Supported flavor materials for aerosol-generating articles or nicotine-containing products

Abstract

A flavor material (50) for use in an aerosol-generating article is provided, wherein a flavor is releasable from the flavor material upon heating of the flavor material. The flavor material (50) comprises: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavor formulation dispersed within the polysaccharide matrix structure, wherein the flavor formulation is at least partially trapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavor material; and a carrier sheet material, wherein the polysaccharide matrix structure and the flavor formulation are supported by the carrier sheet material. An aerosol-generating article (10) comprising one such flavor material (50) is also provided.

Description

[0001] The present disclosure relates to a flavor material for use in an aerosol-generating article. Furthermore, the present disclosure relates to an aerosol-generating article comprising such a flavor material.

[0002] Aerosol-generating articles in which an aerosol-generating substrate (e.g., a tobacco-containing substrate or a non-tobacco nicotine-containing substrate) is heated rather than burned are known in the art. Typically, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which may be positioned in contact with, inside, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. When the released compounds cool, the compounds condense to form an aerosol.

[0003] Several aerosol generating devices for consuming aerosol generating articles are disclosed in the art. Such devices include, for example, electrically heated aerosol generating devices, wherein an aerosol is generated by transferring heat from one or more electrical heater elements of the aerosol generating device to an aerosol generating substrate of the aerosol generating article. For example, electrically heated aerosol generating devices comprising internal heater blades adapted to be inserted into the aerosol generating substrate have been proposed. As an alternative, an inductively heatable aerosol generating article comprising an aerosol generating substrate and a susceptor arranged within the aerosol generating substrate has been proposed by WO 2015 / 176898.

[0004] It has been proposed to include a flavour source in addition to the aerosol-generating substrate in aerosol-generating articles. Indeed, this practice is relatively common in conventional filter cigarettes, and many solutions have been described in the art for providing flavours somewhere in the mouthpiece filter or in the tobacco cut filler rod.

[0005] However, given the way in which the aerosol is generated in an aerosol-generating article and how the aerosol is delivered to the consumer, ensuring consistent flavor delivery during use may be difficult, and as a result, the consumer may perceive the flavor intensity to fluctuate or decrease over time. In addition, even before the aerosol-generating article is used, some flavor species may be lost during certain production steps or during transportation and storage of the aerosol-generating article.

[0006] It has been previously proposed to reduce the loss of volatile flavors from conventional filter cigarettes during storage by flavor encapsulation, for example in the form of capsules or microcapsules containing flavor formulations. The encapsulated flavors can be released by opening the packaging structure before or during smoking the filter cigarette, for example by manually crushing the structure. However, the encapsulated flavors are typically released from the packaging structure in a single burst, and therefore such solutions may not provide sustained, intense flavor delivery during use of the article.

[0007]

[0006] Accordingly, there is a need to provide flavour materials, and aerosol-generating articles containing flavour materials, that are associated with enhanced flavour perception by consumers, particularly towards the end of the life cycle of the aerosol-generating article.

[0008] The present disclosure relates to a flavor material for use in an aerosol generating article, wherein a flavor formulation can be released from the flavor material upon heating the flavor material. The flavor material can include a matrix structure and a flavor formulation dispersed within the matrix structure. The flavor formulation is at least partially captured within the matrix structure and can be released from the matrix structure upon heating the flavor material. The matrix structure can be a polysaccharide matrix structure. The flavor material can include a carrier sheet material, the polysaccharide matrix structure and the flavor formulation being supported by the carrier sheet material.

[0009] According to one aspect of the present invention, there is provided a flavor material for use in an aerosol generating article; the flavor material comprises: a polysaccharide matrix structure; and a flavor formulation dispersed within the polysaccharide matrix structure. The flavor formulation is at least partially captured within the polysaccharide matrix structure and can be released from the polysaccharide matrix structure when the flavor material is heated. The flavor material comprises a carrier sheet material, and the polysaccharide matrix structure and the flavor formulation are supported by the carrier sheet material.

[0010] As used herein, the term "sheet material" refers to a layered material having a width and length much greater than its thickness. For example, the carrier sheet material can be a sheet of homogenized tobacco material or a sheet of paper material. The example of a homogenized tobacco material suitable for making flavor material according to the present invention will be described in more detail below.

[0011] As used herein with reference to the present invention, the term "aerosol-generating article" is used to describe an article comprising an aerosol-generating substrate, which is heated to generate an inhalable aerosol for delivery to a user.

[0012] As used herein with reference to the present invention, the term "aerosol-generating substrate" is used to describe a substrate comprising an aerosol-generating material which is capable of releasing volatile compounds that can generate an aerosol upon heating.

[0013] As used herein with reference to the present invention, the term "aerosol" is used to describe a dispersion of solid particles or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include vapors of substances that are normally liquid or solid at room temperature, as well as solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0014] As used herein with reference to the present invention, the term "aerosol-generating device" is used to describe a device that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0015] The aerosol-generating article according to the present invention has a proximal end through which, in use, the aerosol leaves the aerosol-generating article for delivery to a user. The proximal end of the aerosol-generating article may also be referred to as the downstream end or mouth end of the aerosol-generating article. In use, the user directly or indirectly draws on the proximal end of the aerosol-generating article in order to inhale the aerosol generated by the aerosol-generating article.

[0016] The aerosol-generating article according to the present invention has a distal end. The distal end is opposite to the proximal end. The distal end of the aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0017] Components of an aerosol-generating article according to the invention may be described as being upstream or downstream of each other based on their relative position between the proximal end of the aerosol-generating article and the distal end of the aerosol-generating article.

[0018] As used herein with reference to the present invention, the term "longitudinal" is used to describe the direction between the upstream and downstream ends of the aerosol-generating article.During use, air is drawn through the aerosol-generating article in the longitudinal direction.

[0019] As used herein with reference to the present invention, the term "length" is used to describe the largest dimension of an aerosol-generating article or a component of an aerosol-generating article in the longitudinal direction.

[0020] As used herein with reference to the present invention, the term "transverse" is used to describe a direction perpendicular to the longitudinal direction. Unless otherwise stated, references to a "cross-section" of an aerosol-generating article or component of an aerosol-generating article refer to a cross-section.

[0021] As used herein with reference to the present invention, the term "width" refers to the largest dimension of an aerosol-generating article or a component of an aerosol-generating article in the transverse direction. In the case where the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. In the case where a component of an aerosol-generating article has a substantially circular cross-section, the width of a component of an aerosol-generating article corresponds to the diameter of the component of an aerosol-generating article.

[0022] As used herein with reference to the present invention, the term "hollow tubular element" is used to refer to a generally cylindrical element having a lumen along its longitudinal axis. The tubular portion may have a generally circular, oval or elliptical cross-section. The lumen may have a generally circular, oval or elliptical cross-section. In particular, the term "hollow tubular element" is used to refer to an element defining at least one gas flow conduit that establishes uninterrupted fluid communication between an upstream end of the hollow tubular element and a downstream end of the tubular element.

[0023] It has been found that the inclusion of a carrier sheet material in the flavor material according to the invention increases the structural strength of the flavor material because the carrier sheet material supports the polysaccharide matrix that captures the flavor formulation and holds it in place. By selecting and adjusting certain properties of the carrier sheet material (e.g., its thickness), a flavor material that is particularly resistant to wear and tear and has particularly good mechanical properties can be obtained.

[0024] Compared to flavour materials having a comparable composition and matrix structure but lacking the support of a carrier sheet material, it has therefore been found that the flavour material according to the invention is easier to handle and can be stored more conveniently, for example in the form of a cartridge. This advantageously facilitates its incorporation into aerosol-generating articles, in particular within the framework of a high-speed automated manufacturing process.

[0025] The flavor material according to the present invention also has the following advantages: the polysaccharide matrix structure and the flavor formulation entrapped therein can be deposited onto a carrier sheet material to form a flavor material that is actually in sheet form and can therefore be cut into pieces having a predetermined average size (e.g., a predetermined cut width or a predetermined cut length or both). This makes it easy to combine the flavor material according to the present invention with an aerosol-generating substrate in certain aerosol-generating articles, as will be described in more detail below.

[0026] In some embodiments, the carrier sheet material may alternatively comprise a plurality of fragments cut from a sheet material, the fragments having a predetermined average size (e.g., a predetermined cut width or a predetermined cut length or both). As an alternative, the carrier material may comprise a plurality of fragments cut from naturally occurring plant material, preferably plant leaf material (e.g., tobacco leaves).

[0027] In the flavor material according to the present invention, the polysaccharide matrix structure of the flavor preparation can be formed in situ on the carrier sheet material. If this in situ forming step is carried out after the manufacturing process from which the carrier sheet material can be obtained, the in situ forming step can even be carried out at a later date or at a different location.

[0028] In general, it has been recognized that the use of flavor materials in aerosol-generating articles (where the aerosol-generating substrate is intended to be heated to generate an aerosol) presents different challenges and imposes different limitations than what has been encountered in the past with conventional cigarettes (where the substrate is burned to generate smoke). The inventors have discovered that by adjusting the relative proportions of the various ingredients in the formulation or by changing the composition of the substrate (e.g., by selecting a combination of certain polysaccharides to form the substrate), or by doing both, certain properties of the flavor material can be advantageously finely tailored to specific needs associated with use in an aerosol-generating article. For example, the flavor release profile can be adjusted so that the flavor is released in a more continuous "wave" during use. As a result, the consumer may perceive the flavor note more intensely or for a longer period of time during use. Thus, the flavor material according to the present invention can provide a wider width of the flavor profile that is not obtainable with known flavor materials.

[0029] When flavour materials according to the present invention are incorporated into an aerosol-generating article, such as a heat-not-burn article configured to generate an aerosol upon heating a tobacco-containing aerosol-generating substrate, it has been found that the puff-by-puff flavour release is generally more effective.

[0030] Because the flavor formulation is at least partially trapped within the matrix before being released upon heating, the flavor material according to the present invention has been found to exhibit increased stability. For example, even under stress conditions, a significant reduction in the loss of flavor species during storage, transportation, etc. has been observed. Coupled with the enhanced flavor release, this allows for particularly efficient use of flavors and other ingredients of the flavor formulation.

[0031] Preferably, the polysaccharide matrix structure comprises gellan gum and an emulsifier. The term "gellan gum" is used to identify a water-soluble anionic polysaccharide produced by the bacterium Sphingomonas elodea. The repeating unit of the polymer is a tetrasaccharide consisting of two D-glucose residues and one L-rhamnose residue and one D-glucuronic acid residue. Gellan gum has been approved by authorities in many jurisdictions, including Japan, the United States, Canada, China, South Korea and the European Union, for food, non-food, cosmetic and pharmaceutical uses.

[0032] Two forms of gellan gum are known, high acyl gellan gum and low acyl gellan gum, which differ in the degree / percentage of substitution with O-acyl groups.

