstructed material can also be subjected to an expansion process. For example, a gas such as carbon dioxide can be used, or an expanded sheet can be prepared by using a foaming agent. Suitable expansion media include starch, pullulan or other polysaccharides, solid foaming agents, inorganic salts and organic acids that provide a gas component in situ, organic gaseous media, inorganic gaseous media, and volatile liquid foaming agents. In addition to sheets, extrusion also allows the formation of rods or strands.

[0072] In one aspect, the reconstructed plant material can be formed according to a cast leaf process. In the cast leaf process, the plant material is chopped and then mixed with other materials, such as a binder, and formed into a slurry. The web-building fibers can be contained in the slurry. To form the material web, the slurry is transferred to a sheet-forming device. The sheet-forming device can be a continuous belt, wherein the slurry can be continuously spread onto the belt. The slurry is distributed on a surface to form a sheet. The sheet is then dried, such as by using heat drying. The sheet can be wound on a bobbin, trimmed, slit, or otherwise manipulated to form a product.

[0073] Although the formation of aerosol-generating materials has been described thus far by first extracting and refining the plant material and then mixing it with other fibers, it should be understood that one or more types of plant fibers can be mixed at the extraction stage so that the plant fibers are simultaneously extracted and refined. Of course, as discussed above, each plant individual can be extracted separately and then mixed with other plant fibers during the pulping / refining process.

[0074] Regardless of the aerosol-generating composition formed, the prepared aerosol-generating composition may also be optionally treated with a soluble portion of the plant fiber, such as a concentrated soluble portion separated from an insoluble portion. The soluble portion may be applied to the web using various application methods, such as spraying, using a size press, dipping, and the like. The amount of water-soluble extract applied to the reconstructed material may depend on various factors and the intended end-use application. Typically, the water-soluble extract may be applied to the reconstructed plant material in an amount that is not sufficient to adversely interfere with the neutral taste of the underlying material. For example, in one embodiment, the water-soluble extract is applied to the reconstructed material so that the reconstructed material contains an amount of up to about 40% by weight, such as an amount of less than about 30% by weight, such as an amount of less than about 20% by weight, such as an amount of less than about 10% by weight, such as an amount of less than about 5% by weight, such as an amount of less than about 1% by weight, and a water-soluble extract in an amount generally greater than about 0.5% by weight.

[0075] III. Filler mixture

[0076] Regardless of the method used, in one embodiment, the reconstructed plant material according to the present disclosure can include a mixture of at least two plant fibers, wherein at least one plant fiber is selected from extracted cocoa husk fibers and at least one plant fiber selected from extracted tobacco (as discussed above, it can include any byproduct of tobacco leaf, tobacco stem, tobacco extraction, or a mixture thereof) or extracted herb fiber. Of course, in one embodiment, in addition to being selected from extracted tobacco or extracted herb fiber, the reconstructed plant material can include cocoa husk fibers, or alternatively, can include a combination of extracted tobacco and extracted herb fiber with extracted cocoa husk fibers. In another embodiment, the reconstructed plant material can include extracted tobacco fiber and extracted herb fiber. In particular, the present disclosure has found that the mixture of the above-mentioned extracted fibers produces a reconstructed plant material that is very suitable as an aerosol-generating material because they produce a pleasant, natural taste and smell, and are not "papery", have good combustion quality, do not contain undesirable active compounds, and can also serve as an excellent carrier for aerosol-generating fillers and topical additives.

[0077] For example, in another embodiment, the reconstructed plant material can be formed by the cocoa husk fiber extracted, and the reconstructed plant material can be mixed with at least one of tobacco material or herbaceous plant material.Tobacco material or herbaceous plant material can be mixed with the reconstructed material as an aerosol generating filler.For example, tobacco material and / or herbaceous plant material can form the second reconstructed plant material as described above individually or together, and mix with the first reconstructed plant material (comprising the cocoa husk fiber extracted), as an aerosol generating filler.In such an embodiment, the filler can comprise discrete and / or loose sheets of the first reconstructed plant material and the second reconstructed plant material, or the first reconstructed plant material and the second reconstructed plant material can be refined together or re-refined to form a single reconstructed plant material comprising fibers from both the first reconstructed plant material and the second reconstructed plant material, then processed as described above to form an aerosol generating material.

[0078] Regardless of the selected method of mixing tobacco material and / or herbal material with reconstructed plant material, in one embodiment, the reconstructed plant material may include extracted cocoa husk fibers and may be mixed with at least one of tobacco material and herbal plant material, or may be mixed with both tobacco material and herbal plant material. Alternatively, the reconstructed plant material includes extracted cocoa husk fibers, which are mixed with at least one of tobacco material and herbal plant material, or may be mixed with both tobacco material and herbal plant material. Regardless of the manner in which tobacco material or herbal plant material is mixed with the reconstructed plant material, the present disclosure has found that the above-mentioned reconstructed plant material and aerosol-generating tobacco or herbal plant material produce reconstructed plant materials that are very suitable as aerosol-generating materials because they produce pleasant, natural taste and smell, and are not "papery", have good burning qualities, do not contain undesirable active compounds, and can also serve as an excellent carrier for aerosol-generating fillers and topical additives.

[0079] For example, as discussed above, the present disclosure has been found that cocoa shells produce pleasant, neutral or natural taste and smell, and can serve as other components, such as tobacco and / or the excellent substrate of the herb fiber extracted, because the organoleptic components of cocoa fiber provide a neutral and natural substrate for other organoleptic components while maintaining good combustion performance. In addition, cocoa fiber is also nicotine-free, and can be refined to contain low or no other active compounds or irritating compounds. Similarly, tobacco and / or herb fiber can be used to form a unique aerosol-generating material with any number of various tastes and smells. Therefore, the present invention has been found that a unique mixture can be formed according to the present disclosure, and the mixture produces various aerosol-generating compounds, and the aerosol-generating compounds have neutral or natural taste and smell, good combustion performance, and active compounds and / or irritating compounds are low in content.

[0080] As described above, the reconstructed plant material of the present disclosure generally comprises plant fibers extracted from one or more of tobacco, cocoa husks, and herbs, optionally in combination with web building fibers. The web building fibers may be incorporated into the reconstructed plant material or the fibrous substrate in an amount sufficient to provide strength and integrity to the resulting material when used. Web building fibers may also be incorporated into the reconstructed plant material to facilitate capture and prevent separation of plant fibers and other plant components from the fibrous substrate.

[0081] Various types of web construction fibers can be optionally used in the reconstruction of plant materials. Of course, it should be understood that in one embodiment, there is no web construction fiber in the reconstruction of plant products or aerosol generating compositions, because in some embodiments, reconstruction of tobacco and / or herbaceous plant fibers or fibers from other plants can form a reconstruction plant material with good or sufficient strength properties. However, in the embodiment using web construction fibers, the web construction fibers can be delignified cellulose fibers. For example, the web construction fibers can include wood pulp fibers, such as softwood fibers or hardwood fibers. Other cellulose fibers that can be used include flax fibers, abaca fibers, bamboo fibers, coconut fibers, cotton fibers, kapok fibers, ramie fibers, jute fibers or mixtures thereof. In a specific embodiment, the web construction fibers only include softwood fibers, or are combined with other fibers such as hardwood fibers, abaca fibers.

[0082] Typically, when used, the web building fibers are present in the reconstructed plant material in an amount greater than about 5% by weight, such as an amount greater than about 10% by weight, such as an amount greater than about 15% by weight, such as an amount greater than about 20% by weight, such as an amount greater than about 25% by weight, such as an amount greater than about 30% by weight, such as an amount greater than about 40% by weight. The web building fibers are typically present in the reconstructed plant material in an amount less than about 55%, such as an amount less than about 50%, such as an amount less than about 45%, such as an amount less than about 30%, such as an amount less than about 25%, or any range therebetween.

