Method for preparing aerosol-generating material

Abstract

A method for preparing an aerosol-generating material, the method comprising forming a first composition comprising a binder and optionally an aerosol former, forming a second composition comprising a non-tobacco plant material and a filler, combining the first composition and the second composition to form a mixture of the first composition and the second composition and processing the mixture of the first composition and the second composition to form the aerosol-generating material, wherein optionally the first and / or the second composition comprises an active agent.

Description

Technical Field

[0001] This disclosure relates to a method for preparing aerosol-generating material, aerosol-generating material obtained or obtainable by said method, and articles comprising aerosol-generating material for use with a non-flammable aerosol supply system. Background Technology

[0002] Some products generate aerosols during use, which are then inhaled by the user. For example, tobacco heating devices heat aerosol-generating materials, such as tobacco, to form an aerosol by heating, but not burning, a substrate. These products typically include an aerosol-generating material that produces aerosols when heated, and a mouthpiece through which the aerosol is delivered to the user's mouth. Summary of the Invention

[0003] According to a first aspect, a method for preparing aerosol-generating materials is provided, the method comprising: A first composition is formed, the first composition comprising a binder and optionally an aerosol forming agent; A second composition is formed, the second composition comprising non-tobacco botanical material and filler; The first composition and the second composition are combined to form a mixture of the first composition and the second composition; and A mixture of the first composition and the second composition is processed to form an aerosol-generating material, wherein optionally the first and / or the second composition contains an active ingredient.

[0004] In some embodiments, processing a mixture of the first and second compositions includes extruding the mixture to form a sheet of aerosol-generating material.

[0005] In some embodiments, processing a mixture of the first composition and the second composition includes extruding the mixture to form an extrudate.

[0006] In some embodiments, processing a mixture of the first and second compositions includes forming the extrudate into a sheet of aerosol-generating material.

[0007] In some embodiments, the extrudate is formed into a sheet of aerosol generating material by using at least one roller to roll the extrudate.

[0008] In some embodiments, the mixture of the first composition and the second composition and / or the sheet of aerosol-generating material contains about 40% to about 90% water.

[0009] In some embodiments, the method includes drying sheets of aerosol-generating material.

[0010] In some embodiments, the aerosol forming agent is selected from the group consisting of: glycerol, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, triacetin, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and any mixture thereof.

[0011] In some embodiments, the mixture of the first composition and the second composition has a volatile content of about 30% to about 90%.

[0012] In some embodiments, the volatile content of the aerosol-generating material is less than the volatile content of the mixture of the first composition and the second composition.

[0013] In some embodiments, the volatile content of the aerosol-generating material is between about 25% and about 35%.

[0014] In some implementations, the plant-based materials are selected from the following list: fennel, star anise, rooibos tea, and any mixture thereof.

[0015] In some embodiments, the active ingredient is nicotine or a nicotine salt.

[0016] In some embodiments, the first composition and / or the second composition contain an acid.

[0017] In some embodiments, the acid is selected from the group consisting of nicotine benzoate, nicotine lactate, nicotine citrate, nicotine levulinate, and any mixture thereof.

[0018] In some implementations, the aerosol-generating material does not contain tobacco material.

[0019] In some embodiments, the non-tobacco plant material has a particle size distribution (D90) of 250 μm to about 400 μm.

[0020] In some embodiments, the second composition comprises a second adhesive. The first and second adhesives may be the same or different.

[0021] In some embodiments, the ratio of the first adhesive to the second adhesive is from 1:1 to about 1:10.

[0022] In some embodiments, the mixture of the first composition and the second composition contains an adhesive in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

[0023] In some embodiments, the mixture of the first composition and the second composition comprises a first binder, a second binder, and a filler in a total amount between 5% and 40% by weight of the mixture of the first composition and the second composition.

[0024] In some embodiments, the first composition is a liquid phase and the second composition is a solid phase.

[0025] In some embodiments, the mixture of the first composition and the second composition contains filler in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

[0026] In some embodiments, the method includes shredding the sheet to form strands or strips of aerosol-generating material.

[0027] In some implementations, drying is carried out at a temperature below about 100°C.

[0028] In some embodiments, a mixture of the first composition and the second composition is formed by homogenizing the first composition and the second composition.

[0029] In some embodiments, the aerosol generating material is incorporated into articles used in conjunction with non-flammable aerosol supply systems.

[0030] According to the second aspect, aerosol generating materials that are obtained or obtainable by the method of the first aspect are provided.

[0031] In some implementations, the aerosol generating material is in the form of a sheet or shredded sheet.

[0032] In some embodiments, the sheet or shredded material has a burst strength of at least 150 g.

[0033] In some embodiments, the sheet or shredded material has a density of approximately 170 g / m³. 2 Approximately 240 g / m 2 areadensity.

[0034] In some embodiments, the sheet or shredded material has a tensile strength of about 4 N / 15 mm to about 20 N / 15 mm.

[0035] In some embodiments, the aerosol generating material contains 0 to 15 wt less glycerol and / or nicotine than the mixture of the first and second compositions.