[0033] In the flavor material according to the present invention, gellan gum is preferably low acyl gellan gum. This is partially deacylated or fully deacylated gellan gum. Its most common form is a fully deacylated form without detectable acyl groups, also known as deacylated gellan gum.

[0034] It is preferred to use low acyl gellan gum to form the polysaccharide matrix of the flavor material according to the present invention because low acyl gellan gum is able to form gels at very low concentrations. In addition, the texture of gellan gum-based gels varies with the acyl content, with low acyl gellan gum generally forming firmer, less elastic and more brittle gels than high acyl gellan gum.

[0035] In embodiments where the polysaccharide matrix structure comprises gellan gum and an emulsifier, a flavor material can be advantageously provided in which a significant portion of the flavor formulation is effectively captured within the polysaccharide matrix structure. This is beneficial because it will improve the stability of the flavor material. In addition, as will be discussed in more detail below, it will affect the release pattern of flavors when the flavor material is heated, and thus can help adjust the flavor release profile during use.

[0036] In addition, from a manufacturing perspective, a stable polysaccharide matrix structure comprising gellan gum and an emulsifier can be formed by supplying heat to the starting reagents without the need to use a crosslinking agent. In fact, by kneading and emulsifying the flavor formulation and gellan gum in a heated water bath, the polysaccharide-encapsulated flavor can be in an emulsified state, which is then substantially maintained after drying and cooling. Advantageously, this allows a large amount of flavor to be provided in a fixed state within the polysaccharide matrix, and thus a flavor material with a high flavor content can be provided.

[0037] Preferably, the emulsifier is lecithin. It is advantageous to use lecithin as an emulsifier because it is generally available and generally considered to be non-toxic. Like gellan gum, lecithin is commonly used as an additive in the food industry and has been approved for such use by the U.S. Food and Drug Administration and EU authorities. Therefore, the pairing of gellan gum and lecithin is particularly suitable for inclusion in flavor materials for human use.

[0038] Preferably, where the polysaccharide matrix comprises gellan gum and an emulsifier, the gellan gum comprises 5 to 99.9 wt % of the flavouring material on a dry weight basis.

[0039] More preferably, gellan gum comprises at least 7% by weight of the flavouring material on a dry weight basis, even more preferably at least 10% by weight of the flavouring material on a dry weight basis.

[0040] Gellan gum preferably accounts for up to 80% by weight of the flavor material on a dry weight basis, more preferably up to 60% by weight of the flavor material on a dry weight basis, even more preferably up to 40% by weight of the flavor material on a dry weight basis, and particularly preferably up to 30% by weight of the flavor material on a dry weight basis.

[0041] In some embodiments, gellan gum accounts for 5% to 80% by weight of the flavor material on a dry weight basis, preferably 5% to 60% by weight of the flavor material on a dry weight basis, more preferably 5% to 40% by weight of the flavor material on a dry weight basis, and even more preferably 5% to 30% by weight of the flavor material on a dry weight basis.

[0042] In other embodiments, gellan gum accounts for 10% to 80% by weight of the flavor material on a dry weight basis, preferably 10% to 60% by weight of the flavor material on a dry weight basis, more preferably 10% to 40% by weight of the flavor material on a dry weight basis, and even more preferably 10% to 30% by weight of the flavor material on a dry weight basis.

[0043] The emulsifier may comprise 0.01% to 2% by weight of the flavor material on a dry weight basis. Preferably, the emulsifier comprises 0.02% to 2% by weight of the flavor material on a dry weight basis. More preferably, the emulsifier comprises 0.05% to 2% by weight of the flavor material on a dry weight basis. Even more preferably, the emulsifier comprises 0.1% to 2% by weight of the flavor material on a dry weight basis.

[0044] In a preferred embodiment, the emulsifier is lecithin and accounts for 0.01% to 2% by weight of the flavor material on a dry weight basis. Preferably, lecithin accounts for 0.02% to 2% by weight of the flavor material on a dry weight basis. More preferably, lecithin accounts for 0.05% to 2% by weight of the flavor material on a dry weight basis. Even more preferably, lecithin accounts for 0.1% to 2% by weight of the flavor material on a dry weight basis.

[0045] In certain embodiments, the polysaccharide matrix structure comprises gellan gum as the only polysaccharide.

[0046] In other embodiments, the polysaccharide matrix structure comprises gellan gum in combination with at least one other polysaccharide selected from guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose.

[0047] It has been found that the flavor material according to the present invention, wherein the polysaccharide matrix structure comprises a combination of gellan gum and one or more polysaccharides listed above, provides different flavor release profiles when heated. For example, in an embodiment wherein the polysaccharide matrix structure comprises another combination of gellan gum and the polysaccharides listed above, a flavor release profile characterized by two different peaks at two different temperatures has been observed. Without wishing to be bound by theory, it is speculated that this is due to different interaction strengths between the flavor and each polysaccharide in the matrix structure, and may also be related to thermal decomposition of each polysaccharide at slightly different temperatures.

[0048] Since different polysaccharide combinations in the matrix structure will generally result in slightly different flavor release profiles when the flavor material is heated, embodiments in which gellan gum is combined with one or more of the other polysaccharides listed above can be advantageously used to fine-tune the flavor release during use of an aerosol-generating article containing the flavor material. In addition, different flavor materials, each containing a polysaccharide matrix structure comprising a different polysaccharide combination, can be used in combination in a single aerosol-generating article to further adjust and control the flavor delivery during the entire use cycle of the aerosol-generating article. For example, combining different flavor materials according to the present invention in a single aerosol-generating article (where the different flavor materials are adapted to release a majority of the flavor at different temperatures or at different times during the use cycle) can help keep the overall flavor delivery generally consistent throughout.

[0049] In flavor material embodiments where the matrix structure comprises a combination of gellan gum and at least one of the additional polysaccharides listed above, the at least one additional polysaccharide may comprise at least 0.01% by weight of the flavor delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide comprises at least 0.1% by weight of the flavor delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide comprises at least 1.0% by weight of the flavor delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide comprises at least 2.0% by weight of the flavor delivery material on a dry weight basis. In particularly preferred embodiments, the at least one additional polysaccharide comprises at least 5% by weight of the flavor delivery material on a dry weight basis.

[0050] In flavor material embodiments where the matrix structure comprises a combination of gellan gum and at least one of the additional polysaccharides listed above, the at least one additional polysaccharide may comprise 80% by weight or less of the flavor delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide comprises 35% by weight or less of the flavor delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide comprises 25% by weight or less of the flavor delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide comprises 15% by weight or less of the flavor delivery material on a dry weight basis.

[0051] In some embodiments, the at least one additional polysaccharide comprises 1.0 wt % to 35 wt % or less of the flavor delivery material on a dry weight basis, preferably 2.0 wt % to 35 wt % or less of the flavor delivery material on a dry weight basis, and more preferably 5.0 wt % to 35 wt % or less of the flavor delivery material on a dry weight basis.

[0052] In other embodiments, the at least one additional polysaccharide comprises 1.0 wt % to 25 wt % or less of the flavor delivery material on a dry weight basis, preferably 2.0 wt % to 25 wt % or less of the flavor delivery material on a dry weight basis, and more preferably 5.0 wt % to 25 wt % or less of the flavor delivery material on a dry weight basis.

[0053] In a further embodiment, the at least one additional polysaccharide comprises 1.0 wt % to 15 wt % or less of the flavor delivery material on a dry weight basis, preferably 2.0 wt % to 15 wt % or less of the flavor delivery material on a dry weight basis, more preferably 5.0 wt % to 15 wt % or less of the flavor delivery material on a dry weight basis.

[0054] The flavor material may comprise at least 0.01% flavor by weight on a dry weight basis. Preferably, the flavor material comprises at least 1% flavor by weight on a dry weight basis. More preferably, the flavor material comprises at least 5% flavor by weight on a dry weight basis. Even more preferably, the flavor material comprises at least 10% flavor by weight on a dry weight basis.

[0055] In certain embodiments, the flavor material comprises at least 20% flavor by weight on a dry weight basis, preferably at least 25% flavor by weight on a dry weight basis, and more preferably at least 30% flavor by weight on a dry weight basis.

[0056] The flavor material may comprise up to 90% by weight flavor on a dry weight basis. Preferably, the flavor material may comprise up to 85% by weight flavor on a dry weight basis. More preferably, the flavor material may comprise up to 80% by weight flavor on a dry weight basis. Even more preferably, the flavor material may comprise up to 75% by weight flavor on a dry weight basis.

[0057] In certain preferred embodiments, the flavor material comprises 20 to 80% flavor by weight on a dry weight basis, preferably 25 to 80% flavor by weight on a dry weight basis, and more preferably 30 to 80% flavor by weight on a dry weight basis.

[0058] In other preferred embodiments, the flavor material comprises 20 wt% to 75 wt% flavor on a dry weight basis, preferably 25 wt% to 75 wt% flavor on a dry weight basis, and more preferably 30 wt% to 75 wt% flavor on a dry weight basis.

[0059] Flavours suitable for inclusion in the flavour formulation of the flavour material according to the present invention include, but are not limited to, menthol, limonene and eugenol.

[0060] Menthol is a monoterpenoid that can be produced synthetically or obtained from the oil of peppermint or other mints. It imparts a minty, cooling flavor note.

[0061] Limonene is a cyclic monoterpene commonly found in the oils of citrus peels. It is also a component of the aromatic resins of many coniferous and hardwood trees. It imparts citrus-like flavor notes.

[0062] Eugenol is an allyl chain-substituted guaiacol found in the essential oils of cloves, nutmeg, cinnamon, basil, and bay leaf. It imparts spicy, clove-like flavor notes.

[0063] The present inventors have found that menthol and limonene can be entrapped and immobilized within a polysaccharide matrix quite easily and, therefore, flavour materials comprising flavour formulations containing menthol, limonene or a mixture thereof show very good stability.

[0064] In a preferred embodiment, the flavor preparation comprises menthol.

[0065] The flavor material may comprise at least 0.01 wt% menthol by dry weight. Preferably, the flavor material comprises at least 1 wt% menthol by dry weight. More preferably, the flavor material comprises at least 5 wt% menthol by dry weight. Even more preferably, the flavor material comprises at least 10 wt% menthol by dry weight.

[0066] In certain embodiments, the flavor material comprises at least 20% menthol by weight on a dry basis, preferably at least 25% menthol by weight on a dry basis, and more preferably at least 30% menthol by weight on a dry basis.

[0067] The flavor material may comprise up to 90% by weight of menthol on a dry weight basis. Preferably, the flavor material may comprise up to 85% by weight of menthol on a dry weight basis. More preferably, the flavor material may comprise up to 80% by weight of menthol on a dry weight basis. Even more preferably, the flavor material may comprise up to 75% by weight of menthol on a dry weight basis.