[0083] In one embodiment, the web construction fibers incorporated into the reconstructed plant material include a combination of longer fibers and shorter fibers. Longer fibers can generally have an average length greater than about 1.8 mm, for example, greater than about 2 mm, and shorter fibers can generally have an average length less than about 1.5 mm. Longer fibers can be used to improve strength and integrity, while shorter fibers can better retain cocoa fibers and other components in the fiber substrate. In one embodiment, for example, short fibers can be greater than about 5% by weight, for example, greater than about 10% by weight, and generally less than about 20% by weight in the reconstructed plant material. On the other hand, longer fibers can be greater than about 10% by weight, for example, greater than about 20% by weight, and generally less than about 50% by weight, for example, less than about 40% by weight in the reconstructed web material. In one embodiment, shorter fibers include hardwood fibers, and longer fibers include softwood fibers.

[0084] In one embodiment, the reconstructed web material may also include a wetting agent. Wetting agents may be incorporated into the reconstructed plant material for a variety of reasons to provide different benefits and advantages. For example, in one embodiment, a wetting agent may be incorporated into the reconstructed plant material to improve the processability and handling of the resulting fibrous substrate. In an alternative embodiment, the wetting agent may be added to the reconstructed plant material in larger amounts, making the material well suited for use in applications where the material is heated without combustion to produce an inhalable aerosol.

[0085] A variety of different humectants can be incorporated into the reconstituted plant material. For example, the humectant can comprise glycerol, propylene glycol, or a mixture thereof. Other humectants that can be used include: sorbitol, triethylene glycol, lactic acid, glyceryl diacetate, glyceryl triacetate, triethyl citrate, isopropyl myristate, and mixtures thereof, including mixtures with glycerol and / or propylene glycol.

[0086] As described above, the amount of wetting agent applied to the reconstructed plant material can depend on various factors. In one embodiment, for example, the wetting agent is present in the reconstructed plant material in an amount of less than about 5% by weight, such as less than about 3% by weight, and typically greater than about 0.5% by weight, such as greater than about 1% by weight. In other embodiments, the wetting agent can be present in the plant material in an amount greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, and typically less than about 50% by weight, such as less than about 40% by weight, such as less than about 30% by weight, such as less than about 25% by weight. When added to the reconstituted plant material in an amount of about 10% to 40% by weight, such as in an amount of about 12% to about 30% by weight, such as in an amount of about 15% to about 25% by weight, the humectant acts as an aerosol generating agent that promotes aerosol formation when the reconstituted plant material is heated without combustion.

[0087] The reconstructed plant material of the present disclosure may also include various other optional components. For example, in one embodiment, the reconstructed plant material may be optionally treated with a combustion control agent. The combustion control agent may control the combustion rate of the material and / or may act as an ash regulator to improve the consistency (coherency) and / or color of the ash produced when the material is burned.

[0088] For example, the combustion control agent may include a salt of a carboxylic acid. For example, the combustion control agent may include an alkali metal salt of a carboxylic acid, an alkaline earth metal salt of a carboxylic acid, or a mixture thereof. Examples of combustion control agents that can be used include salts of acetic acid, citric acid, malic acid, lactic acid, tartaric acid, carbonic acid, formic acid, propionic acid, glycolic acid, fumaric acid, oxalic acid, malonic acid, succinic acid, nitric acid, phosphoric acid, or a mixture thereof. Specific combustion control agents that can be used include potassium citrate, sodium citrate, potassium succinate, sodium succinate, or a mixture thereof. When present, the combustion control agent can be generally applied to the reconstructed plant material in an amount greater than about 0.1% by weight, such as in an amount greater than about 0.5% by weight, such as in an amount greater than about 1% by weight, and generally less than about 5% by weight, such as less than about 4% by weight, such as less than about 3% by weight, such as less than about 2% by weight.

[0089] The reconstructed plant material of the present invention may also optionally contain fillers. Fillers may include particles incorporated into the reconstructed web material for any desired purpose, such as for promoting the formation of the reconstructed plant material and / or affecting the appearance of the material. The filler particles that can be incorporated into the reconstructed web material can be prepared from calcium carbonate, magnesium oxide, titanium dioxide, kaolin, barium sulfate, silicate, bentonite, mica, or a mixture thereof. Filler particles may optionally be incorporated into the reconstructed web material in an amount greater than about 1% by weight, such as an amount greater than about 5% by weight, such as an amount greater than about 10% by weight, and typically less than about 30% by weight, such as less than about 25% by weight, such as less than about 20% by weight, such as less than about 15% by weight.

[0090] Once the reconstructed plant material forms a fiber substrate as described above, the material can be used as an aerosol generating material for any suitable smoking article or device for heating but not burning material. In one embodiment, the reconstructed plant material can be formed into a loose filler material by first being fed to a chopping or cutting process. For example, the loose filler material can be in the form of a strip, a plurality of strips, fragments or a mixture thereof. The loose filler material can then be packaged in any suitable aerosol generating device or smoking article.

[0091] For example, Figure 1 and Figure 2 The smoking articles shown in FIG. 1 generally comprise cigarettes, which may contain any filler material discussed herein as all or part of the smokable column 12. For illustrative purposes only, one such smoking article is shown in FIG. Figure 1 and 2As shown, the smoking article 10 includes a smokable column 12. The smoking article 10 may also include a wrapper 100 that defines an outer circumferential surface 16 when wrapped around the smokable column 12. The article 10 may also include a filter 26 that may be surrounded by a tipping paper, however, depending on the material of the smokable column, the filter may be optional or omissible.

[0092] The reconstituted plant material of the present disclosure produces an aerosol or smoke having a very neutral and pleasant taste. The aerosol produced by the material has no irritating components. It is particularly advantageous that the reconstituted plant material of the present disclosure is nicotine-free and can therefore be used to produce nicotine-free smoking articles or nicotine-free aerosol-generating products, or can be used to control nicotine delivery in the above products.

[0093] IV. Additives

[0094] In one embodiment, for example, the reconstructed plant material of the present disclosure can be combined with tobacco in the preparation process of the reconstructed plant material to form an aerosol-generating material, which produces an aerosol or smoke with a controlled amount of nicotine compared to the aerosol produced by the tobacco material itself. For example, the reconstructed plant material of the present invention can be combined with any suitable tobacco material in an amount sufficient to produce an aerosol containing a controlled amount of nicotine or tobacco flavoring. For example, in one embodiment, the reconstructed plant material can include a small amount of nicotine, particularly compared to natural tobacco products, and can include about 0.5% or less nicotine by weight of the reconstructed plant material. Alternatively, compared to the above-mentioned low nicotine embodiment, a reconstructed plant material containing a "high" amount of nicotine can be formed so that the reconstructed plant material includes nicotine greater than about 0.5% by weight of the reconstructed plant material.

[0095] As discussed above, in one embodiment, the reconstructed plant material of the present disclosure can be in the form of a loose filler material that is uniformly mixed with a tobacco material or herbal plant material to form an aerosol-generating material with reduced nicotine delivery and a desired taste and smell. For example, the aerosol-generating material can contain the reconstructed plant material of the present disclosure in an amount greater than about 5% by weight, such as an amount greater than about 10% by weight, such as an amount greater than about 20% by weight, such as an amount greater than about 30% by weight, such as an amount greater than about 40% by weight, such as an amount greater than about 50% by weight, such as an amount greater than about 60% by weight, such as an amount greater than about 70% by weight, such as an amount greater than about 80% by weight. The reconstructed plant material of the present disclosure can be combined with tobacco material so that the aerosol generating material produced can include an amount of less than about 90% by weight, such as an amount of less than about 80% by weight, such as an amount of less than about 70% by weight, such as an amount of less than about 60% by weight, such as an amount of less than about 50% by weight, such as an amount of less than about 40% by weight, such as a reconstructed plant material of less than about 30% by weight. For example, in one embodiment, the aerosol generating material can include an amount of about 5% to about 30% by weight, such as a reconstructed plant material of the present disclosure in an amount of about 10% to about 20% by weight. In an optional embodiment, more amounts of reconstructed plant materials can be incorporated into the aerosol generating material. In this embodiment, the reconstructed plant material can be included in the aerosol generating material in an amount of about 30% to about 80% by weight, such as an amount of about 40% to about 60% by weight. The above weight percentages are based on the gross weight of the aerosol generating material. In one embodiment, the remainder of the aerosol generating material may be provided solely by tobacco filler or herbal filler.