[0036] According to the third aspect, articles for use in non-flammable aerosol supply systems are provided, comprising the aerosol generating material of the second aspect or the aerosol generating material prepared according to the method of the first aspect.

[0037] According to other aspects, a non-flammable aerosol supply system comprising articles according to the third aspect is provided.

[0038] According to the fifth aspect, the use of the aerosol generating material according to the second aspect or the aerosol generating material prepared according to the method of the first aspect in articles for use in non-flammable aerosol supply systems is provided. Attached Figure Description

[0039] Embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings, wherein: Figure 1 The steps of a method for manufacturing aerosol-generating materials are shown; Figure 2 It is a side cross-sectional view of an article containing aerosol-generating materials; and Figure 3 It is used from Figure 2 A perspective view of a non-flammable aerosol supply device that generates aerosols from the aerosol-generating materials of the product. Detailed Implementation

[0040] This invention relates to a method for preparing aerosol-generating materials. The method includes forming a first composition comprising a binder and optionally an aerosol-forming agent; forming a second composition comprising a non-tobacco plant material and a filler; combining the first and second compositions to form a mixture of the first and second compositions; and processing the mixture of the first and second compositions to form an aerosol-generating material. The first and / or second compositions may contain an active ingredient. The first composition may contain water. Water may also be present in the non-tobacco plant material and / or the filler.

[0041] Aerosol-generating materials are materials that, for example, are capable of generating aerosols when heated, irradiated, or otherwise powered. Aerosol-generating materials can be in solid, liquid, or gel form, and may or may not contain active substances and / or fragrances. Aerosol-generating materials can be incorporated into articles used in aerosol-generating systems.

[0042] According to one aspect of this disclosure, an aerosol-generating material prepared by the method described herein is provided. The aerosol-generating material is arranged such that it generates an aerosol upon heating.

[0043] The second composition comprises non-tobacco plant materials. “Non-tobacco plant materials” are plant materials other than tobacco. The use of non-tobacco plant materials can enhance the sensory properties of the aerosols produced by the aerosol-generating materials generated by this method. For example, when rooibos tea, fennel, star anise, and / or peppermint are used in the aerosol-generating materials, non-tobacco plant materials can produce a particularly neutral aroma profile. Due to the relatively neutral aroma profile of non-tobacco plant materials, relatively neutral aerosols can be formed. Furthermore, when one or more of these botanical materials are used in combination with active ingredients, such as nicotine, the user can more easily perceive sensory properties attributable to the active ingredient. For example, aroma can be enhanced when combined with flavoring agents such as menthol, spearmint, and / or peppermint; berry fruits, citrus fruits, and / or tropical fruits, or any combination of these flavoring agents.

[0044] The moisture content of the aerosol-generating materials described herein can vary depending on, for example, the temperature, pressure, and humidity conditions used to maintain the composition. As is known to those skilled in the art, the moisture content can be determined by Karl-Fisher analysis.

[0045] Unless otherwise stated, as used herein, the phrases “volatile components,” “volatiles,” “total volatiles,” “volatile content,” and “total volatiles” are used to refer to volatile compounds, including water. The volatile content of a material can be measured as the mass reduction when the sample is dried in a forced-air drying oven at a temperature adjusted to 110°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is allowed to cool to room temperature in a desiccator for approximately 30 minutes.

[0046] Figure 1This illustrates how an aerosol generating material can be manufactured according to some embodiments. A first composition comprising a binder, optional active ingredient, water, and an aerosol forming agent is formed and mixed with a second composition comprising a non-tobacco plant material, a filler, and optional a second binder. In a subsequent step, the first and second compositions are mixed and extruded. Afterward, the extruded mixture of the first and second compositions can be dried to form a sheet of aerosol generating material. In an optional step, the extruded mixture of the first and second compositions can be rolled to form a sheet before drying the sheet. The sheet can then be shredded to prepare the aerosol generating material, which can then be incorporated into consumables for use in non-flammable aerosol delivery systems. The sheet can be shredded to form multiple strands or strips of aerosol generating material. The multiple strands or strips of aerosol generating material may have the same or similar physical properties as strands or strips of aerosol generating material described in WO 2021 / 255453.

[0047] The first composition, also known as a “wet mixture,” may comprise an aerosol forming agent or wetting agent, an active ingredient, water, and a binder. The wet mixture may be in the form of a suspension. The first composition may also comprise other liquids or suspensions disclosed herein. The first composition may be a liquid phase.

[0048] The first composition may include an aerosol forming agent. The aerosol forming agent comprises one or more components capable of forming aerosols. The aerosol forming agent comprises one or more of the following: glycerol, glycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl caprylate, triethyl citrate, glyceryl triacetate, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tribose, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol forming agent is glycerol, glycerin, or propylene glycol.

[0049] The first composition includes a binder. The binder is applied to bond the components of the first composition. Once combined with the second composition, the binder bonds the components of the first and second compositions to form an aerosol-generating material. The first composition may contain more than one binder. In these embodiments, the binders in the first composition may be the same or different.