[0068] In certain preferred embodiments, the flavor material comprises 20 to 80 weight percent menthol on a dry weight basis, preferably 25 to 80 weight percent menthol on a dry weight basis, and more preferably 30 to 80 weight percent menthol on a dry weight basis.

[0069] In other preferred embodiments, the flavor material comprises 20 to 75 weight percent menthol on a dry weight basis, preferably 25 to 75 weight percent menthol on a dry weight basis, and more preferably 30 to 75 weight percent menthol on a dry weight basis.

[0070] In some embodiments, the flavor formulation comprises granular plant material. Granular plant material can be obtained by crushing, grinding or pulverizing plant material such as plant leaves, plant stems, flowers, seeds, etc.

[0071] It has advantageously been found that the use of particulate plant material provides a stable way of incorporating flavour compounds into the flavour material according to the invention, which enables optimised delivery of flavour into the aerosol during use.

[0072] In some preferred embodiments, the granular plant material is selected from one or more of the following: clove particles, star anise particles, rosemary particles, peppermint particles, sage particles, chamomile particles and lavender particles. Preferably, the granular plant material is selected from clove particles, star anise particles and rosemary particles. More preferably, the granular plant material consists of clove particles.

[0073] As is well known, cloves are the effective dried flower buds and stems of the tree Syzygium aromaticum of the Myrtaceae family and are commonly used as a flavoring agent. Thus, each clove includes the sepals of the calyx and the corolla of the unopened petals, which form a bulbous portion attached to the calyx. The term "clove particles" as used herein includes particles derived from clove flower buds and stems, and may include whole cloves, ground or crushed cloves, or cloves that have been subjected to other physical treatments to reduce particle size.

[0074] It is desirable in certain markets to provide clove particles in the flavor material for use in aerosol-generating articles because it provides a unique sensory user experience that is popular among some users.

[0075] Cloves have a unique aromatic smell, which is due to the presence of one or more flavors in the plant material, which are volatile compounds and evaporate when heated. The main component of clove essential oil is eugenol (4-allyl-2-methoxyphenol, chemical formula: C10H12O2, Chemical Abstracts Service Registration No. 97-53-0). Eugenol is considered to be the compound that mainly causes the clove flavor and usually accounts for about 70% to about 90% of the clove essential oil. However, the clove flavor also includes other compounds, such as but not limited to acetyl eugenol, β-caryophyllene and vanillin, maslinic acid, tannic acids (such as tannin, gallotannic acid, methyl salicylate), flavonoids eugenol, camphor, rhamnetin and eugenol, triterpenoids (such as oleanolic acid and sesquiterpenes). The presence of clove flavor can be determined by measuring the eugenol content in the aerosol generated when the plant material is heated. However, the presence of clove flavoring may also be determined by measuring the levels of other compounds present in clove essential oil, including but not limited to those listed above.

[0076] Preferably, the flavour material comprises at least 0.001 wt% of particulate plant material. More preferably, the flavour material comprises at least 0.01 wt% of particulate plant material. Even more preferably, the flavour material comprises at least 0.1 wt% of particulate plant material.

[0077] In particularly preferred embodiments, the flavour material comprises at least 1 wt% particulate plant material, preferably at least 2 wt% particulate plant material, more preferably at least 5 wt% particulate plant material, even more preferably at least 10 wt% particulate plant material.

[0078] Preferably, the flavour material comprises less than or equal to 80% by weight of particulate plant material. More preferably, the flavour material comprises less than or equal to 70% by weight of particulate plant material. Even more preferably, the flavour material comprises less than or equal to 60% by weight of particulate plant material.

[0079] In some embodiments, the flavor material comprises 1 wt% to 80 wt% of the particulate plant material, preferably 2 wt% to 80 wt% of the particulate plant material, more preferably 5 wt% to 80 wt% of the particulate plant material, even more preferably 10 wt% to 80 wt% of the particulate plant material.

[0080] In other embodiments, the flavor material comprises 1 wt% to 70 wt% of the particulate plant material, preferably 2 wt% to 70 wt% of the particulate plant material, more preferably 5 wt% to 70 wt% of the particulate plant material, even more preferably 10 wt% to 70 wt% of the particulate plant material.

[0081] In a further embodiment, the flavor material comprises 1 wt% to 60 wt% of the particulate plant material, preferably 2 wt% to 60 wt% of the particulate plant material, more preferably 5 wt% to 60 wt% of the particulate plant material, even more preferably 10 wt% to 60 wt% of the particulate plant material.

[0082] In some embodiments, the flavor material further comprises a compound having formula C n H 2n+2 O n of polyols.

[0083] The term "polyol" is used herein to describe an organic compound containing two or more hydroxyl groups. Polyols containing two, three, and four hydroxyl groups may also be referred to as diols, triols, and tetraols, respectively.

[0084] Preferred polyols for inclusion in the flavoring material according to the present invention include glycerol, sorbitol, xylitol, mannitol and erythritol.

[0085] Incorporating a polyol into the flavour material has a beneficial effect on its flexibility. This may make the flavour material easier to handle and have a predetermined form, thereby facilitating its incorporation into an aerosol-generating article.

[0086] Preferably, in the embodiment where the flavor material comprises a polyol as described above, the polyol comprises 0.01 wt % to 20 wt % of the flavor material on a dry weight basis. More preferably, the polyol comprises 0.01 wt % to 15 wt % of the flavor material on a dry weight basis. Even more preferably, the polyol comprises 0.01 wt % to 10 wt % of the flavor material on a dry weight basis.

[0087] In some embodiments, the flavor material comprises fibers, preferably cellulose fibers. The incorporation of fibers, especially cellulose fibers, can advantageously improve the tensile strength of the flavor material, particularly when it is provided in sheet form. This will facilitate the manufacturing process of both the flavor material itself and the aerosol-generating article comprising the flavor material. This benefit can be particularly felt in those embodiments in which the polysaccharide matrix entrapping the flavor formulation is not supported by a carrier material.

[0088] The present inventors have found that the inclusion of fibres can increase the structural strength of the flavour material, which is particularly beneficial in those embodiments where the polysaccharide matrix of the flavour entrapping formulation is not supported by a carrier sheet material.

[0089] In the flavor material embodiment comprising cellulose fibers, the cellulose fibers may account for at least 0.01% by weight of the flavor material on a dry weight basis. Preferably, the cellulose fibers account for at least 0.05% by weight of the flavor material on a dry weight basis. More preferably, the cellulose fibers account for at least 0.5% by weight of the flavor material on a dry weight basis. Even more preferably, the cellulose fibers account for at least 1.0% by weight of the flavor material on a dry weight basis. In a particularly preferred embodiment, the cellulose fibers account for at least 2.0% by weight of the flavor material on a dry weight basis.

[0090] The cellulose fibers may comprise 10% or less by weight of the flavor material on a dry weight basis. Preferably, the cellulose fibers comprise 8.0% or less by weight of the flavor material on a dry weight basis. More preferably, the cellulose fibers comprise 7.0% or less by weight of the flavor material on a dry weight basis. Even more preferably, the cellulose fibers comprise 5.0% or less by weight of the flavor material on a dry weight basis.

[0091] In some embodiments, the fiber accounts for 0.01% to 10% by weight of the flavor material on a dry weight basis. Preferably, the fiber accounts for 0.01% to 8.0% by weight of the flavor material on a dry weight basis. More preferably, the fiber accounts for 0.01% to 7.0% by weight of the flavor material on a dry weight basis. Even more preferably, the fiber accounts for 0.01% to 5% by weight of the flavor material on a dry weight basis.

[0092] In other embodiments, the fiber accounts for 1.0% to 10% by weight of the flavor material on a dry weight basis. Preferably, the fiber accounts for 1.0% to 8.0% by weight of the flavor material on a dry weight basis. More preferably, the fiber accounts for 1.0% to 7.0% by weight of the flavor material on a dry weight basis. Even more preferably, the fiber accounts for 1.0% to 5% by weight of the flavor material on a dry weight basis.

[0093] In a further embodiment, the fiber accounts for 2.0% to 10% by weight of the flavor material on a dry weight basis. Preferably, the fiber accounts for 2.0% to 8.0% by weight of the flavor material on a dry weight basis. More preferably, the fiber accounts for 2.0% to 7.0% by weight of the flavor material on a dry weight basis. Even more preferably, the fiber accounts for 2.0% to 5% by weight of the flavor material on a dry weight basis.

[0094] In some embodiments, flavor materials according to the present invention may include calcium salts or magnesium salts, or both, such as calcium chloride or calcium lactate.

[0095] In embodiments where the flavor material comprises calcium salt or magnesium salt or both, the one or more salts comprise 0.01 wt% to 10 wt% on a dry weight basis. Preferably, the one or more salts comprise 0.01 wt% to 5 wt% on a dry weight basis.

[0096] The flavor material according to the present invention may typically contain water. This is because the flavor material will typically be manufactured by combining the various compounds described above in a water bath. After drying, the water content will decrease, but may generally not be zero.

[0097] Therefore, the flavour material according to the present invention may comprise 0.01 to 10 wt% water, preferably 0.01 to 8 wt% water, more preferably 0.01 to 6 wt% water, even more preferably 0.01 to 4 wt% water.

[0098] In some embodiments, the flavor material comprises 0.5 wt % to 10 wt % water, preferably 0.01 wt % to 8 wt % water, more preferably 0.5 wt % to 6 wt % water, even more preferably 0.5 wt % to 4 wt % water.

[0099] In other embodiments, the flavor material comprises 1.0 wt% to 10 wt% water, preferably 1.0 wt% to 8 wt% water, more preferably 1.0 wt% to 6 wt% water, even more preferably 1.0 wt% to 4 wt% water.

[0100] In a further embodiment, the flavor material comprises 1.5 wt% to 10 wt% water, preferably 1.5 wt% to 8 wt% water, more preferably 1.5 wt% to 6 wt% water, even more preferably 1.5 wt% to 4 wt% water.

[0101] As mentioned previously, in some preferred embodiments the carrier sheet material may be in the form of a sheet of homogenised tobacco material.

[0102] As used in this specification, term " homogenized tobacco material " contains any tobacco material formed by the agglomeration of tobacco material particles.Sheet material or the web material of homogenized tobacco material are formed by making particulate tobacco agglomerate, and this particulate tobacco is by one or both grinding or otherwise powdering and obtains in tobacco blade and tobacco leaf stem.In addition, homogenized tobacco material can comprise one or more in tobacco dust, tobacco granules and other particulate tobacco byproducts formed during a spot of processing, operation and transportation of tobacco.The sheet material of homogenized tobacco material can be produced by casting, extruding, papermaking process or other any suitable techniques known in the art.