[0096] In another embodiment, the reconstructed plant material of the present disclosure, not combined with tobacco material or herbaceous plant material, or in addition to being combined with tobacco material and / or herbaceous plant material, can also be processed with an aerosol delivery composition comprising nicotine, other active compounds or flavorings (including topical additives).For example, an aerosol delivery composition can be topically applied to the reconstructed plant material, so that the nicotine, other active compounds or flavorings of a controlled amount are incorporated into the material. Nicotine, other active compounds or flavorings are applied to the reconstructed plant material and many benefits and advantages can be provided.For example, nicotine, other active compounds or flavorings are applied to the reconstructed plant material to allow the delivery of accurate amounts of nicotine, other active compounds or flavorings when the reconstructed plant material is converted into an aerosol and inhaled. In addition, nicotine, other active compounds or flavorings can be applied to the reconstructed plant material in such a way that the amount of the compound contained in the aerosol generated by the material is uniform and consistent between each suction. Thus, in one embodiment, the reconstituted plant material of the invention may be used to prepare an aerosol-generating material whose taste is neutral and pleasant while still delivering controlled amounts, such as low amounts, of nicotine, other active compounds or flavorings.

[0097] For example, in one embodiment, the aerosol delivery composition applied to the reconstruction plant material can include, particularly a small amount of nicotine compared to natural tobacco products, and can include about 0.5% or less nicotine by weight of the reconstruction plant material. Alternatively, compared with the above-mentioned low nicotine embodiment, a reconstruction plant material comprising "high" amount of nicotine can be formed so that the reconstruction plant material includes nicotine greater than about 0.5% by weight of the reconstruction plant material. Additionally or alternatively, the tobacco material from which all or a portion of nicotine has been extracted can be used to produce tobacco taste and smell, and nicotine can be applied to packaging material separately in the form of an aerosol delivery composition, to better control nicotine levels. In this embodiment, the amount of the tobacco material in the aerosol generating material can be less than about 50% by weight, for example, less than about 40% by weight, for example, less than about 30% by weight, for example, less than about 20% by weight, for example, less than about 10% by weight, and generally greater than about 2% by weight.

[0098] In addition to being combined with tobacco material and / or herbal plant material, it will be appreciated that the reconstituted plant material of the present disclosure may be combined with any suitable aerosol-generating filler material.

[0099] In addition to nicotine, the reconstructed plant materials of the present disclosure are well suited for receiving other aerosol delivery agents. For example, the reconstructed plant materials are highly absorbable and can contain up to 50% by weight of topical additives. In this regard, the reconstructed plant materials of the present disclosure are also well suited for serving as carriers for a variety of different aerosol delivery compositions. For example, each aerosol delivery composition can contain one or more aerosol delivery agents.

[0100] Aerosol delivery compositions that can be applied to the reconstituted plant material of the present disclosure include solutions, suspensions, oils, etc. For example, solutions and suspensions can be applied to the reconstituted plant material and then dried, leaving a solid residue within the fibrous matrix.

[0101] In one embodiment, an aerosol delivery composition can be obtained by extracting plant matter from plants to be applied to reconstructed plant material. Additionally or selectively, the present disclosure may include a step for separating at least one compound from plant matter, concentrating plant matter, or even purifying or eliminating compounds from plant matter to obtain modified plant matter to be applied to reconstructed plant material. Although optional, such a method can cause the original unprocessed plant matter to be converted into modified plant matter, which is in the form of dry extract, liquid extract, solution or separated material based on the desired final properties of the plant matter to be applied to the aerosol generating material. Of course, although the plant matter can be original plant matter or modified plant matter, in one embodiment, the plant matter is applied to the reconstructed plant material after extraction without undergoing any further processing. In addition, although the aerosol delivery composition has been described as extracting from plants, it should be understood that synthetic or naturally occurring aerosol delivery compositions (e.g., without the need for extraction) can also be used.

[0102] Examples of aerosol delivery agents that may be included in the aerosol delivery composition include or may be the following extracts (in addition to nicotine): sugar, licorice extract, menthol, honey, coffee, maple syrup, tobacco, regional plant extracts, plant extracts, tea, fruit extracts, flavoring agents such as cloves, anise, cinnamon, sandalwood, geranium, rose oil, vanilla, caramel, cocoa, lemon oil, cinnamon, spearmint, cumin or ginger, flavoring agents or aromatics such as cocoa, vanilla and caramel, medicinal plants, vegetables, spices, roots, berries, bar, seeks, essential oils, and extracts thereof such as anise oil, clove oil, carvone, etc., artificial flavoring agents and flavor materials such as vanillin and mixtures thereof. The extract applied to the reconstructed plant material may be water-soluble or oil-soluble. Therefore, a variety of different carrier liquids may be used to apply the aerosol delivery agent to the reconstructed plant material.

[0103] Additional components that can be added to the reconstitution material are various flavorants, particularly terpenes. For example, a terpene or a mixture of terpenes can be used to produce a desired aroma and indicate the quality of the product to the user. One or more terpenes can also improve the sensory response to inhalation of the aerosol generated by the reconstitution material.

[0104] A variety of different terpenes can be applied to the reconstructed plant material. Such terpenes include, but are not limited to, pinene, humulene, b-caryophyllene, isopulegol, guaiacol, neryl acetate, neomenthyl acetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranyl acetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyl alcohol, pinane, neomenthyl acetate, alpha-bisabolol, borneol, camphene, camphor, caryophyllene oxide, alpha-cedrene, beta-eudesmol, fenchol, geraniol, isoborneol, nerol, sabinene, alpha-terpineol, and mixtures thereof.

[0105] In one embodiment, various different terpenes can be mixed together so as to simulate the ratios of terpenes present in natural plants. For example, about 2 to about 12 terpenes can be mixed together and applied to the reconstructed plant material. Each terpene can be applied to the reconstructed plant material in an amount greater than about 0.001% by weight and typically less than about 2% by weight. For example, each terpene can be applied in an amount of about 0.01% by weight to about 1.5% by weight. For example, each terpene can be applied in an amount of about 0.1% to about 1.1% by weight.

[0106] Exemplary mixtures of terpenes include α-pinene, β-caryophyllene, and β-pinene; α-humulene, α-pinene, β-caryophyllene, β-pinene, and guaiacol; β-caryophyllene, β-pinene, and d-limonene; β-caryophyllene, β-pinene, and nerolidol; β-caryophyllene, β-pinene, d-limonene, and terpinolene; α-bisabolol, α-pinene, β-caryophyllene, β-myrcene, β-pinene, and d-limonene. Limonene; β-caryophyllene, β-pinene and p-cymene; α-humulene, β-caryophyllene, β-pinene, d-limonene, linalool and nerolidol; β-caryophyllene and β-pinene; β-caryophyllene, β-myrcene and terpinolene; α-pinene, β-caryophyllene, β-pinene, d-limonene; α-humulene, α-pinene, β-caryophyllene, β-myrcene, β-pinene, d-limonene and guaiacol.

[0107] The aerosol delivery composition comprising one or more aerosol delivery agents as described above can be applied to the reconstructed plant material using any suitable method or technique. For example, the aerosol delivery composition can be sprayed or coated onto the fibrous substrate in any suitable manner.

[0108] The reconstructed plant material prepared according to the present invention has excellent mechanical properties and has a very satisfactory and aesthetic appearance. Typically, the reconstructed plant material has a basis weight of greater than about 40 gsm, such as greater than about 45 gsm, such as greater than about 55 gsm. The basis weight of the reconstructed plant material is typically less than about 120 gsm, such as less than about 100 gsm, such as less than about 85 gsm.