[0050] The binder may be selected from one or more compounds, including but not limited to: alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of the following: alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, calcined silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder includes alginate and / or pectin or carrageenan. In some embodiments, the binder includes CMC.

[0051] The second composition, also referred to herein as a “dry mixture,” comprises non-tobacco plant material, filler, and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be a solid phase.

[0052] As used herein, the term "plant material" includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, skins, shells, etc. Alternatively, the material may include naturally occurring active compounds found in plant material or synthesized active compounds. The material may be in the form of liquid, gas, solid, powder, dust, pulverized particles, granules, small particles, fragments, strips, flakes, etc. In a preferred embodiment, the plant material is a solid.

[0053] Exemplary plant materials include tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos tea, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, wintergreen tea, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, anise seeds, basil, bay leaf, cardamom, coriander, fennel, nutmeg, oregano, red chili pepper, rosemary. Saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, deer hoof grass, perilla, turmeric, turmeric root, sandalwood, coriander leaf, bergamot, orange blossom, myrtle, blackcurrant, valerian, chili pepper, nutmeg, damiensis, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following varieties: wild mint (Mentha Arventis), cultivated mint (Mentha cv), Egyptian mint (Menthaniliaca), peppermint (Mentha piperita), peppermint cultivar (Mentha piperitacitrata cv), peppermint cultivar (Mentha piperita cv), wrinkled green mint (Mentha spicata crispa), madder mint (Mentha cordifolia), European mint (Mentha longifolia), variegated pineapple mint (Mentha suaveolens variegata), peppermint (Mentha pulegium), spearmint cultivar (Mentha spicata cv), and apple mint (Mentha suaveolens). In some preferred embodiments, the plant material is selected from the group consisting of: fennel, star anise, rooibos tea, and any mixture thereof.

[0054] In some embodiments, the second composition comprises tobacco material. The aerosol-generating material produced by the method may comprise tobacco material. As used herein, the term "tobacco material" means any material comprising tobacco or its derivatives or substitutes. Tobacco material can be in any suitable form. The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, paper-process reconstituted tobacco, or tobacco substitutes. Tobacco material can include one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stem, tobacco sheet, reconstituted tobacco, and / or tobacco extract.

[0055] The plant-based material can be a microparticle or particulate material. In some embodiments, the plant-based material is a powder. The plant-based material can be formed by grinding solid plant-based material to produce a ground plant-based material. Alternatively or additionally, the plant-based material may comprise strips, strands, or fibers of the plant-based material. For example, the plant-based material may comprise particles, granules, fibers, strips, and / or strands of the plant-based material. In some embodiments, the plant-based material consists of particles or granules of the plant-based material. In some embodiments, the plant-based material is in microparticle or ground form because this facilitates the formation of a dough-like material when the first and second compositions are combined.

[0056] In embodiments where the plant material is particulate plant material, each particle of the plant-based tobacco material may have a maximum size. As used herein, the term "maximum size" refers to the longest straight-line distance from the surface of a particle of plant material or any point on the particle surface to any other surface point of the same plant material particle or particle surface. The maximum size of the particles of the particulate tobacco material can be measured using scanning electron microscopy (SEM).

[0057] In some embodiments, the maximum size of each plant material particle is up to about 800 μm. In some embodiments, the maximum size of each plant material particle is up to about 2000 μm. In some embodiments, the maximum size of each plant material particle is about 200 μm to about 800 μm.

[0058] The population of plant-based material particles can have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of plant-based material particles has a particle size distribution (D90) of at least about 50 μm, at least about 60, at least about 70 μm, at least about 80 μm, at least about 90, at least about 100 μm, at least about 110 μm, at least about 120 μm, or at least about 130 μm. In some embodiments, the population of plant-based material particles has a particle size distribution (D90) of up to about 720 μm, up to about 740 μm, up to about 760 μm, up to about 780 μm, up to about 800 μm, up to about 820 μm, up to about 840 μm, or up to about 860 μm. In some embodiments, the population of plant-based material particles has a particle size distribution (D90) of about 600 μm. Particle size and shape analyzer, such as... Camsizer It can be used to measure particle size distribution, and sieving analysis can be used to determine the particle size distribution of plant materials.

[0059] The particle size distribution (D90) of plant-based materials can be controlled to achieve the desired areal density of aerosol-generating materials and the resulting sheets, shredded materials, or products. This can be expressed in GSM (grams per square meter or g / m²). 2 The areal density of a material is measured. For example, a lower particle size distribution (D90) is associated with a higher areal density. This higher areal density can reduce the filler value of plant-based materials when aerosol-generating materials are incorporated into articles used in non-flammable aerosol supply systems. A specific example is predicting a particle size distribution (D90) of 320 to provide approximately 190 to 200 g / m³. 2 Surface density.