[0103] Sheets or webs of homogenized tobacco material for use in the present invention may have a tobacco content of at least about 40% by weight on a dry basis, more preferably at least about 60% by weight on a dry basis, more preferably at least about 70% by weight on a dry basis, and most preferably at least about 90% by weight on a dry basis.

[0104] The sheet or web of the homogenized tobacco material used as the carrier sheet material can include one or more intrinsic binders (i.e. tobacco endogenous binders), one or more non-intrinsic binders (i.e. tobacco exogenous binders) or their combination, to help agglomeration particle tobacco.Alternately or additionally, the sheet of the homogenized tobacco material used as the carrier sheet material can include other additives, including but not limited to tobacco and non-tobacco fibers, aerosol forming agents, humectants, plasticizers, flavors, fillers, aqueous and non-aqueous solvents and their combination.

[0105] Suitable non-inherent binders for inclusion in sheets or webs of homogenized tobacco material for use as carrier sheet material are known in the art and include, but are not limited to: gums such as guar gum, xanthan gum, gum arabic and locust bean gum; cellulosic binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as starch; organic acids such as alginic acid; conjugate base salts of organic acids such as sodium alginate, agar and pectin; and combinations thereof.

[0106] Suitable non-tobacco fibers for inclusion in a sheet or web of homogenized tobacco material used as a carrier sheet material are known in the art and include, but are not limited to, cellulose fibers; softwood fibers; hardwood fibers; jute fibers and combinations thereof. Prior to inclusion in a sheet of homogenized tobacco material used as a carrier sheet material, the non-tobacco fibers may be treated by suitable methods known in the art, including, but not limited to, mechanical pulping; refining; chemical pulping; bleaching; kraft pulping; and combinations thereof.

[0107] Preferably, the sheet or web of homogenised tobacco material comprises an aerosol former. As used herein, the term "aerosol former" describes any suitable known compound or mixture of compounds which, in use, promotes the formation of an aerosol and which is substantially resistant to thermal degradation at the operating temperature of the aerosol generating article.

[0108] Suitable aerosol formers are known in the art and include, but are not limited to, polyols such as propylene glycol, triethylene glycol, 1,3-butylene glycol, glycerol; esters of polyols such as glycerol monoacetate, glycerol diacetate or glycerol triacetate; and fatty acid esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0109] Preferred aerosol formers are polyols or mixtures thereof such as propylene glycol, triethylene glycol, 1,3-butylene glycol and most preferably glycerol.

[0110] The sheet or web of homogenised tobacco material may comprise a single aerosol-forming agent. Alternatively, the sheet or web of homogenised tobacco material may comprise a combination of two or more aerosol-forming agents.

[0111] The sheet or web of homogenized tobacco material has an aerosol forming agent content of greater than 10% by dry weight. Preferably, the sheet or web of homogenized tobacco material has an aerosol forming agent content of greater than 12% by dry weight. More preferably, the sheet or web of homogenized tobacco material has an aerosol forming agent content of greater than 14% by dry weight. Even preferably, the sheet or web of homogenized tobacco material has an aerosol forming agent content of greater than 16% by dry weight.

[0112] The sheet of homogenised tobacco material may have an aerosol former content of from about 10% to about 30% by dry weight.Preferably, the sheet or web of homogenised tobacco material has an aerosol former content of less than 25% by dry weight.

[0113] In a preferred embodiment, the sheet of homogenised tobacco material has an aerosol former content of about 20% by dry weight.

[0114] The sheet or web of homogenized tobacco used as the carrier sheet material in the flavor material of the present invention can be manufactured by methods known in the art (e.g., methods disclosed in International Patent Application WO-A-2012 / 164009A2). In a preferred embodiment, the sheet of homogenized tobacco material used as the carrier sheet material is formed by a slurry comprising granular tobacco, guar gum, cellulose fibers and glycerol through a casting process.

[0115] In other embodiments, the carrier sheet material can be in the form of a sheet of non-tobacco aerosol generating material. For example, the carrier sheet material can be a sheet of a sorbent non-tobacco material loaded with nicotine (for example, in the form of nicotine salts) and an aerosol forming agent. The example of such a strip is described in International Application WO-A-2015 / 082652. In addition or as an alternative, the carrier sheet material can be a sheet of homogenized non-tobacco plant material such as an aromatic non-tobacco plant material.

[0116] In certain embodiments, the carrier sheet material may be in the form of a paper wrapper material. This has the benefit that the flavor material may be used as a replacement or supplement for conventional paper wrapper materials in the manufacture of aerosol-generating articles. Thus, the flavor material may be incorporated into the aerosol-generating article without significantly changing existing manufacturing processes and without requiring major modifications to existing manufacturing equipment.

[0117] In certain embodiments, the carrier sheet material comprises carbon particles. Preferably, the carrier sheet material comprises greater than 0.1 wt% carbon particles having a volume average particle size greater than 10 microns.

[0118] It has been found that the inclusion of a carbon-based material (such as graphite, expanded graphite, graphene, etc.) in the carrier sheet material of the flavor material according to the present invention enhances flavor release, particularly at lower temperatures, relative to flavor materials of comparable composition and structure but lacking a carbon-rich carrier sheet material. Without wishing to be bound by theory, it is speculated that this is related to the enhancement of the thermal conductivity of the carrier sheet material, which may allow the flavor formulation to be released more rapidly from the polysaccharide matrix structure because a certain threshold temperature may be reached more quickly.

[0119] The improvement in flavor release is believed to be related to a more uniform temperature distribution throughout the flavor material during use. With a greater proportion of the flavor material reaching a sufficiently high temperature to release the flavor species from the matrix structure, the flavor formulation can be used more efficiently.

[0120] The improved flavor species release provided by embodiments of flavor materials according to the present invention comprising carbon particles as described above may also allow a heater configured to supply heat to an aerosol-generating article incorporating the flavor delivery material to operate at a lower temperature and therefore require less power.

[0121] By adjusting the amount and size of the carbon particles, it may be possible to control and fine tune the flavor release enhancement. For example, a relatively narrow particle size distribution may provide a carrier sheet material that is more uniform in thermal conductivity. This may mean that, during use, temperature gradients in the flavor delivery material of the aerosol-generating article that are exposed to different parts of the same heating curve are minimized.

[0122] Preferably, the carbon particles are composed of one or more of the following: graphite particles, expanded graphite particles and graphene particles. In a preferred embodiment, the carbon particles are composed of one or both of expanded graphite particles and graphene particles.

[0123] Advantageously, particles (such as those listed above, particularly graphite and expanded graphite) may have high thermal conductivity and low density, and therefore, they may be able to greatly improve the thermal conductivity of the carrier sheet material without significantly increasing the density of the flavor material. This may be advantageous because an increase in density may increase the weight and, therefore, the shipping cost for a given volume of the flavor material itself. Likewise, when the flavor material is incorporated into an aerosol-generating article, an increase in density may have a proportional effect on shipping costs.

[0124] Additionally, particles such as those listed above have the benefit of being inductively heatable, and therefore heat can be supplied directly within the flavour material according to the invention when the flavour material is exposed to the electromagnetic field generated by the induction coil.

[0125] Preferably, the carbon particles have a volume average particle size of 30 microns to 150 microns.

[0126] As used herein, the term "volume average particle size" may refer to an average value calculated using the following equation, where d[4,3] is the volume average particle size, and d is the particle size.

[0127]

[0128] In other words, the volume average particle size may refer to an average value calculated by dividing the sum of the fourth powers of the particle sizes by the sum of the third powers of the particle sizes.

[0129] Surprisingly, the inventor has found that these relatively small particle size ranges are particularly effective in increasing the thermal conductivity of the carrier material, particularly when the carrier material is in the form of a sheet. In addition, compared to if using a larger particle size, these relatively small particle sizes can advantageously cause a more uniform thermal conductivity distribution, and cause the sheet to have a more uniform thickness. In addition, particles within this size range can also more easily be mixed with particles of similar size for making carrier sheet materials, such as in the case of a sheet of homogenized tobacco material or other plant materials.

[0130] The carbon particles may have a particle size distribution having a D10 particle size, a D50 particle size, and a D90 particle size. In this particle size distribution, 10% of the particles have a particle size less than or equal to the D10 particle size, and 90% of the particles have a particle size less than or equal to the D90 particle size. The D50 particle size is the median particle size, so 50% of the particles have a particle size less than or equal to the D50 particle size.

[0131] The D90 particle size can be less than or equal to 50, 40, 30, 25, 20, 15, 10, 8, 5, or 3 times the D10 particle size. The D90 particle size can be greater than or equal to 2, 3, 5, or 8 times the D10 particle size.

[0132] The D90 particle size can be 3 to 50 times, 3 to 40 times, 3 to 30 times, 3 to 25 times, 3 to 20 times, 3 to 15 times, 3 to 10 times, 3 to 8 times, 3 to 5 times, 5 to 50 times, 5 to 40 times, 5 to 30 times, 5 to 25 times, 5 to 20 times, 5 to 15 times, 5 to 10 times, 5 to 8 times, 8 to 50 times, 8 to 40 times, 8 to 30 times, 8 to 25 times, 8 to 20 times, 8 to 15 times, 8 to 10 times, 10 to 50 times, 10 to 40 times, 10 to 30 times, 10 to 25 times, 10 to 20 times, 10 to 15 times, 15 to 50 times, 15 to 40 times, 15 to 30 times, 15 to 25 times, 15 to 20 times,

[0133] Preferred particle size distributions may have a D90 particle size between 3 and 25 times, or 3 and 15 times, the D10 particle size. Particularly preferred particle size distributions may have a D90 particle size between 5 and 20 times, or 5 and 10 times, the D10 particle size.

[0134] In certain preferred embodiments, in the flavor material according to the present invention, the carbon particles have a particle size distribution having a D90 particle size and a D10 particle size, and the D90 particle size is not greater than 25 times or 15 times the D10 particle size.

[0135] A compromise must be made in terms of particle size distribution. A tighter particle size distribution may advantageously provide a more uniform thermal conductivity throughout the flavor material. This is because the particle size variation in different locations in the flavor material will be smaller. This may advantageously allow for a more efficient use of the flavor formulation throughout the flavor material. However, a tighter particle size distribution may disadvantageously be more difficult to achieve and more expensive. The inventors have discovered that the above-described particle size distribution may provide an optimal compromise between these two factors.

[0136] The desired D10 and D90 particle sizes can be obtained by sieving. Sieving can therefore be used to obtain a narrow particle size distribution when required.

[0137] The carbon particles can have a D10 particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns. Each of the carbon particles can have a particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns.

[0138] The carbon particles may have a D10 particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns. Each of the carbon particles may have a particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns.

[0139] The carbon particles may have a D90 particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns. Each of the carbon particles may have a particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns.