[0109] In one embodiment, the reconstructed plant material of the present invention may be formed into a loose filler using various methods, such as extrusion or by cutting and / or chopping the reconstructed material. The filler material prepared according to the present disclosure may have a diameter greater than about 4 cm 3 / g, for example, greater than about 5cm 3 / g, for example greater than about 6cm 3 / g, and is usually less than about 10 cm 3 / g, for example, less than about 8 cm 3 / g filling capacity. The reconstructed plant material can have excellent combustion performance. For example, the reconstructed plant material can have a static combustion rate greater than about 4 mm / mm, such as greater than about 5 mm / mm, and generally less than about 8 mm / mm, such as less than about 7 mm / mm.

[0110] The reconstructed plant material of the present disclosure has excellent taste characteristics while also being nicotine-free and producing relatively small amounts of tar, particularly compared to conventional tobacco materials. Unexpectedly, it has also been found that the reconstructed plant fiber material of the present disclosure does not produce a "papery" taste, even though the material may contain a large amount of cellulose fibers, such as cork fibers. Although unknown, it is believed that when the material is burned or otherwise heated, the extracted cocoa fibers mask or otherwise inhibit any papery taste. This discovery is surprising and completely unexpected.

[0111] Therefore, aerosol-generating materials comprising the reconstructed plant material of the present disclosure can be used in all different types of aerosol-generating products. In one embodiment, for example, the aerosol-generating material of the present disclosure can be formed into a smokeable rod and surrounded by an outer wrapper. The smoking article or cigarette may include a filter located at one end of the smoking article. However, due to the neutral and mild characteristics of the aerosol produced by the reconstructed plant material, and because the reconstructed plant material has no irritating components and is low in nicotine and tar, the cigarettes that can be prepared according to the present disclosure can be filter-free.

[0112] In one embodiment, the reconstructed plant material is formed on a paper forming machine and is in the form of a sheet. The sheet can then be cut into strips and fed to a rotating or stirring drum. When in the drum, the reconstructed plant material can be mixed with one or more humectants and packaging (casing). The packaging can contain various flavorings or mainstream smoke to generate enhanced elements. For example, the packaging can contain licorice, corn syrup and / or sugar. From the drum, the reconstructed plant material can undergo a cutting or grinding process to reduce the material to a desired particle size. The cut reconstructed plant material is sometimes referred to as tobacco shreds. Once cut to the desired size, various aerosol delivery agents or flavorings can be applied to its reconstructed plant material. For example, one or more terpenes can be applied to the reconstructed plant material. Once an aerosol delivery agent is applied to the reconstructed plant material, the reconstructed plant material can be packaged and transported for use in any suitable form. On the one hand, the reconstructed plant material can be fed to a cigarette manufacturing machine for forming the reconstructed plant material into a rod-shaped element. Alternatively, the material can be packaged into a loose form and used as a filler, a heated but non-burned product or snuff for self-rolling products.

[0113] In addition to cigarettes, aerosol-generating materials prepared according to the present disclosure may also include cigars and cigarillos.

[0114] The reconstituted plant material of the present invention may also be used to prepare a snuff product. The snuff product may be a dry product, or may contain a significant amount of moisture.

[0115] When preparing a snuff product, the product may be prepared exclusively from the reconstructed plant material of the present invention, or may be formed from the reconstructed plant material of the present invention mixed with other filler materials. When the reconstructed plant material of the present invention is used to form snuff, the amount of web-building fibers contained in the product may be reduced. For example, the amount of web-building fibers may be less than about 5% by weight, such as less than about 3% by weight. In one aspect, the reconstructed plant material may not contain any web-building fibers. In another embodiment, the reconstructed plant material contains web-building fibers in an amount of about 5% to about 50% by weight.

[0116] To form a snus product, the reconstructed plant material of the present disclosure is ground or cut into a desired size. For example, the particle size can be relatively small, or can be made into strips depending on the end-use application. On the one hand, for example, the material is cut or ground so as to have an average particle size greater than about 50 microns, such as greater than about 100 microns, and generally less than about 3 mm, such as less than about 2 mm. Alternatively, the material can be ground into a powder or granular material, wherein the average particle size is less than about 100 microns.

[0117] If desired, the reconstructed plant material can be subjected to heat treatment.Heat treatment can provide texture and color to the material, and enhance natural taste.After the optional heat treatment step, additives such as pH-adjusting agents and flavoring agents can be added to the mixture.When forming a moist smokeless product, water can be added to the product so that the water content is greater than about 10% by weight, for example, greater than about 20% by weight, for example, greater than about 30% by weight, for example, greater than about 40% by weight, and usually less than about 60% by weight, for example, less than about 50% by weight.If desired, one or more moisturizing agents (moisture agent) can be added to the product to contribute to the moisture retention performance of the mixture.On the one hand, for example, sodium chloride and / or sodium carbonate can be added to the reconstructed plant material.

[0118] Alternatively, the reconstituted plant material can be used to prepare dry snuff, such as dry oral snuff. To prepare dry oral snuff, the material is ground into a powder to which other ingredients such as flavorings are added.

[0119] On the one hand, the smokeless reconstructed plant material can be placed in an oral bag intended for use in the oral cavity, such as by placing the bag between the upper and lower gums of the lips or cheeks. The oral bag product can have a rectangular shape, such as a rectangular shape. The gross weight of the oral bag can generally be in the range of about 0.1g to about 2.5g, such as about 0.2g to about 0.8g. The bag can be made of any suitable saliva-permeable bag material, such as a non-woven fabric. An adhesive can be included in the bag to promote the sealing of the material by ultrasonic welding. For example, the adhesive can be an acrylate polymer. On the one hand, the bag can be formed by a non-woven material comprising regenerated cellulose fibers, such as viscose rayon staple fibers and an adhesive. If desired, the bag material can also include additional flavorings and / or coloring agents.

[0120] In one embodiment, the smoking article prepared according to the present disclosure may also have a deceleration burning tendency feature. For example, the outer wrapper of the smoking article may include a plurality of discrete deceleration burning zones spaced apart axially of the smoking article. For example, in one embodiment, the discrete deceleration burning zone may be in the form of a circular strip. The strip may have such a width that if the smoking article is in a static combustion state, oxygen is limited to keeping a burning ember (coal) for enough length or time period and extinguishing the ember. For example, the strip may have a width generally greater than about 3mm, for example, greater than about 4mm, for example, greater than about 5mm, and generally less than about 10mm, for example, less than about 8mm, for example, less than about 7mm.

[0121] The spacing between the deceleration combustion zone also can change according to multiple variables. The spacing should not be large enough to make the cigarette burn long enough, to ignite the substrate before the ember burns to the deceleration combustion zone. The interval also can affect the thermal inertia of the burning ember, or the ability of the ember burning through the deceleration combustion zone without self-extinguishing. Usually, the strip spacing should be greater than about 5mm, for example, greater than about 10mm, for example, greater than about 15mm, and usually less than about 50mm, for example, less than about 40mm, for example, less than about 30mm. Every kind of smoking article can comprise about 1 to about 3 strips.

[0122] Usually, any suitable slowing down burning composition can be applied to the outer wrapper of smoking article.In one embodiment, for example, slowing down burning composition comprises film-forming material.For example, film-forming material that can be used according to the present invention comprises alginate, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives such as ethyl cellulose, methyl cellulose and carboxymethyl cellulose, starch, starch derivatives etc.

[0123] In a specific embodiment, film-forming material can comprise independent alginate or the alginate of starch combination.Usually, alginate is the derivative of acidic polysaccharide or gum, and it is present in brown algae (Phaeophyceae) brown algae as insoluble mixed calcium, sodium, potassium and magnesium salt.Generally speaking, these derivatives are calcium, sodium, potassium and / or magnesium salt of the high molecular weight polysaccharide composed of D-mannuronic acid and L-guluronic acid of different proportions.Exemplary alginic salt or derivative include ammonium alginate, potassium alginate, sodium alginate, propylene glycol alginate and / or its mixture.