[0060] Lower areal density can be associated with better taste and sensory properties of aerosol-generating materials and the sheets, shreds, or products produced therefrom. Without being bound by theory, superior taste and sensory properties can be attributed to improved heat transfer through the material. Lower areal density is believed to facilitate heat transfer through the aerosol-generating material, which in turn facilitates aerosol generation and thus improves the sensory characteristics of the material. Since the method for producing aerosol-generating materials using the methods disclosed herein involves less drying than conventional methods, fewer volatile components are lost, many of which are considered desirable. Taste and aroma are better preserved, and this is therefore associated with better sensory properties. Furthermore, the method requires less energy to remove volatile compounds.

[0061] However, the areal density cannot be too low, as this relates to undesirable sensory properties due to a reduction in the amount of tobacco in the material, which consumers find to provide positive sensory properties. Furthermore, materials with high areal density can contain more tobacco material, and therefore reducing the areal density reduces the amount of tobacco material required, which can provide further economic advantages.

[0062] The particle size distribution (D90) can be controlled to achieve the desired tensile strength of the aerosol-generating material and the resulting sheets, chips, or products. For example, a higher particle size distribution (D90) is associated with lower tensile strength. Undesirably, with a higher particle size distribution, less material is bound together. This can result in weaker aerosol-generating materials and, consequently, weaker sheets, chips, or products with lower tensile strength. A particle size distribution (D90) of 160 to 450 μm, specifically 300 to 350 μm, can provide optimal tensile strength.

[0063] A balance can be achieved between the optimal areal density and tensile strength of the aerosol-generating material and the sheets, shreds, or products produced therefrom, and this balance can be achieved through the selection of the particle size distribution (D90). The particle size distribution (D90) should be low enough to provide sufficient tensile strength, but high enough to provide areal density that offers positive sensory properties to the user and facilitates the removal of volatile compounds.

[0064] For example, a particle size distribution (D90) can be selected to provide a sufficiently low areal density to provide positive sensory properties, but a sufficiently high tensile strength should be within the operating limits of the manufacturing machine.

[0065] A particle size distribution (D90) of at least about 100 μm is considered to contribute to the tensile strength of aerosol-generating materials. The inventors have found that a particle size distribution (D90) of less than 100 μm provides aerosol-generating materials with excellent tensile strength. However, the inclusion of these fine tobacco particles in the aerosol-generating material can increase its density. This higher density can reduce the filler value of the tobacco material when the aerosol-generating material is incorporated into articles used in non-flammable aerosol supply systems. Advantageously, the inventors have found that a satisfactory balance between tensile strength and suitable areal density (and therefore filler value) can be achieved when the particle size distribution (D90) is at least 100 μm. In some embodiments, the particle size distribution (D90) is 100-800 μm.

[0066] In some embodiments, the particle size distribution (D90) is 160-450 μm. In some embodiments, the particle size distribution (D90) is 200-450 μm.

[0067] A particle size distribution of at least approximately 180 μm (D90) is considered to contribute to suitable tensile strength in aerosol-generating materials. A particle size distribution of at least approximately 200 μm (D90) provides aerosol-generating materials with excellent tensile strength. The inclusion of fine tobacco particles in aerosol-generating materials can increase their areal density.

[0068] The selection of particle size distribution (D90) can provide sufficient tensile strength and areal density of aerosol-generating materials to be the same as or improved as those produced by the "belt casting" technique.

[0069] The second composition comprises a filler. The filler may be a non-tobacco component, i.e., a component that does not contain any tobacco-derived ingredients or components. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may be a non-tobacco fiber, such as wood fiber, pulp, or wheat fiber. The filler may be a cellulose-containing material or a material containing cellulose derivatives. The filler component may also be a non-tobacco casting material or a non-tobacco extrusion material. In some embodiments, the filler is a cellulose material, cellulose, or CMC. In some embodiments, the filler is essentially composed of or consists of cellulose.

[0070] In specific embodiments incorporating filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood, wood pulp, hemp fiber, cellulose, or cellulose derivatives. Without being bound by theory, it is believed that including fibrous fillers can improve the tensile strength of the resulting aerosol-generating material. The use of cellulose as a filler can have a particularly favorable effect on the burst strength of the aerosol-generating material.

[0071] Fillers can also contribute to the texture of aerosol-generating materials. For example, fibrous fillers, such as cellulose, can provide aerosol-generating materials with relatively rough first and second surfaces. Conversely, non-fibrous, particulate fillers, such as powdered chalk, can provide aerosol-generating materials with relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials. Fillers can help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0072] The incorporation of a relatively large amount of binder relative to the aerosol forming agent in the first composition can result in a highly viscous mixture, thus making it difficult to blend the first composition with the second composition. This problem can be solved by reducing the amount of binder in the first composition and adding a second binder (which may be the same as or different from the first binder) to the second composition.

[0073] Therefore, the second composition may optionally contain a second binder. In some embodiments of the invention, the first and second binders are the same. In some embodiments of the invention, the first and second binders are different. The binder may be selected from one or more compounds, including the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder contains one or more of the following: alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, calcined silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder contains alginate and / or pectin or carrageenan. In some embodiments, the binder contains CMC.