[0140] The carbon particles can have a D90 particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns. Each of the carbon particles can have a particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns.

[0141] The carbon particles can have one or both of a D50 particle size and a volume average particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns.

[0142] The carbon particles may have one or both of a D50 particle size and a volume average particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns.

[0143] One or both of the D50 particle size and the volume average particle size of the carbon particles may be between 1 and 1000 microns, preferably between 10 and 200 microns, more preferably between 30 and 150 microns, or even more preferably between 50 and 75 microns. Alternatively or in addition, each of the carbon particles may have a particle size between 1 and 1000 microns, preferably between 10 and 200 microns, more preferably between 30 and 150 microns, or even more preferably between 50 and 75 microns.

[0144] Surprisingly, the inventors have found that these relatively small particle size ranges are particularly effective in increasing the thermal conductivity of flavor materials according to the present invention, particularly in those embodiments in which the flavor material comprises a carrier sheet material supporting a polysaccharide matrix that captures the flavor formulation. Additionally, these relatively small particle sizes can advantageously result in a carrier sheet material that is more uniform in thermal conductivity, and in a carrier sheet material having a more uniform thickness, than if larger particle sizes were used. Particles within this size range can also be more easily mixed with similarly sized particles used in some manufacturing processes for forming carrier sheet materials.

[0145] The carbon particles can have a volume average particle size greater than or equal to 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 microns.

[0146] It may be particularly preferred that the carbon particles have a volume average particle size greater than 10 microns.

[0147] The carbon particles can have a volume average particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 microns.

[0148] The carbon particles may have a volume average particle size of between 1 and 1000 microns, 10 and 200 microns, 30 and 150 microns or 50 and 75 microns. These volume average particle size ranges may be particularly preferred where the flavour material comprises or is in the form of a sheet.

[0149] The carbon particles can have a volume average particle size that is at least 2, 3, 5, 8, 10, 15, or 20 times the number average particle size.

[0150] It may be particularly preferred if the thermally conductive particles are or contain graphite particles.

[0151] The graphite particles may have a particle size distribution with a D10 particle size between 5 and 20, such as 10 and 14 microns, such as about 12 microns. The graphite particles may have a particle size distribution with a D50 particle size between 25 and 45 microns, such as about 35 microns. The graphite particles may have a particle size distribution with a D90 particle size between 45 and 75 microns, such as about 55 microns. Advantageously, such particles are commercially available, and the inventors have found that such particles provide a significant increase in the thermal conductivity of the flavor material.

[0152] It may be particularly preferred if the thermally conductive particles are or contain expanded graphite particles.

[0153] Expanded graphite particles can have a particle size distribution with a D10 particle size of 5 and 20 microns, for example, between 9 and 12 microns, for example, about 10.5 microns. Expanded graphite particles can have a particle size distribution with a D50 particle size of 15 and 25 microns, for example, about 20 microns. Expanded graphite particles can have a particle size distribution with a D90 particle size of 46 and 66 microns, for example, about 56 microns. Advantageously, such particles are commercially available, and the inventor has found that such particles provide a significant increase in the thermal conductivity of flavor materials. Expanded graphite particles can also advantageously reduce the overall density of flavor materials.

[0154] Each of the carbon particles may have three mutually perpendicular dimensions. The largest of the three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the smallest of the three dimensions. The largest of the three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the second largest of the three dimensions. Each of the three dimensions may be substantially equal. Each of the carbon particles may be substantially spherical.

[0155] The carbon particles may include at least 10, 20, 50, 100, 200, 500, or 1000 particles.

[0156] In the flavor material according to the present invention, the carbon particles account for 0.01 wt % to 10 wt % of the flavor material on a dry weight basis.

[0157] In the flavour material according to the invention, the polysaccharide matrix structure and the flavour preparation form a layer on the carrier sheet material. The layer may have a thickness of at least 5 microns.

[0158] In the flavor material according to the present invention, the polysaccharide matrix structure and the flavor preparation form a layer on the carrier sheet material, which layer preferably has a thickness of at least 10 microns, more preferably has a thickness of at least 15 microns, and even more preferably has a thickness of at least 20 microns.

[0159] In the flavor material according to the present invention, the polysaccharide matrix structure and the flavor preparation form a layer on the carrier sheet material, which layer preferably has a thickness of less than or equal to 150 microns, more preferably has a thickness of less than or equal to 125 microns, and even more preferably has a thickness of less than or equal to 100 microns.

[0160] In some embodiments, the polysaccharide matrix structure and the flavor formulation form a layer on the carrier sheet material, the layer preferably having a thickness of 10 to 150 microns, the layer more preferably having a thickness of 10 to 125 microns, and the layer even more preferably having a thickness of 10 to 100 microns.

[0161] In other embodiments, the polysaccharide matrix structure and the flavor formulation form a layer on the carrier sheet material, the layer preferably having a thickness of 15 microns to 150 microns, the layer more preferably having a thickness of 15 microns to 125 microns, and the layer even more preferably having a thickness of 15 microns to 100 microns.

[0162] In a further embodiment, the polysaccharide matrix structure and the flavor formulation form a layer on the carrier sheet material, the layer preferably having a thickness of 20 microns to 150 microns, the layer more preferably having a thickness of 20 microns to 125 microns, and the layer even more preferably having a thickness of 20 microns to 100 microns.

[0163] The flavor material according to the present invention can be prepared by different routes. The disclosure also relates to a method for making a flavor material according to the present invention, which may include a first step of heating water to a temperature of at least 50 degrees Celsius. The method may include a second step of dispersing gellan gum in heated water to form a gellan gum aqueous dispersion. The method may include a third step of heating the gellan gum aqueous dispersion to a temperature of at least 80 degrees Celsius to dissolve gellan gum and form a gellan gum aqueous solution. The method may include a fourth step of cooling the gellan gum aqueous solution to a temperature of 65 degrees Celsius to 75 degrees Celsius. The method may include a fifth step of adding a flavor preparation and an emulsifier to form a precursor composition in the cooled gellan gum aqueous solution. The method may include a sixth step of applying the precursor composition to a carrier sheet material. The method may include a seventh step of drying the carrier sheet material with the applied precursor composition to obtain a flavor delivery material.

[0164] According to another aspect of the present invention, a method for manufacturing a flavor material according to the present invention is provided, the method comprising a first step of heating water to a temperature of at least 50 degrees Celsius; a second step of dispersing gellan gum in the heated water to form a gellan gum aqueous dispersion; a third step of heating the gellan gum aqueous dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form a gellan gum aqueous solution; a fourth step of cooling the gellan gum aqueous solution to a temperature of 65 degrees Celsius to 75 degrees Celsius; a fifth step of adding a flavor preparation and an emulsifier to the cooled gellan gum aqueous solution to form a precursor composition; a sixth step of applying the precursor composition to a carrier sheet material; and a seventh step of drying the carrier sheet material with the applied precursor composition to obtain a flavor delivery material.

[0165] In some embodiments, the method further comprises the step of adding a polysaccharide selected from guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose and hydroxypropyl methylcellulose to the cooled aqueous gellan gum solution. This additional step may be performed before the sixth step of applying the precursor composition to the carrier sheet material.

[0166] Preferably, in the method according to the invention, the emulsifier is lecithin.

[0167] In certain embodiments, the sixth step of applying the precursor composition to the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material.

[0168] Preferably, the sixth step of applying the precursor composition to the carrier sheet material comprises forming a layer of the precursor composition having a thickness of at least 10 micrometers on the carrier sheet material.

[0169] The present disclosure also relates to an aerosol generating article comprising a flavor material, wherein a flavor formulation can be released from the flavor material upon heating the flavor material. The flavor material can include a matrix structure and a flavor formulation dispersed within the matrix structure. The flavor formulation is at least partially captured within the matrix structure and can be released from the matrix structure upon heating the flavor material. The matrix structure can be a polysaccharide matrix structure. The flavor material can include a carrier sheet material, wherein the polysaccharide matrix structure and the flavor formulation are supported by the carrier sheet material.

[0170] According to yet another aspect of the present invention, there is provided an aerosol generating article comprising a flavor material, wherein a flavor can be released from the flavor material upon heating the flavor delivery material. The flavor material comprises a polysaccharide matrix structure; and a flavor formulation dispersed within the polysaccharide matrix structure. The flavor formulation is captured within the polysaccharide matrix structure and can be released from the polysaccharide matrix structure upon heating the flavor material. The flavor material further comprises a carrier sheet material, the polysaccharide matrix structure and the flavor formulation being supported by the carrier sheet material.

[0171] As will be apparent from the foregoing description of flavor materials according to the present invention, by incorporating such a flavor material in an aerosol-generating article, a range of new aerosol-generating articles can be advantageously provided that are capable of delivering flavor to consumers in a more consistent and controlled manner. In addition, because the flavor formulation is at least partially captured within the matrix until released when heat is supplied to the aerosol-generating article during use, the loss of flavor species during storage and transportation of the aerosol-generating article can be greatly reduced.

[0172] Because the carrier sheet material provides enhanced structural support for the polysaccharide matrix structure that captures the flavor formulation, the manufacture of the aerosol-generating article can be facilitated by adjusting the composition and geometry of the carrier sheet material. In some embodiments, as discussed in more detail below, the carrier sheet material is also the source of aerosolizable species, and thus, by closely combining these with the flavor source at a selected location within the aerosol-generating article, a number of interesting

[0173] In certain embodiments, the aerosol-generating article comprises a strip of aerosol-generating substrate; a downstream segment disposed downstream of the strip of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article; and optionally, an upstream segment disposed downstream of the strip of aerosol-generating substrate and extending to a distal end of the aerosol-generating article. The flavor material is disposed in at least one of the strip of aerosol-generating substrate, the downstream segment, and the optional upstream segment.

[0174] As described above, the carrier sheet material may in particular be a sheet of homogenized tobacco material. In embodiments in which the flavor material comprises one such carrier sheet material, the aerosol-generating article may include a rod of aerosol-generating substrate; a downstream section disposed downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article; optionally, an upstream section disposed downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article; and the flavor material may be disposed in the rod of aerosol-generating substrate.

[0175] Incorporation of flavour materials according to the present invention into aerosol-generating articles may be carried out according to one of several routes.

[0176] For example, fragments of flavour material may be mixed with solid particles of aerosol-generating material, such as cut tobacco, to form a rod of an aerosol-generating substrate for an aerosol-generating article.

[0177] Alternatively or additionally, the fragments of flavor material may be disposed at other locations within the aerosol-generating article, such as along a downstream section of the aerosol-generating article. The downstream section of the aerosol-generating article may comprise a plurality of components, and thus, the flavor material may be incorporated into any of such components.