[0124] In one embodiment, relatively low molecular weight alginate can be used. For example, when in an aqueous solution containing 3% by weight, the viscosity of the alginate is less than about 500 cP at 25 ° C. More specifically, the alginate can have a viscosity less than 250 cP, particularly less than 100 cP, and in one embodiment, a viscosity of about 20-60 cP under the above conditions. As used herein, viscosity is determined by a Brookfield LVF viscometer with a suitable rotor that meets the viscosity. At the above-mentioned lower viscosity level, alginate compositions with higher solids content can be formed, but at a sufficiently low solution viscosity, it is still allowed to use conventional techniques to apply the composition to paper packaging. For example, the solids content of the alginate solution prepared according to the present disclosure can be greater than about 6% by weight, particularly greater than about 10%, more particularly from about 10% to about 20%.

[0125] At the above solid content, the alginate composition used according to the present invention may have a solution viscosity of greater than about 250 cP, particularly greater than about 500 cP, more particularly greater than about 800 cP at 25°C, and in one embodiment the viscosity is greater than about 1,000 cP. Generally, the solution viscosity of the alginate film-forming composition can be adjusted according to the manner in which the composition is applied to the packaging. For example, the solution viscosity of the composition can be adjusted according to whether the composition is sprayed onto the packaging or printed onto the packaging.

[0126] In other embodiments, it will also be appreciated that, depending on the application, relatively high molecular weight alginates may be used. For example, the alginate may have a viscosity greater than about 500 cP when contained at 3% by weight in an aqueous solution at 25°C.

[0127] In addition to the film-forming material, the slowing combustion composition applied to the packaging can include various other ingredients. For example, in one embodiment, a filler can be included in the composition. The filler can be, for example, calcium carbonate, calcium chloride, calcium lactate, calcium gluconate, etc. In addition to calcium compounds, other various particles can also be used, including magnesium compounds such as magnesium oxide, clay particles, etc.

[0128] In one embodiment, the deceleration combustion composition can be water-based. In particular, the deceleration combustion composition can include an aqueous dispersion or an aqueous solution. Alternatively, the deceleration combustion composition before being applied to the paper wrapper can include a non-aqueous solution or dispersion. In this embodiment, for example, alcohol can be present to apply the composition to the wrapper.

[0129] In contrast to film-forming compositions, the slowing combustion composition can also include a cellulose slurry (a type of dispersion). As used herein, a slurry comprising a papermaking material is not a film-forming composition. The cellulose slurry applied to the paper substrate can include fibrous cellulose, one or more fillers and / or cellulose particles. As used herein, cellulose fibers and cellulose particles are distinguished from derivatized cellulose such as carboxymethyl cellulose. For example, cellulose fibers and cellulose particles are insoluble in water. In one embodiment, the cellulose slurry applied to the wrapper can include microcrystalline cellulose.

[0130] Once the slowing combustion composition is prepared, the composition can be applied to discrete areas of the packaging. The mode of applying the composition to the packaging can be varied. For example, the composition can be sprayed, brushed, applied or printed on the packaging with a moving hole. In order to form the treated area, the composition can be applied with a single pass or multiple passes. For example, the composition can be applied to the packaging in a continuous step to form a region with a slowing combustion tendency on the packaging. Typically, in multiple methods, the treated area can be formed by applying the composition about 2 times to about 8 times.

[0131] The amount of the combustion-decelerating composition applied to the wrapper can also vary. For example, the composition can be applied to the wrapper in an amount less than about 15% by weight, such as less than about 10% by weight, such as less than about 8% by weight. Typically, the composition is applied in an amount greater than 1% by weight based on the weight of the composition in the combustion-decelerating region.

[0132] As used herein, the above weight percentages are based on the area treated with the chemical composition. In other words, the above weight percentages of the combustion retarding composition are the amount applied in the treated area, relative to the total amount applied over the entire surface of the wrapper.

[0133] By the method of the present disclosure, a slow burn zone having a relatively high permeability while also having a relatively low diffusivity can be produced. For example, the slow burn zone can have a permeability greater than 10 CORESTA while still being able to produce a smoking article that passes ASTM test E2187-09 at least 75% of the time.

[0134] Typically, the deceleration combustion zone has a relatively low diffusivity. The diffusivity can be measured at room temperature (23° C.). Typically, the diffusivity of the deceleration combustion zone at 23° C. is less than about 0.5 cm / s, for example, less than 0.4 cm / s, for example, less than 0.3 cm / s. In one embodiment, the reduced ignition zone can have a diffusivity greater than about 0.05 cm / s, for example, greater than about 0.15 cm / s, for example, greater than 0.16 cm / s, for example, greater than 0.17 cm / s, while still having the desired deceleration combustion tendency characteristics. Use a Sodim CO2 diffusivity tester to measure the diffusivity.

[0135] In addition to being incorporated into smoking articles, the aerosol-generating materials of the present disclosure may also be packaged and sold to users in a variety of other forms. For example, in one embodiment, the aerosol-generating materials may be packaged and sold as filler materials in the form of strips or shreds. The filler materials may then be used in pipes, as fillers in roll-your-own smoking articles, or may be used in aerosol-generating devices that heat but do not burn materials.

[0136] The present invention may be better understood with reference to the following examples.

[0137] Example

[0138] The following test methods were used not only to define the various parameters, but also to obtain the results in the examples below.

[0139] Tests and Methods

[0140] Filling Power and Equilibrium Moisture Content (EMC)

[0141] Samples of filler material were conditioned according to ISO 3402 (22°C + / - 1°C, 60% + / - 3% RH, for a minimum of 48 hours). After conditioning, the material was unrolled and cut into shreds (equipment: BUROMA disc cutter; width: 0.7 mm).

[0142] For the filling force analysis, 14 g of cut filler (accuracy: + / - 0.01 g) was placed in a Borgwaldt cylinder (DM4625 type; diameter = 5.98 cm, height = 10.8 cm). A weight of 2 kg was applied within 60 seconds. When the piston was released, the height of the packed column was displayed and recorded (H, in cm).

[0143] The filling force (in cc / g) of the sample is calculated as: 2 x H.

[0144] The equilibrium moisture content was measured according to the following method: The weight of an empty pan (made of glass) was measured with an accuracy of + / - 1 mg and recorded (T).

[0145] The disc was then filled with cut filler (5 g to 7 g) and the weight of the disc with cut filler was recorded (W1 , accuracy + / - 1 mg).

[0146] The disks with the cut filler were then dried in a Hearson oven (Mark V) at 100°C during 3 hours (+ / - 5 minutes).

[0147] After drying, the disk was cooled in a desiccator within 15 minutes and its weight was measured (W2, accuracy + / - 1 mg).

[0148] The moisture content (%) of the sample is calculated as:

[0149] Water soluble content

[0150] The filler sample was ground into a powder (using an IKA or RETSCHE-MUHLE grinder; mesh size: 1 mm).

[0151] A glass fiber filter (DURIEUX filter NR 28, diameter = 55 mm) is placed in a stainless steel pan. The pan + filter is then tare weighed (T, accuracy + / - 1 mg). 5000 mg (+ / - 200 mg) of ground filler sample is placed in the pan and accurately weighed (W1, accuracy + / - 1 mg).

[0152] The ground filler was lightly sprayed with water and the cup was mounted in a laboratory percolator (Reneka LC). Three extractions were performed according to the predefined percolation settings. After percolation, the samples were carefully washed with water and the discs were dried in an electric oven at 100°C for 16 hours.

[0153] After washing, the disk was cooled in a desiccator within 15 minutes and its weight was measured (W3, accuracy + / - 1 mg).

[0154] The dry weight (W2) of the ground sample for the water solubles test was calculated as: W2 = W1 x (100-H) / 100.