[0074] As previously mentioned, by incorporating the second binder into the second composition, the amount of the first binder in the first composition can be reduced, thus reducing the viscosity of the first composition and facilitating the formation of a mixture of the first and second compositions. The binder can at least partially coat the surface of the tobacco material. When the plant material is in particulate form, the binder can at least partially coat the surface of the plant material particles and bind them together.

[0075] The total volatile content of the second composition may be about 5%-40% or about 10-20% by weight of the second composition.

[0076] The first and second compositions described herein can be mixed to provide a mixture of the first and second compositions. A mixture of the first and second compositions can be formed by homogenizing the first and second compositions. The mixture of the first and second compositions can be in the form of a "dough". Water can be included in the first composition. The inclusion of water in the first composition helps ensure uniform dispersion of the binder throughout the mixture. Water can also contribute to the hydration of the binder.

[0077] As previously mentioned, non-tobacco plant-based materials have a relatively neutral aroma spectrum. Compared to tobacco-based aerosol-generating materials, combining one or more of these plant materials with active ingredients allows users to more easily perceive sensory properties attributable to the active ingredient (such as nicotine or menthol). Therefore, any changes in the consistency of the aerosol-generating material when heated to produce an aerosol can be more easily perceived by the user. Thus, it is desirable to ensure that both the non-tobacco plant materials and the active ingredient are uniformly mixed throughout the aerosol-generating material to achieve a product with consistent aerosol properties.

[0078] The aerosol-generating material produced by the method described herein exhibits homogeneous properties, and therefore the aerosols produced by the aerosol-generating material are relatively uniform. A homogeneous aerosol-generating material is formed by separately forming a first composition comprising a binder and optionally an aerosol-forming agent from a second composition comprising non-tobacco plant material and filler, and then combining the first and second compositions to form a mixture of the first and second compositions, wherein the non-tobacco plant material, filler, binder, and optionally active agent are uniformly distributed throughout the aerosol-generating material.

[0079] In some implementations, it may be necessary to add a minimal amount of water, or none at all, to the mixture to provide a homogeneous dough suitable for subsequent processing steps. For example, the dough can then be extruded through a mold, and the homogeneous dough can pass properly through the mold without further addition of water or with the addition of a small amount of water.

[0080] In some embodiments, the first composition contains water. The inclusion of water in the first composition allows the binder to bind and contributes to the formation of a homogeneous mixture.

[0081] Mixing the first binder, optional active ingredient, optional aerosol forming agent, non-tobacco plant material, filler, and optional second binder in a single step (i.e., not forming the first and second compositions separately and then combining them) can result in a viscous mixture that is difficult to process and handle. By forming the first and second compositions separately and then combining them, the resulting "dough-like" mixture can be processed more easily.

[0082] The non-tobacco plant material may be present in an amount of about 10% to about 90% by weight of the mixture of the first and second compositions. For example, the plant material may be present in an amount of about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% by weight of the mixture of the first and second compositions. In some embodiments, the non-tobacco plant material is present in an amount of about 10% to 80% or about 20% to 50% by weight of the mixture of the first and second compositions. The non-tobacco plant material may be present in an amount of about 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, or 40%.

[0083] The filler component may be present in an amount of 0 to 20% by weight of the mixture of the first and second compositions, or in an amount of 1 to 10% by weight of the mixture of the first and second compositions. For example, the filler may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the mixture of the first and second compositions. In some embodiments, the filler component is present in an amount of 5 to 10% by weight of the mixture of the first and second compositions. Containing 5 to 10% filler can improve the burst strength of the aerosol-generating material and reduce its brittle properties.

[0084] The aerosol forming agent may be present in an amount of about 10% to about 25% by weight of the mixture of the first and second compositions, or in an amount of 1% to about 10% by weight of the mixture of the first and second compositions. For example, the aerosol forming agent may be present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% by weight of the mixture of the first and second compositions. In some embodiments, the aerosol forming agent is present in an amount of about 15%, 16%, 17%, 18%, or 19% by weight of the mixture of the first and second compositions.

[0085] The binder may be present in an amount of about 1 to about 20% by weight of the mixture of the first and second compositions, or in an amount of 1 to about 10% by weight of the mixture of the first and second compositions. For example, the binder may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the mixture of the first and second compositions. In some embodiments, the binder is present in an amount greater than about 2% by weight of the mixture of the first and second compositions. In some embodiments, the binder is present in an amount of about or up to about 5% by weight of the mixture of the first and second compositions. The amount of binder in the first composition, the second composition, and the mixture of the first and second compositions is important because it changes the consistency of the composition and mixture. Excessive binder can make the composition / mixture too viscous to process, for example, by pumping and machining.