[0178] As a further alternative, the flavour material comprising the carrier sheet material in the form of a paper wrapper may be used alone or in combination with another paper wrapper as a stick wrapper for a strip of an aerosol-generating article.

[0179] This list of possible arrangements is not intended to be exhaustive, and it will be apparent that different placements of the flavour material in the aerosol-generating article may be possible, provided that the flavour material is supplied with sufficient heat during use of the aerosol-generating article to release the flavour formulation from the polysaccharide matrix.

[0180] The aerosol-generating article containing a flavor material according to the present invention can be used in combination with an aerosol-generating device, such as a handheld electric heater configured to supply heat to the aerosol-generating article in a controlled manner. In this way, by heating the aerosol-generating substrate and the flavor material, a flavor-enriched aerosol can be delivered to the consumer.

[0181] Therefore, the aerosol generating article according to the present invention is particularly applicable in an aerosol generating system, which comprises an aerosol generating device, the aerosol generating device having a heating chamber, the aerosol generating article being received in the heating chamber so that heat can be supplied to the aerosol generating substrate. This can be achieved by providing one or more heating elements arranged around the periphery of the heating chamber, the one or more heating elements being resistively heated or inductively heated. Alternatively, this can also be achieved by a resistively heated blade-shaped component of the aerosol generating device, which blade-shaped component is inserted into the aerosol generating substrate when the aerosol generating article is inserted into the heating chamber.

[0182] According to yet another alternative, a susceptor element may be provided within the aerosol-generating substrate, and the aerosol-generating device may have an inductor for generating an alternating or fluctuating electromagnetic field. When the aerosol-generating article is engaged with the aerosol-generating device, the fluctuating electromagnetic field generated by the inductor induces a current in the susceptor element, thereby causing the susceptor element to heat up. An electrically operated aerosol-generating device may be capable of generating a fluctuating electromagnetic field having a magnetic field strength (H field strength) between 1 and 5 kiloamperes per meter (kA / m), preferably between 2 and 3 kA / m, for example about 2.5 kA / m.

[0183] The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment or aspect described herein.

[0184] Example Ex1: A flavor material for use in an aerosol-generating article, wherein a flavor can be released from the flavor material when the flavor material is heated; the flavor material comprises: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavor preparation dispersed within the polysaccharide matrix structure, wherein the flavor preparation is at least partially captured within the polysaccharide matrix structure and can be released from the polysaccharide matrix structure when the flavor material is heated; and a carrier sheet material, wherein the polysaccharide matrix structure and the flavor preparation are supported by the carrier sheet material.

[0185] Example Ex2: The flavor material according to Example Ex1, wherein the polysaccharide matrix structure comprises gellan gum as the sole polysaccharide or a combination of gellan gum and at least one other polysaccharide selected from guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose and hydroxypropyl methylcellulose.

[0186] Example Ex3: The flavor material according to example Ex1 or Ex2, wherein the gellan gum accounts for 5 to 99.9 weight % of the flavor material on a dry weight basis.

[0187] Example Ex4: The flavor material according to any one of Examples Ex1 to Ex3, wherein the flavor material further comprises a compound having formula C n H 2n+2 O n of polyols.

[0188] Example Ex5: The flavor material according to example Ex4, wherein the polyol is selected from glycerol, sorbitol, xylitol, mannitol and erythritol.

[0189] Example Ex6: The flavor material according to example Ex4 or Ex5, wherein the polyol accounts for 0.01 wt% to 20 wt% of the flavor material on a dry weight basis.

[0190] Example Ex7: The flavor material according to any one of the preceding examples, further comprising fiber.

[0191] Example Ex8: The flavor material according to example Ex7, wherein the fiber accounts for 0.01 wt% to 10 wt% of the flavor material on a dry weight basis.

[0192] Example Ex9: The flavor material according to any one of the preceding examples, comprising 0.01 wt% to 80 wt% of menthol.

[0193] Example Ex10: The flavor material according to any one of the preceding examples, wherein the carrier sheet material is a sheet of homogenized tobacco material.

[0194] Example Ex11: The flavor material according to any one of the preceding examples, wherein the carrier sheet material is a sheet of stick paper wrapper material.

[0195] Example Ex12: The flavor material according to any one of the preceding examples, wherein the polysaccharide matrix structure and the flavor formulation form a layer on the carrier sheet material, the layer having a thickness of at least 10 micrometers.

[0196] Example Ex13: The flavor material according to example Ex12, wherein the layer has a thickness of less than 150 microns.

[0197] Example Ex14: The flavor material according to any one of the preceding examples, wherein the carrier sheet material comprises greater than 0.1 wt% of carbon particles having a volume average particle size greater than 10 microns.

[0198] Example Ex15: The flavor material according to example Ex14, wherein the carbon particles have a volume average particle size greater than 10 microns.

[0199] Example Ex16: The flavor material according to example Ex14 or example Ex15, wherein the carbon particles have a volume average particle size of 30 microns to 150 microns.

[0200] Example Ex17: The flavor material according to any one of Examples Ex14 to Ex16, wherein the carbon particles consist of one or more of the following: graphite particles, expanded graphite particles, and graphene particles.

[0201] Example Ex18: The flavor material according to any one of Examples Ex14 to Ex17, wherein the carbon particles account for 0.01 wt% to 10 wt% of the flavor material on a dry weight basis.

[0202] Example Ex19: The flavor material according to any one of Examples Ex14 to Ex18, wherein the carbon particles have a particle size distribution having a D90 particle size and a D10 particle size, wherein the D90 particle size is not greater than 25 times or 15 times the D10 particle size.

[0203] Example Ex20: A method for preparing a flavor material for use in an aerosol-generating article, the method comprising: heating water to a temperature of at least 50 degrees Celsius; dispersing gellan gum in the heated water to form a gellan gum aqueous dispersion; heating the gellan gum aqueous dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form a gellan gum aqueous solution; cooling the gellan gum aqueous solution to a temperature of 65 degrees Celsius to 75 degrees Celsius; adding a flavor preparation and an emulsifier to the cooled gellan gum aqueous solution to form a precursor composition; applying the precursor composition to a carrier sheet material; drying the carrier sheet material with the applied precursor composition to obtain the flavor material.

[0204] Example Ex21: According to the method of Example Ex20, the method further comprises the step of adding a polysaccharide selected from guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose and hydroxypropyl methylcellulose to the cooled aqueous gellan gum solution.

[0205] Example Ex22: The method according to example Ex20 or Ex21, wherein the emulsifier is lecithin.

[0206] Example Ex23: The method according to any one of Examples Ex20 to Ex22, wherein the step of applying the precursor composition to the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material.

[0207] Example Ex24: The method according to any one of Examples Ex20 to Ex23, wherein the step of applying the precursor composition to the carrier sheet material comprises forming a layer of the precursor composition having a thickness of at least 10 micrometers on the carrier sheet material.

[0208] Example Ex25: An aerosol-generating article comprising a flavor material, wherein a flavor can be released from the flavor material when the aerosol-generating article is heated; the flavor material is according to any one of Examples Ex1 to Ex19.

[0209] Example Ex26: An aerosol-generating article comprising a flavor material, wherein a flavor can be released from the flavor material when the aerosol-generating article is heated; the flavor material comprises: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavor preparation dispersed in the polysaccharide matrix structure, wherein the flavor preparation is at least partially captured in the polysaccharide matrix structure and can be released from the polysaccharide matrix structure when the flavor material is heated; and a carrier sheet material, wherein the polysaccharide matrix structure and the flavor preparation are supported by the carrier sheet material.

[0210] Example Ex27: An aerosol-generating article according to Example Ex25, the article comprising: a strip of an aerosol-generating substrate; a downstream section disposed downstream of the strip of the aerosol-generating substrate and extending to the mouth end of the aerosol-generating article; optionally, an upstream section disposed downstream of the strip of the aerosol-generating substrate and extending to the distal end of the aerosol-generating article; wherein the flavor material is disposed in at least one of the strip of the aerosol-generating substrate, the downstream section and the optional upstream section.

[0211] Example Ex28: An aerosol generating article according to Example Ex26 or Ex27, wherein the carrier sheet material is a sheet of homogenized tobacco material; wherein the aerosol generating article comprises: a strip of an aerosol generating substrate; a downstream section disposed downstream of the strip of the aerosol generating substrate and extending to the mouth end of the aerosol generating article; optionally, an upstream section disposed downstream of the strip of the aerosol generating substrate and extending to the distal end of the aerosol generating article; wherein the flavor material is disposed in the strip of the aerosol generating substrate.

[0212] Several examples will now be further described with reference to the accompanying drawings, in which:

[0213] Figure 1 shows a schematic side cross-sectional view of an aerosol-generating article comprising a flavour material in a rod of an aerosol-generating substrate according to the present invention; and

[0214] Figure 2 Shown in Figure 1 Scanning electron microscope image of a flavor material used in an aerosol-generating article.

[0215] Figure 1 An aerosol-generating article 10 according to the present invention is shown in FIG. Figure 1 The aerosol-generating article 10 shown in comprises a strip 12 of aerosol-generating substrate and a downstream section 14 at a position downstream of the strip 12 of aerosol-generating substrate. Furthermore, the aerosol-generating article 10 comprises an upstream section 16 at a position upstream of the strip 12 of aerosol-generating substrate.

[0216] The ventilation zone 60 is provided at a location downstream of the strip 12 of aerosol-generating substrate.

[0217] In more detail, Figure 1 In the embodiment of the invention, the downstream section 14 comprises a mouthpiece element 18 and a hollow section 20. The hollow section 20 comprises an aerosol-cooling element 22 comprising a hollow tubular element and a ventilation zone 60 comprising a plurality of openings formed through the wall of the hollow tubular element. The aerosol-cooling element 22 is positioned immediately downstream of the strip 12 of aerosol-generating substrate. Figure 1 As shown in the figure, the upstream end of the aerosol-cooling element 22 is adjacent to the downstream end of the strip of aerosol-generating substrate 12. The mouthpiece element 18 is positioned immediately downstream of the aerosol-cooling element 22. Figure 1 As shown in the Figures, the upstream end of the mouthpiece element 18 abuts the downstream end of the aerosol-cooling element 22. The mouthpiece element 18 comprises a rod 24 of low density filter material.

[0218] The rod 12 comprises an aerosol-generating substrate in the form of a gathered sheet of homogenised tobacco material. However, other types of tobacco-containing substrates, such as tobacco cut filler, may replace the gathered sheet of homogenised tobacco material.

[0219] The upstream section 16 comprises a cylindrical rod 26 of compressed and plasticized cellulose acetate defined by a wrapper 28. The rod 26 of the upstream section 16 has a length of about 5 mm.

[0220] Furthermore, the aerosol-generating article comprises a flavour material 50. In more detail, a plurality of fragments of flavour material in sheet form are dispersed within the rod 12. The flavour material 50 is of the type described in detail above.