[0155] Finally, the proportion (%) of water-soluble matter in the dry finished product is calculated as follows:

[0156]

[0157] Cigarette preparation

[0158] Condition the filler samples according to ISO 3402 (22°C + / - 1°C, 60% + / - 3% RH, for a minimum of 48 hours). After conditioning, cut the filler sheets into pieces (equipment: BUROMA disc cutter, width: 0.7 mm). Sieve the cut material on a laboratory sieve (mesh size: 1 mm).

[0159] The empty cigarette tubes were then filled with 100% cut filler using a hand rolling machine from PRIVILEG. The weight of the cut filler was adjusted to achieve a pressure drop of 100 + / - 5 mm WG.

[0160] ATC has the following characteristics:

[0161] -Tube weight = 200 ± 5 mg,

[0162] -Total length = 84mm, diameter = 8.1±0.1mm, tipping length = 25mm

[0163] - Acetate filter (fineness = 3.0Y / 35000HK, length = 15 ± 0.5 mm, pressure drop = 43 ± 3 mm WG),

[0164] -Cigarette paper porosity = 50 CU,

[0165] - No filtered ventilation.

[0166] The cigarettes were then sorted on a SODIMAT machine. The cigarette batches selected for smoke analysis had the following characteristics: Filler weight: average target weight + / - 10 mg, Pressure drop: average target PD + / - 3.5 mm WG.

[0167] Prior to smoke analysis, cigarettes were conditioned according to ISO 3402 (22°C + / - 1°C, 60% + / - 3% RH for a minimum of 48 hours).

[0168] Flammability Analysis

[0169] 10 cigarettes were placed on a FILTRONA static burn rate machine having 10 cigarette holders and 10 individual timers.

[0170] Two cotton strings 40 mm apart from each other are fixed just above the 10 cigarettes. Each string is connected to a timer.

[0171] The cigarettes are lit in sequence. For each cigarette, the timer is automatically activated when the combustion cone cuts the front cotton thread. Once the burnt thread reaches the second cotton thread, the timer automatically stops, giving the time to burn the 40mm filler rod.

[0172] Calculate the average time (in seconds) from 10 timers

[0173] The average flammability (in mm / min) is calculated as:

[0174] Analysis of tar, nicotine, water and CO in aerosol

[0175] Two groups of 20 cigarettes were smoked on a Borgwaldt RM20 kit machine under standard ISO conditions (ISO 3308).

[0176] Nicotine and water in smoke (mg / cig) were measured by gas chromatography according to ISO 10315 and ISO 10362-1.

[0177] The tar in smoke is measured according to ISO 4387 (mg / cig).

[0178] The CO (mg / cig) in aerosol was measured by non-dispersive infrared absorption spectroscopy (NDIR) according to ISO 8454.

[0179] Example 1

[0180] A cocoa filler according to the present disclosure comprising fibers derived from the Theobroma cacao tree is manufactured according to the following method: the cocoa husks are ground using a knife grinder so as to obtain particles of about 1 mm in size. The ground husk material is then mixed with water at 70° C. for 45 minutes, with a husk / water ratio of 1 / 10. The mixture is then extruded so as to separate the aqueous part (cocoa husk liquor) from the insoluble part (cocoa husk fibers). The fiber fraction is refined using a disc refiner. After refining, delignified fibers derived from a resin tree (softwood fibers) are added to the refined fiber fraction in a ratio of 40% / 60% delignified fibers / fibers from the cocoa tree according to the present invention so as to prepare a reconstructed cocoa filler sheet. The cocoa filler sheet is then dried.

[0181] Cocoa filler materials exhibit the following characteristics:

[0182]

[0183] Example 2

[0184] A cocoa filler according to the present disclosure comprising fibers derived from the Theobroma cacao tree is manufactured according to the following method: the cocoa husks are ground using a knife grinder so as to obtain particles of about 1 mm in size. The ground husk material is then mixed with water at 70° C. for 45 minutes, with a husk / water ratio of 1 / 10. The mixture is then extruded so as to separate the aqueous portion (cocoa husk liquor) from the insoluble portion (cocoa husk fibers). The fiber fraction is refined using a disc refiner. After refining, delignified fibers derived from a resin tree (softwood fibers) are added to the refined fiber fraction in a ratio of 40% / 60% delignified fibers / cocoa husk fibers in order to prepare a reconstituted cocoa filler sheet. The cocoa filler sheet is then dried. In parallel, the aqueous part derived from the cocoa tree (cocoa husk liquor), also called "extract", prepared as above, was concentrated in an evaporator to a solid concentration of 20% and then applied to the cocoa filler sheet by coating with a size press, with or without coating. Before drying, various other substances were added to the cocoa filler sheet by coating and / or spraying according to the following table:

[0185]

[0186] Several cigarettes (A, B, C, D, E, F, H) were prepared for the purpose of sensory evaluation by a panel of experts. Sample G was evaluated in a PAX 3 system for heat not burn applications.

[0187] The following results are obtained:

[0188]

[0189]

[0190] Example 3

[0191] A cocoa filler according to the present disclosure comprising fibers derived from the Theobroma cacao tree is manufactured according to the following method: the cocoa husks are ground using a knife grinder so as to obtain particles of about 1 mm in size. The ground husk material is then mixed with water at 70° C. for 45 minutes, with a husk / water ratio of 1 / 10. The mixture is then extruded so as to separate the aqueous portion (cocoa husk liquor) from the insoluble portion (cocoa husk fibers). The fiber fraction is refined using a disc refiner. After refining, delignified fibers derived from a resin tree (softwood fibers) are added to the refined fiber fraction in a ratio of 40% / 60% delignified fibers / cocoa tree fibers in order to prepare a reconstituted cocoa filler sheet. The cocoa filler sheet is then dried.

[0192] Tobacco extracts are obtained from the tobacco material prepared as above, to use the aqueous portion (tobacco liquid), also referred to as tobacco "extracts". These extracts are then added to the cocoa filler sheet by coating. For demonstration purposes, some reconstituted tobacco materials are also prepared according to the same method.

[0193] Prepare the following samples:

[0194] A 55% cocoa filler / 30% tobacco extract / 15% glycerin B 63% cocoa filler / 22% tobacco extract / 15% glycerin D 60% cocoa filler / 40% tobacco extract E Control: 60% tobacco fiber / 40% tobacco extract F Control: 55% tobacco fiber / 30% tobacco extract / 15% glycerin

[0195] Sensory evaluation

[0196] - Comparison of Sample A and Sample F in a heat-not-burn device (PAX3). No significant difference. Cocoa filler is neutral. It can replace tobacco fiber.

[0197] - Comparison of Sample D and Sample E under normal cigarette conditions. No significant difference. Cocoa filler is neutral. It can replace tobacco fiber.

[0198] - Comparing Sample A and Sample B in a heat-not-burn device. As expected, Sample B had lower tobacco flavor and nicotine impact.

[0199] Example 4

[0200] The cocoa and tobacco filler according to the present disclosure comprising fibers derived from the cocoa (Theobroma cacao) tree and the tobacco (Nicotania tabcum) plant is manufactured according to the following method: the cocoa husk is ground using a knife grinder so as to obtain particles having a size of about 1 mm. The ground husk material is then mixed with water at 70°C for 45 minutes, with a husk / water ratio of 1 / 10. The mixture is then extruded so as to separate the aqueous portion (cocoa husk liquor) from the insoluble portion (cocoa husk fiber). The fiber fraction is refined with a disc refiner. After refining, the delignified fiber and tobacco fiber derived from the resin tree prepared as above are added to the refined fiber fraction in a ratio of 20% / 60% / 20% delignified fiber / tobacco fiber / cocoa fiber so as to prepare the cocoa and tobacco filler sheet. The cocoa and tobacco filler sheet is then dried.

[0201] In parallel, the aqueous portion (tobacco liquor) derived from the tobacco plant, also called tobacco "extract", is prepared as above, concentrated in an evaporator to a solid concentration of 50%, and then applied by coating with a size press, with or without coating, onto a cocoa and tobacco filler sheet, and later dried. For demonstration purposes, some reconstituted tobacco materials are also prepared according to the same method.