[0086] In embodiments of the invention in which first and second adhesives are provided, the ratio of the first adhesive to the second adhesive can be between 1:1 and 1:10. This ratio is advantageously chosen to maintain the physical properties of the sheet and to provide adequate adhesion of the mixture and / or aerosol-generating material without adversely altering the texture of the composition. The ratio between the first and second adhesives can be approximately 1:10, 2:8, 3:7, 4:6, 5:5, 10:1, 8:2, 7:3, or 6:4, respectively. In some embodiments, the ratio between the first adhesive and the second adhesive is 4:6 to maintain the physical properties of the sheet or shredded material. Including all the adhesives in the first composition can make the first composition too viscous to process, for example, by pumping and machining. Providing adhesives in both the first and second compositions makes the composition easy to process.

[0087] Incorporating the first binder, optionally the second binder, and filler into the mixture of the first and second compositions at a total weight of about 1% to about 15% can have beneficial effects on the burst strength, strength, and flexibility of the aerosol-generating material. The mixture of the first and second compositions may contain about 2%, about 5%, about 8%, about 10%, about 12%, or about 15% of the total weight of the first binder, optionally the second binder, and filler on a dry weight (dwb) basis. In some embodiments, the mixture of the first and second compositions contains 5% of the first binder, optionally the second binder, and 5% of the filler. This incorporation of the first binder, optionally the second binder, and filler can reduce the viscosity of the aerosol-generating material, increase its burst strength, and improve its flexibility.

[0088] In one specific embodiment, both the first and optional second binders are CMC, with a total binder content of 5%, and the filler is cellulose with a total cellulose content of 8.2%. Therefore, in this embodiment, the mixture of the first and second compositions comprises 5% CMC and 8.2% cellulose.

[0089] In some embodiments, both the first and optional second binders are CMC, with a total binder content of 10%, and the filler is cellulose with a total cellulose content of 14%. Thus, in this embodiment, the mixture of the first and second compositions comprises 10% CMC and 14% cellulose.

[0090] The presence of binders and fillers in these amounts can have particularly beneficial effects on the physical properties of aerosol-generating materials, including improved strength and flexibility. Cellulose fillers improve the burst strength of aerosol-generating materials and reduce their brittleness.

[0091] The burst strength of aerosol-generating materials produced by the method described herein can be measured using a calibrated texture analyzer (50 kg force gauge, 20 mm probe height calibration, 1 g contact force) manufactured by Stable Micro Systems and Exponent software. A 5 mm stainless steel ball probe and a 3 cm [unclear text - possibly a reference to a specific type of probe] can be used. 2 The blast strength of aerosol-generating materials is determined by the sheet material. Blasting strength can be reported in unit force (g).

[0092] The aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the aerosol-generating material may have a burst strength of at least 150 g.

[0093] If the burst strength is too low, the aerosol-generating material can be relatively brittle. As discussed herein, the aerosol-generating material can be formed into sheets or fragments. Therefore, fracture can occur in the sheets or fragments during the manufacturing process of the aerosol-generating material. For example, when a sheet is shredded to form fragments, the sheet can be crushed or broken into pieces or fragments during the cutting process. The incorporation of a first binder, optionally a second binder, and fillers can help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0094] The total volatile matter content (oven volatiles) of the mixture of the first and second compositions may be greater than 20% by weight of the mixture of the first and second compositions. The volatile matter content by weight of the mixture of the first and second compositions may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, or 60%. In some embodiments, about 20% to about 60% water is added to the mixture of the first and second compositions. In some embodiments, about 30% to 60% or 40% to 60% water is added.

[0095] The total volatile matter content of the mixture of the first and second compositions may be approximately 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, or 80% by weight of the mixture of the first and second compositions.

[0096] The water content of the mixture of the first and second compositions may be greater than 20% by weight. The water content, by weight, may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, or 60%. In some embodiments, about 20% to about 60% water is added to the mixture of the first and second compositions. In some embodiments, about 30% to 60% or 40% to 60% water is added.

[0097] The total water content of the mixture of the first composition and the second composition may be about 40 to 90% by weight. The total water content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 80% or 90% by weight of the mixture of the first composition and the second composition.

[0098] This invention offers further advantages: it requires less water than other conventional compositions to prepare the dough-like mixture of the first and second compositions. This has the following advantages: the mixture of the first and second compositions can therefore be easily mixed without the addition of additional water or reagents to form a homogeneous mixture suitable for extrusion. An additional benefit of the reduced amount of water required is that it improves the reliability of the manufacturing process. Therefore, the manufacturing process is also repeatable, which also has cost-saving implications. Consequently, the total water content of the mixture of the first and second compositions is relatively low.

[0099] Due to this lower moisture content, less water needs to be removed during the processing stages. For example, the "belt casting" method uses a slurry with a target moisture content of about 75% to about 80%. This slurry must then be dried to about 13% of the target moisture content, resulting in a loss of about 67% of the water. In the invention disclosed herein, minimal water is incorporated into the mixture of the first and second compositions. For example, only about 47% of the water can be lost from the resulting dough to the final product. Therefore, the water loss in the method described herein can be significantly lower compared to methods for forming aerosol-generating materials containing a slurry, such as the belt casting method. Advantageously, less energy is consumed because less water needs to be removed during the processing stages. This is more environmentally friendly, faster, and cost-effective. Additionally, more flavor and aroma are retained due to the need for less drying.