[0221] Examples of suitable formulations for the flavor material 50 and methods for forming the flavor material 50 are set forth below.

[0222] Preparation A - comprising a thin film of polysaccharide entrapped in a matrix of gellan gum supported on a carrier sheet material (paper wrapper). Flavor materials for hol preparations

[0223] 100g water is heated to about 60 degrees Celsius and 3.0g gellan gum is added to this water bath. The resulting mixture is homogenized and heated to a temperature in the range of 80 to 85 degrees Celsius, and kept at this temperature for 5 minutes. Subsequently, the mixture is cooled to a temperature in the range of 70 to 75 degrees Celsius and 0.1g lecithin and 8.0g menthol are added to the mixture. This flavor-containing mixture is homogenized for 3 minutes. Subsequently, the resulting aqueous composition is cast on a sheet of paper wrapper material on a metal tray, and its gelation is dried in a static oven at 75 degrees Celsius. The layer of the gellan gum matrix that obtains the menthol preparation is fixed on the paper wrapper.

[0224] Preparation B1 - comprising gellan gum-guar gum entrapped on a carrier sheet material (homogenized tobacco material) Flavor materials for menthol formulations in a polysaccharide matrix

[0225] 100g water is heated to about 60 degrees Celsius and in this water-bath, 1.0g gellan gum is added. The gained mixture is homogenized and is heated to the temperature in the scope of 80 to 85 degrees Celsius, and kept 5 minutes at this temperature. Subsequently, the mixture is cooled to the temperature in the scope of 70 to 75 degrees Celsius and in the mixture, 0.1g lecithin and 8.0g menthol are added. This mixture containing flavor is homogenized 3 minutes. Subsequently, 2.0g guar gum is added in the mixture, and then it is homogenized again other 3 minutes. Subsequently, the gained aqueous composition is cast on the sheet material of homogenized tobacco material and is positioned on the metal tray, and its gelation is dried in the static oven of 75 degrees Celsius. The layer of the gellan gum / guar gum matrix that obtains and comprises the menthol preparation that is captured, and this layer is fixed on the homogenized tobacco material.

[0226] Preparation B2 - comprising gellan gum-guar gum entrapped on a carrier sheet material (homogenized tobacco material) Flavor materials for menthol formulations in a polysaccharide matrix

[0227] 100g water is heated to about 60 degrees Celsius and 1.0g gellan gum is added to this water bath. The resulting mixture is homogenized and heated to a temperature in the range of 80 to 85 degrees Celsius, and kept at this temperature for 5 minutes. Subsequently, the mixture is cooled to a temperature in the range of 70 to 75 degrees Celsius and 0.1g lecithin and 8.0g menthol are added to the mixture. This flavor-containing mixture is homogenized for 3 minutes. Subsequently, 2.0g guar gum is added to the mixture, and then it is homogenized again for another 3 minutes. Subsequently, the resulting aqueous composition is cast on the sheet of paper packaging material and positioned on a metal tray, allowing it to gel and dry in a static oven of 75 degrees Celsius. The layer of the gellan gum / guar gum matrix that obtains the menthol preparation is captured, and the layer is fixed on the paper packaging material.

[0228] Preparation C - comprising a gellan gum-alginate multilayer supported on a carrier sheet material (homogenized tobacco material) Flavor materials for menthol formulations in a sugar matrix

[0229] 100g water is heated to about 60 degrees Celsius and in this water-bath, 2.0g gellan gum and 0.5g alginate are added. The gained mixture is homogenized and heated to the temperature in the scope of 90 to 95 degrees Celsius, and kept 5 minutes at this temperature. Subsequently the mixture is cooled to the temperature in the scope of 70 to 75 degrees Celsius and in the mixture, 0.1g lecithin and 8.0g menthol are added. This mixture containing flavor is homogenized 3 minutes. Subsequently, the gained aqueous composition is cast on the sheet material of homogenized tobacco material and is positioned on the metal tray, allowing its gelation and drying in the static oven of 75 degrees Celsius. The layer of the gellan gum / alginate matrix that obtains and comprises the menthol preparation that is captured, and this layer is fixed on the homogenized tobacco material.

[0230] Preparation D1 - Aerosol-generating article comprising a flavor material produced according to Preparation A

[0231] An amount of flavor material produced according to Preparation A (consisting of 5 mg of total menthol content) was added to a stick of a commercial aerosol-generating article (manufactured by Philip Morris Products SA). )middle.

[0232] Preparation D2 - Aerosol-generating article comprising a flavor material produced according to Preparation A

[0233] An amount (consisting of 35 mg of total menthol content) of the flavor material produced according to Preparation A was added to a stick of a commercial aerosol-generating article (manufactured by Philip Morris Products SA) )middle.

[0234] Preparation D3 - Aerosol-generating article comprising a flavor material produced according to Preparation A

[0235] An amount (constituting a total menthol content of 37 mg) of the flavor material produced according to Preparation A was added to a stick of a commercial aerosol-generating article (produced by Philip Morris Products SA). )middle.

[0236] Morphological characterization

[0237] Figure 2 A scanning electron microscope (SEM) image of a flavor material 50 produced according to Preparation B1 embedded in wax is shown. As can be seen from the image, the internal structure of the flavor material includes a matrix 52 having a plurality of small pockets 54 suitable for capturing the flavor composition, the pockets 54 being dispersed in the matrix 52. The pockets are relatively evenly distributed in the material and are relatively uniform in size. The flavor material 50 also includes a carrier sheet material 56 in the form of a sheet of homogenized tobacco material, which supports the matrix 52.

[0238] Thermogravimetric analysis

[0239] The flavor release profile of the flavor material produced according to the above preparation can be analyzed in a thermogravimetric analysis (TGA). The TGA test is performed using a thermogravimetric machine connected to a mass spectrometer or similar TGA equipment. In the analysis, the flavor material is heated from 25 degrees Celsius to 400 degrees Celsius in an inert nitrogen atmosphere, wherein the temperature is increased at a rate of 15 degrees Celsius per minute with an air flow rate of 60 ml per minute. As the temperature is increased, the release of menthol is evaluated by detecting menthol molecules by means of specific ions representing menthol.

[0240] Data collected from TGA testing of flavor materials according to the present invention can be compared with data collected from equivalent TGA testing of a separate flavor formulation (e.g., pure menthol). One such comparison can provide some information about the release mechanism and kinetics, which can help fine-tune the flavor release profile when the flavor material is incorporated into an aerosol-generating article.

[0241] When heated in the described thermogravimetric analysis, pure menthol is released unimodally between 50°C and 166°C, with a maximum at around 138°C.

[0242] In contrast, when heated in the described thermogravimetric analysis, the flavor material produced according to Preparation B2 was found to provide a multimodal release of menthol. A first, smaller portion of menthol was released between about 57 degrees Celsius and about 137 degrees Celsius, with a local maximum at about 116 degrees Celsius. A second, much more consistent portion of menthol was released between about 229 degrees Celsius and 264 degrees Celsius, with a local maximum at about 243 degrees Celsius. A third, smaller portion of menthol was released between about 265 degrees Celsius and 302 degrees Celsius, with a local maximum at about 279 degrees Celsius.

[0243] The release maximum of the first portion of menthol at slightly above 115 degrees Celsius may indicate that some of the menthol preparation is dissolved or relatively weakly fixed in the flavor material. On the other hand, the release maximum of the second, much larger portion of menthol is above 240 degrees Celsius - a temperature that may be related to the thermal degradation of gellan gum - which may support the following hypothesis: a significant portion of the menthol preparation is actually trapped in the matrix structure and has a somewhat stronger interaction with the gellan gum in the matrix structure. The release of the remaining portion of menthol at even higher temperatures may indicate that the menthol preparation interacts with the guar gum in the matrix structure in a different way and is even more stably held by the guar gum in the matrix structure.

[0244] The same TGA test was performed on the flavor material prepared according to Preparation A. It was found that this flavor material also provided a multi-peak release of menthol. A first smaller portion of menthol was released between about 57 degrees Celsius and about 239 degrees Celsius, with a local maximum at about 200 degrees Celsius. A second more significant portion of menthol was released between 240 degrees Celsius and 306 degrees Celsius, with a local maximum at about 249 degrees Celsius. Another portion of menthol was released between about 307 degrees Celsius and about 384 degrees Celsius, with a local maximum at about 351 degrees Celsius.

[0245] The release of the first portion of menthol at around 200 degrees Celsius may indicate that a small portion of the menthol preparation contained in the flavor material is less strongly immobilized, while the release of a larger portion of the menthol preparation contained in the flavor material at higher temperatures appears to indicate a stronger interaction with the gellan gum, which results in effective immobilization.

[0246] Comparison between the menthol release profiles of flavor materials prepared according to Preparations B2 and E suggests that adjusting the composition of the polysaccharide matrix - for example, using gellan gum alone or in combination with another polysaccharide - can help fine-tune flavor delivery when the flavor material is incorporated into an aerosol-generating article. In particular, it may be possible to control at what temperature the flavor release begins and around what temperature the flavor release reaches a maximum. In addition, flavor materials with different flavor release profiles (with local maxima at different temperatures) (such as flavor materials prepared according to Preparations B2 and E) can be combined in a single aerosol-generating article to provide consumers with an even wider range of flavor delivery options.

[0247] Thermal stability

[0248] The thermal stability of the flavor material according to the present invention under stress conditions can be evaluated by aging the flavor material at a constant temperature and monitoring its weight loss over time. To this end, samples of the flavor material cut into regular and uniformly sized pieces are weighed and distributed in a series of Schott glass open bottles. The samples are aged for a period of two weeks in a laboratory oven set at 50 degrees Celsius. For the flavor material produced according to Preparation A, a weight loss of about 35% was measured at the end of the test. It is presumed that such a weight loss value includes not only some migration of flavor species, but also the loss of moisture and glycerol, and is therefore considered satisfactory.

[0249] Puff-by-puff flavor delivery evaluation

[0250] Flavour delivery of aerosol-generating articles incorporating flavour materials according to the invention may be assessed by heating the aerosol-generating article in a commercially available compatible heating device and measuring the menthol delivered at the mouth end of the article per puff.

[0251] In more detail, proton transfer mass spectrometry (PTR-MS) may be used to analyze the products released per puff from an aerosol-generating article heated by a heating device.

[0252] The puff-by-puff menthol delivery of aerosol-generating articles produced according to Preparations D1, D2 and D3 was measured. Their behavior was compared with a commercial aerosol-generating article loaded with 5 mg of pure menthol (produced by Philip Morris Products SA). ) behavior.

[0253] It was observed that the commercially available aerosol-generating articles loaded with pure menthol reached their maximum menthol delivery around the third puff, after which the menthol level gradually decreased. In contrast, for aerosol-generating articles produced according to preparations D1, D2 and D3, menthol delivery appeared to increase until the third puff, and then generally remained at the same level until around the twelfth puff throughout the use cycle of the article.