[0202] Prepare the following samples:

[0203]

[0204] Sensory evaluation

[0205] - Comparison of Sample C and Sample F in a heat not burn device (PAX3). No significant difference. Cocoa filler is neutral and can replace tobacco fiber.

[0206] As noted above, a variety of different aerosol generating materials may be prepared in accordance with the present disclosure.

[0207] In one embodiment, the aerosol generating material may comprise a reconstructed plant material containing a combination of extracted plant fibers and extracted tobacco fibers. In one embodiment, the reconstructed plant material may comprise a combination of extracted plant fibers and extracted herbaceous plant fibers. In one embodiment, the reconstructed plant material may comprise a combination of extracted plant fibers and extracted tobacco fibers and extracted herbaceous plant fibers.

[0208] In one embodiment, the aerosol generating material may comprise a reconstructed plant material containing extracted plant fibers, extracted tobacco fibers, and extracted herbaceous plant fibers. In one embodiment, the reconstructed plant material may comprise a combination of extracted plant fibers and extracted tobacco fibers. In one embodiment, the reconstructed plant material may comprise extracted plant fibers and extracted herbaceous plant fibers.

[0209] In any of the above embodiments, the reconstructed plant material may further comprise web building fibers.

[0210] In any of the above embodiments, the web building fibers combined with the reconstructed plant material can vary. In one embodiment, the web building fibers are pulp fibers, such as softwood fibers, hardwood fibers, or mixtures thereof. In one embodiment, the web building fibers comprise softwood fibers and hardwood fibers in a ratio of 1:2 to 2:1. In one embodiment, the web building fibers comprise flax fibers. In one embodiment, the web building fibers are abaca fibers. In one embodiment, the web building fibers are bamboo fibers. In one embodiment, the web building fibers are coconut fibers. In one embodiment, the web building fibers are ramie fibers. In one embodiment, the web building fibers are jute fibers. In one embodiment, the web building fibers are present in the aerosol generating material in an amount greater than about 3% by weight. In one embodiment, the web building fibers are present in the aerosol generating material in an amount greater than about 5% by weight. In one embodiment, the web building fibers are present in the aerosol generating material in an amount greater than about 8% by weight. In one embodiment, the web building fibers are present in the aerosol generating material in an amount greater than about 12% by weight. In one embodiment, the web building fibers are present in the aerosol generating material in an amount greater than about 18% by weight. In one embodiment, the web building fibers are present in the aerosol generating material in an amount less than about 50% by weight, such as less than about 40% by weight.

[0211] In one embodiment, the aerosol generating material may include an aerosol delivery composition applied to the reconstructed plant material. The aerosol delivery composition includes an aerosol delivery agent. In one embodiment, the aerosol delivery agent includes a drug or edible flavor. The aerosol delivery composition may be an oil, an aqueous solution, an aqueous dispersion, or a solid in any one of the embodiments described herein. In one embodiment, the aerosol delivery agent includes nicotine. Nicotine may also be combined with other aerosol delivery agents. In one embodiment, other aerosol delivery agents are sugars. In one embodiment, other aerosol delivery agents include licorice extract. In one embodiment, other aerosol delivery agents include honey. In one embodiment, other aerosol delivery agents include coffee. In one embodiment, other aerosol delivery agents include maple syrup. In one embodiment, other aerosol delivery agents include plant extracts, such as tea extracts or regional plant extracts. In one embodiment, other aerosol generating agents include tobacco extracts. In one embodiment, the aerosol delivery agent includes only tobacco extracts. In one embodiment, the aerosol delivery composition includes terpenes or a mixture of terpenes. The terpene or mixture of terpenes may be used with any aerosol delivery agent as described above, including nicotine.

[0212] The aerosol delivery composition comprising one or more aerosol delivery agents may be present in the reconstructed plant material in an amount greater than about 1% by weight. In one embodiment, the one or more aerosol delivery agents are present in an amount greater than about 3% by weight, such as greater than about 5% by weight. In any of the embodiments described above, the one or more aerosol delivery agents may be present on the reconstructed plant material in an amount less than about 50% by weight, such as less than about 25% by weight.

[0213] In embodiments, the aerosol generating material may include a reconstructed plant material mixed with another material. For example, in embodiments, the aerosol generating material includes a reconstructed plant material containing a tobacco material. In embodiments, the reconstructed plant material may include an extracted plant fiber mixed with a tobacco material. In embodiments, the reconstructed plant material may include an herb material. In embodiments, the reconstructed plant material may include an extracted plant fiber combined with an herb material. In embodiments, the aerosol generating material may include a reconstructed plant material containing an extracted plant fiber and a tobacco material. In embodiments, the aerosol generating material may include a reconstructed plant material containing an extracted plant fiber combined or mixed with an herb material. In embodiments, the aerosol generating material may include a reconstructed plant material containing a tobacco material and an herb material. In one embodiment, the aerosol generating material may include a reconstructed plant material containing an extracted plant fiber mixed with a tobacco material and an herb material.

[0214] The above-mentioned tobacco material may be cut tobacco leaves.

[0215] In one embodiment, the reconstituted plant material comprises extracted plant fibers comprising tobacco fibers. The reconstituted plant material further comprises an aerosol delivery composition comprising an aerosol delivery agent. The aerosol delivery agent may comprise nicotine.

[0216] The aerosol-generating material in any one of the embodiments described above can be used in many different products. In one embodiment, the aerosol-generating material in any one of the embodiments described above can be formed into a suckable rod surrounded by an outer wrapper to form a smoking article. The smoking article can optionally include a filter tip located at one end. Optionally, the wrapper can include a plurality of discrete deceleration combustion zones.

[0217] In one embodiment, any of the aerosol generating materials described above may be used in a heat-not-burn device.

[0218] In any of the aerosol-generating material embodiments described above, the aerosol-generating material may be used as a snus product.

[0219] Those of ordinary skill in the art may implement these and other modifications and variations of the present invention without departing from the spirit and scope of the present invention, which are more specifically set forth in the appended claims. In addition, it should be understood that the aspects of the various embodiments may be interchangeable in whole or in part. In addition, those of ordinary skill in the art will appreciate that the above description is only by way of example and is not intended to limit the invention further described in these appended claims.

Claims

1. An aerosol generating material comprising: A reconstructed plant material comprising a mixture of at least two different plant fibers, the reconstructed plant material comprising: (1) Extracted plant fibers; In combination with: (2)(a) extracted tobacco fibers comprising tobacco leaves, tobacco stems, tobacco extraction by-products, or mixtures thereof; or (b) extracted herbal plant fibres; or (c) mixtures thereof.

2. An aerosol-generating material as defined in any preceding claim, wherein the reconstituted plant material comprises extracted tobacco fibres.

3. An aerosol-generating material as defined in any preceding claim, wherein the reconstituted plant material comprises a combination of extracted plant fibres and extracted tobacco fibres.

4. An aerosol generating material as defined in any preceding claim, wherein the reconstituted plant material comprises extracted plant fibres.

5. An aerosol-generating material as defined in any one of the preceding claims, wherein the reconstituted plant material comprises extracted herbal fibers obtained from: coffee, tea, vines, ginger, ginkgo, chamomile, tomato, ivy, yerba mate, rooibos, cucumber, cereals, turmeric, cloves, liquorice, sandalwood, cinnamon, mint, coriander, cumin, thyme or a mixture thereof.

6. An aerosol generating material as defined in any one of the preceding claims, wherein the reconstituted plant material further comprises web building fibers.

7. An aerosol generating material as defined in claim 6, wherein the web building fibers comprise delignified cellulosic fibers comprising flax fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or mixtures thereof.

8. An aerosol generating material as defined in claim 6 or 7, wherein the web-building fibers are present in the reconstructed plant material in an amount greater than about 3% by weight, such as in an amount greater than about 5% by weight, such as in an amount greater than about 8% by weight, and in an amount less than about 40% by weight.

9. An aerosol-generating material as defined in any preceding claim, wherein the reconstituted plant material has been treated with a wetting agent.