[0100] The aerosol-generating material produced by the method disclosed herein has a volatile content between approximately 5% and approximately 30%. This makes it relatively easy to cut the aerosol-generating material into strips. If the volatile content, specifically the moisture content, is too high, the aerosol-generating material can be torn during the cutting process, which is undesirable. If the volatile content is too low, it can become too brittle and crumble during the cutting process.

[0101] The present invention offers further advantages: during the drying of the mixture of the first and second compositions, a smaller amount of specific volatile components, specifically nicotine and glycerin, are lost. Unwilling to be bound by any particular reason, the mixture of the first and second compositions contains a relatively low water content and thus requires less drying than slurries known to those skilled in the art. For example, lower temperatures and shorter drying times can be used to achieve the desired volatile content of the aerosol-generating material. This also reduces the loss of specific valuable volatile components, resulting in improved flavor, taste, and mouthfeel properties of the aerosols generated in the final product.

[0102] In an exemplary embodiment, the mixture of the first and second compositions comprises about 66% plant-based material (rooibos tea), about 17% aerosol forming agent (glycerin), about 8.2% filler (cellulose), and about 5% binder (CMC). The inventors have found that this mixture of the first and second compositions provides the advantages disclosed herein.

[0103] Once formed and mixed, the mixture of the first and second compositions can be extruded using any extrusion technique or equipment known in the art to form an aerosol-generating material.

[0104] Extrusion involves feeding a precursor composition through an orifice to produce extruded agglomerates. A method of applying a combination of pressure and shear force to the precursor composition results in the formation of agglomerated structures, which may be in sheet form.

[0105] Extrusion can be carried out using one of the main types of extruders: screw extruders, basket extruders, roll extruders, plunger extruders, and pin barrel extruders. Forming sheet structures by extrusion offers the advantages of combining this process with the mixing, conditioning, homogenization, and molding of the mixture of the first and second compositions.

[0106] Other materials, such as alkalis, diluents, solid aerosol forming agents, solid flavor modifiers, expanding agents, and other additives known in the art, can also be added during the extrusion process. This has the advantage that the additives are uniformly distributed throughout the formed agglomerate structure.

[0107] The extruded mixture of the first and second compositions can be dried using any suitable drying technique known in the art. For example, microwave drying, infrared drying, air drying, and oven drying are suitable techniques for drying aerosol-generating materials. The temperature of the drying step can be below 100°C, and in some embodiments of the invention, below 90°C. The drying temperature used can be up to about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C.

[0108] The resulting extruded mixture of the first and second compositions can be processed by forming a layer of the mixture on the surface, and then the mixture can be dried to remove at least some water and form a sheet of aerosol-generating material.

[0109] Water can be removed from the extrusion mixture by causing it to evaporate at ambient temperature and pressure (e.g., 25°C and 101 kPa). Alternatively, water can be removed by applying heat to the extrusion mixture (e.g., by heating it to above about 25°C) and / or by reducing the atmospheric pressure around the extrusion mixture of the first and second compositions (e.g., reducing it to less than 101 kPa).

[0110] The low drying temperature used is advantageous because it reduces the loss of volatile components that contribute to the flavor, taste, and mouthfeel of the final product, such as nicotine, glycerin, and flavoring agents. In some embodiments of the invention, the loss is less than about 10%, about 8%, about 5%, about 4%, about 2%, or about 1% of the total nicotine and glycerin. In some embodiments, the total volatile matter loss is less than 5%. Therefore, the aerosol-generating material has a lower total volatile matter content than the mixture of the first and second compositions.

[0111] The aerosol-generating material may contain less than about 40%, less than about 30%, less than about 20%, less than about 15%, less than about 10%, or less than about 5% of total volatiles by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material contains about 0% to about 40%, about 10% to about 35%, or about 20% to about 30% of total volatiles by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material may have a total volatile content of about 25% to about 35% by weight.

[0112] The aerosol generating material may contain water. The aerosol generating material may contain less than about 20%, less than about 15%, less than about 10%, or less than about 5% water by weight. In some embodiments, the aerosol generating material contains about 0% to about 15% or about 5% to about 15% water by weight. In some embodiments, the aerosol generating material contains about 5% to about 15% water by weight. Therefore, the aerosol generating material has a lower water content than the mixture of the first composition and the second composition.

[0113] In some embodiments, the water loss in the mixture of the first and second compositions and the aerosol-generating material is between 5% and 60%. In some embodiments of the invention, there is a water loss of about 10%, about 15%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60%. In some embodiments, there is a water loss of about 40% to 55%.