[0254] Preparation E1 - comprising a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) Clove granules in the flavor material

[0255] 160g water is heated to about 60 degrees Celsius and in this water-bath, 6.0g gellan gum is added. The gained mixture is homogenized and is heated to the temperature in the scope of 80 to 85 degrees Celsius, and kept 5 minutes at this temperature. Subsequently the mixture is cooled to the temperature in the scope of 70 to 75 degrees Celsius and in the mixture, 0.2g lecithin and 8.0g clove powder are added. This mixture containing cloves is homogenized 3 minutes. Subsequently, the gained aqueous composition is cast on the sheet material of the homogenized tobacco material on the metal tray, and its gelation is dried in the static oven of 75 degrees Celsius. Acquisition comprises the layer that captures the gellan gum matrix containing the clove preparation, and this layer is fixed on the homogenized tobacco material.

[0256] Preparation E2 - comprising a gellan gum polysaccharide matrix entrapped on a carrier sheet material (homogenized tobacco material) Clove granules in the flavor material

[0257] 160g water is heated to about 60 degrees Celsius and in this water-bath, 6.0g gellan gum is added. The gained mixture is homogenized and is heated to the temperature in the scope of 80 to 85 degrees Celsius, and kept 5 minutes at this temperature. Subsequently the mixture is cooled to the temperature in the scope of 70 to 75 degrees Celsius and in the mixture, 0.2g lecithin and 8.0g clove powder are added. This mixture containing cloves is homogenized 3 minutes. Subsequently, the gained aqueous composition is cast on the sheet material of the homogenized tobacco material on the metal tray, and its gelation is dried in the static oven of 75 degrees Celsius. Acquisition comprises the layer that captures the gellan gum matrix containing the clove preparation, and this layer is fixed on the homogenized tobacco material.

[0258] Preparation E3 - comprising a gellan gum polysaccharide matrix entrapped on a carrier sheet material (homogenized tobacco material) Menthol and clove granules in flavor

[0259] 160g water is heated to about 60 degrees Celsius and in this water-bath, 6.0g gellan gum is added. The gained mixture is homogenized and is heated to the temperature in the scope of 80 to 85 degrees Celsius, and kept 5 minutes at this temperature. Subsequently the mixture is cooled to the temperature in the scope of 70 to 75 degrees Celsius and in the mixture, 0.2g lecithin, 4.0g menthol and 4.0g clove powder are added. This mixture containing local flavor is homogenized 3 minutes. Subsequently, the gained aqueous composition is cast on the sheet material of the homogenized tobacco material on the metal tray, and its gelation is dried in the static oven of 75 degrees Celsius. Acquisition comprises the layer that captures the gellan gum matrix that contains the clove preparation, and this layer is fixed on the homogenized tobacco material.

[0260] Preparation E4 - comprising gellan gum-guar gum entrapped on a carrier sheet material (homogenized tobacco material) Flavour material of clove particles in a polysaccharide matrix

[0261] 160g water is heated to about 60 degrees Celsius and 3.0g gellan gum is added to this water bath. The resulting mixture is homogenized and heated to a temperature in the range of 80 to 85 degrees Celsius, and kept at this temperature for 5 minutes. Subsequently, the mixture is cooled to a temperature in the range of 70 to 75 degrees Celsius and 0.2g lecithin and 8.0g clove powder are added to the mixture. This mixture containing cloves is homogenized for 3 minutes. Subsequently, 2.0g guar gum is added to the mixture, and then it is homogenized again for another 3 minutes. Subsequently, the resulting aqueous composition is cast on the paper packaging material and positioned on a metal tray, allowing it to gel and dry in a static oven of 75 degrees Celsius. The layer of the gellan gum / guar gum matrix comprising the menthol preparation is obtained, and the layer is fixed on the paper packaging material.

[0262] Thermogravimetric analysis

[0263] The flavor release profiles of the flavor materials produced according to preparations E1 to E4 can be analyzed in a thermogravimetric analysis (TGA). TGA tests are performed using a thermogravimetric machine coupled to a mass spectrometer or similar TGA equipment. In the analysis, the flavor materials are heated from 25 degrees Celsius to 400 degrees Celsius in an inert nitrogen atmosphere, wherein the temperature is increased at a rate of 15 degrees Celsius per minute with an air flow of 60 ml per minute. As the temperature is increased, the release of eugenol is evaluated by detecting the eugenol molecules by means of specific ions representing eugenol.

[0264] Data collected from TGA testing of flavor materials according to the present invention can be compared with data collected from equivalent TGA testing of pure eugenol and of clove material alone. One such comparison can provide some information about the release mechanism and kinetics, which can help fine-tune the flavor release profile when the flavor material is incorporated into an aerosol-generating article.

[0265] When heated in the described thermogravimetric analysis, pure eugenol is released unimodally between 90°C and 199°C with a maximum at around 191°C, whereas when clove powder is heated under the same conditions, eugenol is released unimodally between 88°C and 216°C with a maximum at around 151°C.

[0266] In contrast, when heated in the described thermogravimetric analysis, the flavor material produced according to Preparation B2 was found to provide a multimodal release of eugenol. A first, smaller portion of eugenol was released between about 215 degrees Celsius and about 228 degrees Celsius, with a local maximum at about 222 degrees Celsius. A second, much more consistent portion of eugenol was released between about 229 degrees Celsius and 300 degrees Celsius, with a local maximum at about 248 degrees Celsius.

[0267] The release maximum of the first portion of eugenol at around 215 degrees Celsius may indicate that some of the clove powder is relatively weakly fixed in the flavor material, and therefore the eugenol is released at only slightly higher temperatures than pure eugenol and clove powder alone. On the other hand, the release maximum of the second, much larger portion of eugenol is above 240 degrees Celsius - a temperature that may be associated with thermal degradation of gellan gum - which may support the hypothesis that a significant portion of the clove powder is actually trapped in the matrix structure and has a somewhat stronger interaction with the gellan gum in the matrix structure.

[0268] For the purpose of this specification and the appended claims, unless otherwise stated, all numbers indicating amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may or may not be specifically listed herein. Therefore, in this context, the number A is understood to be A±5%A. In this context, the number A can be regarded as including a numerical value within the general standard error for the measurement of the attribute modified by the number A. In certain cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of A deviation does not substantially affect the basic features and novel features of the invention claimed for protection. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may or may not be specifically listed herein.

Claims

1. A flavor material for use in an aerosol-generating article, wherein a flavor can be released from the flavor material when the flavor material is heated; the flavor material comprising: A polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavor formulation dispersed within the polysaccharide matrix structure, wherein the flavor formulation is at least partially entrapped within the polysaccharide matrix structure and is releasable from the polysaccharide matrix structure upon heating of the flavor material; as well as A carrier sheet material, wherein the polysaccharide matrix structure and the flavor formulation are supported by the carrier sheet material.

2. The flavor material according to claim 1, wherein the polysaccharide matrix structure comprises gellan gum as the sole polysaccharide or comprises gellan gum in combination with at least one other polysaccharide selected from the group consisting of guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose and hydroxypropyl methylcellulose.

3. The flavor material according to claim 1 or 2, wherein the gellan gum accounts for 5 to 99.9 weight % of the flavor material on a dry weight basis.

4. The flavor material according to any one of claims 1 to 3, further comprising a compound having formula C n H 2n+2 O n The polyol is preferably selected from glycerol, sorbitol, xylitol, mannitol and erythritol, or wherein the polyol preferably accounts for 0.01 wt % to 20 wt % of the flavor material on a dry weight basis, or both.

5. A flavour material according to any one of the preceding claims, further comprising fibres, wherein the fibres preferably constitute 0.01 wt% to 10 wt% of the flavour material on a dry weight basis.

6. A flavour material according to any preceding claim, wherein the carrier sheet material is a sheet of homogenised tobacco material or a sheet of stick paper wrapper material.

7. A flavour material according to any preceding claim, wherein the carrier sheet material comprises greater than 0.1 wt% carbon particles having a volume average particle size greater than 10 microns.

8. A flavour material according to any one of the preceding claims, wherein the polysaccharide matrix structure and the flavour formulation form a layer on the carrier sheet material, the layer having a thickness of at least 10 microns and preferably at least 150 microns.

9. A method of preparing a flavor material for use in an aerosol-generating article, the method comprising: Heat the water to a temperature of at least 50 degrees Celsius; dispersing gellan gum in heated water to form a gellan gum aqueous dispersion; heating the gellan gum aqueous dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form an aqueous gellan gum solution; Cooling the gellan gum aqueous solution to a temperature of 65 degrees Celsius to 75 degrees Celsius; adding a flavor preparation and an emulsifier to the cooled aqueous gellan gum solution to form a precursor composition; applying the precursor composition to a carrier sheet material; The carrier sheet material with the applied precursor composition is dried to obtain the flavor material.

10. The method according to claim 9, further comprising the step of adding a polysaccharide selected from the group consisting of guar gum, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose and hydroxypropyl methylcellulose to the cooled aqueous gellan gum solution.

11. The method of claim 9 or 10, wherein the step of applying the precursor composition to the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material.

12. The method according to any one of claims 9 to 11, wherein the step of applying the precursor composition to the carrier sheet material comprises forming a layer of the precursor composition having a thickness of at least 10 micrometers on the carrier sheet material.

13. An aerosol-generating article comprising a flavor material, wherein a flavor is released from the flavor material upon heating the aerosol-generating article; the flavor material comprising: A polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavor formulation dispersed within the polysaccharide matrix structure, wherein the flavor formulation is at least partially entrapped within the polysaccharide matrix structure and is releasable from the polysaccharide matrix structure upon heating of the flavor material; as well as A carrier sheet material, wherein the polysaccharide matrix structure and the flavor formulation are supported by the carrier sheet material.

14. An aerosol-generating article according to claim 13, comprising: strips of aerosol-generating substrate; a downstream section disposed downstream of the strip of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article; Optionally, an upstream section disposed downstream of the strip of aerosol-generating substrate and extending to a distal end of the aerosol-generating article; Wherein the flavour material is provided in at least one of the stripe, the downstream section and, optionally, the upstream section of the aerosol-generating substrate.

15. An aerosol-generating article according to claim 13 or 14, wherein the carrier sheet material is a sheet of homogenised tobacco material; The aerosol generating article comprises: a strip of an aerosol generating substrate; a downstream section disposed downstream of the strip of the aerosol generating substrate and extending to the mouth end of the aerosol generating article; optionally, an upstream section disposed downstream of the strip of the aerosol generating substrate and extending to the distal end of the aerosol generating article; wherein the flavor material is disposed in the strip of the aerosol generating substrate.

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