10. An aerosol-generating material as defined in claim 9, wherein the humectant comprises glycerol, propylene glycol or a mixture thereof.

11. An aerosol generating material as defined in claim 9 or 10, wherein the humectant is present in the reconstituted plant material in an amount of 5% by weight or less.

12. An aerosol generating material as defined in claim 9 or 10, wherein the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or more, such as in an amount of about 10% by weight or more, such as in an amount of about 15% by weight or more, and in an amount of about 50% by weight or less.

13. An aerosol generating material as defined in any preceding claim, further comprising an aerosol delivery composition applied to the reconstituted plant material, the aerosol delivery composition comprising an aerosol delivery agent.

14. An aerosol generating material as defined in claim 13, wherein the aerosol delivery agent comprises a medicament or a flavorant.

15. An aerosol generating material as defined in claim 13, wherein the aerosol delivery composition comprises an oil or a solid.

16. An aerosol generating material as defined in claim 13, wherein the aerosol delivery agent comprises nicotine.

17. An aerosol generating material as defined in claim 13, wherein the aerosol delivery agent comprises sugar, licorice extract, honey, coffee extract, maple syrup, tea extract, regional plant extract, plant extract, tobacco extract or fruit extract.

18. An aerosol generating material as defined in claim 13, wherein the aerosol delivery composition comprises a mixture of terpenes.

19. An aerosol generating material as defined in any one of claims 13 to 18, wherein the aerosol delivery composition is present on the reconstructed plant material in an amount greater than about 1% by weight, such as greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, such as greater than about 30% by weight, such as greater than about 35% by weight, such as greater than about 40% by weight, and less than about 50% by weight.

20. An aerosol-generating material as defined in any preceding claim, wherein the reconstituted plant material has a basis weight of from about 40 gsm to about 120 gsm, such as from about 55 gsm to about 85 gsm.

21. An aerosol generating material as defined in any one of the preceding claims, wherein the aerosol generating material is in the form of a filler material comprising a strip, a plurality of strips, fragments or a mixture thereof of the reconstituted plant material.

22. A smoking article comprising an outer wrapper surrounding a smokeable rod comprising an aerosol-generating material as claimed in any preceding claim.

23. The smoking article as defined in claim 22, wherein the wrapper comprises a plurality of discrete burn deceleration zones spaced axially of the smoking article, the burn deceleration zones having a diffusivity of less than about 0.5 cm / s at 23°C.

24. The smoking article as defined in claim 23, wherein the plurality of burn retarding zones have been formed by applying a burn retarding composition to the wrapper.

25. A smoking article as defined in any one of claims 22 to 24, wherein: When the smoking articles are tested according to ASTM test E2187-09, at least 75% of the smoking articles self-extinguish.

26. A smoking article comprising heating means and a chamber containing an aerosol generating material as defined in any one of claims 1 to 21, the heating means being positioned so as to heat the aerosol generating material to produce an inhalable aerosol without combusting the aerosol generating material.

27. An aerosol generating material comprising: Reconstituted plant material comprising: (1) Extracted plant fibers; The reconstituted plant material is mixed with: (1) Tobacco materials; (2) Herbal plant material; or (3) mixtures thereof.

28. An aerosol generating material as defined in claim 27, wherein the reconstituted plant material comprises extracted plant fibres.

29. An aerosol generating material as defined in claim 27 or 28, wherein the reconstituted plant material is mixed with the tobacco material.

30. An aerosol-generating material as defined in any one of claims 27 to 29, wherein the reconstituted plant material is mixed with the herbal plant material, the herbal plant material comprising coffee, tea, vine, ginger, ginkgo, chamomile, tomato, ivy, yerba mate, rooibos, cucumber, cereals, turmeric, cloves, liquorice, sandalwood, cinnamon, mint, coriander, cumin, thyme or a mixture thereof.

31. An aerosol generating material as defined in any one of claims 27 to 30, wherein the reconstituted plant material further comprises web building fibres.

32. An aerosol-generating material as defined in claim 31, wherein the web building fibers comprise delignified cellulosic fibers comprising flax fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or mixtures thereof.

33. An aerosol generating material as defined in claim 31 or 32, wherein the web-building fibers are present in the reconstructed plant material in an amount greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 8% by weight, and in an amount less than about 40% by weight.

34. An aerosol-generating material as defined in any one of claims 27 to 33, wherein the reconstituted plant material has been treated with a wetting agent.

35. An aerosol-generating material as defined in claim 34, wherein the humectant comprises glycerol, propylene glycol or a mixture thereof.

36. An aerosol generating material as defined in claim 34 or 35, wherein the humectant is present in the reconstituted plant material in an amount of 5% by weight or less.

37. An aerosol generating material as defined in claim 34 or 35, wherein the wetting agent is present in the reconstructed plant material in an amount of 5% by weight or more, for example in an amount of about 10% by weight or more, for example in an amount of about 15% by weight or more, and in an amount of 50% by weight or less.

38. An aerosol generating material as defined in any one of claims 27 to 37, further comprising an aerosol delivery composition applied to the reconstituted plant material, the aerosol delivery composition comprising an aerosol delivery agent.

39. An aerosol generating material as defined in claim 38, wherein the aerosol delivery agent comprises a medicament or a flavorant.

40. An aerosol generating material as defined in claim 38, wherein the aerosol delivery composition comprises an oil or a solid.

41. An aerosol generating material as defined in claim 38, wherein the aerosol delivery agent comprises nicotine.

42. An aerosol-generating material as defined in claim 38, wherein the aerosol delivery agent comprises sugar, licorice extract, honey, coffee extract, maple syrup, tea extract, regional plant extract, plant extract, tobacco extract or fruit extract.

43. An aerosol generating material as defined in any one of claims 38 to 42, wherein the aerosol delivery composition is present on the reconstructed plant material in an amount greater than about 1% by weight, such as greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, such as greater than about 30% by weight, such as greater than about 35% by weight, such as greater than about 40% by weight, and less than about 50% by weight.

44. An aerosol-generating material as defined in any one of claims 27 to 43, wherein the reconstituted plant material has a basis weight of from about 40 gsm to about 120 gsm, such as from about 55 gsm to about 85 gsm.

45. An aerosol generating material as defined in any one of claims 27 to 44, wherein the reconstructed plant material is contained in the aerosol generating material in an amount greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, and is present in the aerosol generating material in an amount less than about 90% by weight, such as less than about 80% by weight, such as less than about 70% by weight.

46. ​​An aerosol-generating material as defined in any one of claims 27 to 45, wherein the aerosol-generating material is in the form of a filler material comprising strips, chips or a mixture thereof.

47. An aerosol generating material as defined in claim 29, wherein the reconstituted plant material comprises extracted plant fibers, the extracted plant fibers comprise tobacco fibers, the aerosol generating material further comprises an aerosol delivery composition, the aerosol delivery composition comprises an aerosol delivery agent, the aerosol delivery agent comprises nicotine.

48. A smoking article comprising an outer wrapper surrounding a smokeable rod comprising the aerosol-generating material of any one of claims 27 to 47.

49. The smoking article as defined in claim 48, wherein the wrapper comprises a plurality of discrete burn deceleration zones spaced axially apart from each other in the smoking article, the burn deceleration zones having a diffusivity of less than about 0.5 cm / s at 23°C.

50. The smoking article as defined in claim 49, wherein the plurality of burn retarding zones have been formed by applying a burn retarding composition to the wrapper.

51. A smoking article as defined in any one of claims 48 to 50 wherein: When the smoking articles are tested according to ASTM test E2187-09, at least 75% of the smoking articles are self-extinguishing.

52. A smoking article comprising heating means and a chamber containing an aerosol generating material as defined in any one of claims 27 to 47, the heating means being positioned so as to heat the aerosol generating material to produce an inhalable aerosol without combusting the aerosol generating material.

53. A web building fiber comprising delignified cellulosic fibers comprising flax fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or mixtures thereof.

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