[0114] The sheet or shredded aerosol-generating material may contain less than about 30% by weight or less than about 25% by weight of water and aerosol-forming agent. It is believed that incorporating less than 30% by weight of water and aerosol-forming agent into the sheet or shredded aerosol-generating material can advantageously reduce the tackiness of the sheet. This can improve the ease of handling the aerosol-generating material during processing. For example, it is easier to roll the sheet of aerosol-generating material into a bobbin, and then unrolling the bobbin will not cause the sheet layers to adhere together. Reducing tackiness also reduces the tendency for strands or strips of shredded material to clump or stick together, thus further improving the processing efficiency and quality of the final product.

[0115] The extrusion mixture of the first and second compositions can be passed through one or a series of rollers to form a sheet of aerosol-generating material with a desired thickness.

[0116] In some implementations, the distance between the rollers varies in different roller presses. For example, the distance between the rollers may gradually decrease to gradually flatten the material and control its thickness.

[0117] In some embodiments, the rollers are smooth. This provides the advantage of providing a sheet with reduced roughness and increased smoothness. In embodiments where more than one roller press is used, repeated rolling on the material can further increase smoothness and reduce roughness.

[0118] In embodiments where the roll press includes two rolls, both the first and second surfaces of the sheet can benefit from increased smoothness and reduced roughness. This provides the additional advantage that the first and second sides of the sheet or shredded material can be more consistent and have similar smoothness.

[0119] Reducing the thickness of the extruded mixture can shorten the drying time. The sheet can then be dried. After drying, the aerosol generating material sheet can be cut into strips or strands of aerosol generating material. Sheets of a single thickness of aerosol generating material can be fed into a shredding device. This can be achieved, for example, by providing a spool of sheet material that can be continuously fed into the shredding device. Alternatively, discontinuous portions of the aerosol generating material in sheet form (such as flag-shaped sheets known to those skilled in the art) can be fed into the shredding device. The strips or strands of aerosol generating material can be aggregated and formed into articles for use in non-flammable aerosol supply systems. Optionally, the aerosol generating material can be rolled up before aggregating and forming articles. Optionally, a second cutting step can be performed on the aerosol generating material, such as in a cross-cut type shredding method, to obtain a defined cut length.

[0120] The first and / or second surfaces of the sheet or shredded material can be relatively uniform (e.g., they can be relatively smooth) or they can be uneven or irregular. For example, the first and / or second surfaces of the sheet can be textured or patterned to define relatively rough surfaces. In some embodiments, the first and / or second surfaces are relatively rough.

[0121] The smoothness of the first and second surfaces can be affected by factors such as the areal density of the sheet or shredded material, the nature of the components constituting the aerosol generating material, or whether the surface of the material has been manipulated, for example, embossed, engraved, or otherwise altered to give them a pattern or texture.

[0122] The sheet or shredded material of the aerosol generating material has a thickness of at least about 100 μm. The sheet or shredded material may have a thickness of at least about 100 μm, 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm, 280 μm, 290 μm or 300 μm. In some embodiments, the thickness of the sheet or shredded material is about 100 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the thickness of the sheet or shredded material is about 170 μm to about 280 μm, about 180 μm to about 270 μm, about 190 μm to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm. In some embodiments, the thickness of the sheet or shredded material is about 230 μm to about 270 μm or about 240 μm to about 260 μm.

[0123] The thickness of the sheet or shredded material can vary between the first and second surfaces. In some embodiments, a single strip or sheet of aerosol-generating material has a minimum thickness of about 100 μm over its area. In some cases, a single strip or shred of the aerosol-generating material has a minimum thickness of about 0.05 mm or about 0.1 mm over its area. In some cases, a single strip, strand, or sheet of the aerosol-generating material has a maximum thickness of about 1.0 mm over its area. In some cases, a single strip or shred of the aerosol-generating material has a maximum thickness of about 0.5 mm or about 0.3 mm over its area.

[0124] The thickness of sheet material can be determined using ISO 534:2011 "Paper and Board - Determination of Thickness".

[0125] If the sheets or shreds of the aerosol-generating material are too thick, heating efficiency can be compromised. This can adversely affect power consumption, such as the power consumption for releasing flavorings from the aerosol-generating material. Conversely, if the sheets or shreds of the aerosol-generating material are too thin, they can be difficult to manufacture and handle; very thin materials may be more difficult to cast and can be brittle, thus impairing aerosol formation during use.

[0126] If the sheet or shredded material of the aerosol-generating material is too thin (e.g., less than 100 μm), it may be necessary to increase the cut width of the shredded material to achieve adequate packaging of the sheet or shredded material when incorporated into the article. Increasing the cut width of the shredded material can increase the pressure drop, which is undesirable.

[0127] Assuming that during its manufacturing process, the thickness is at least about 100 μm and the areal density is about 100 g / m². 2 Approximately 240 or 250 g / m 2 The aerosol-generating material is not easily torn, cracked, or otherwise deformed. Additionally, its areal density is approximately 100 g / m³ during manufacturing. 2 Approximately 240 or 250 g / m 2 The aerosol-generating material is less prone to tearing, cracking, or other deformation. A thickness of at least about 100 μm can have a positive impact on the overall structural integrity and strength of the sheet or shredded material. For example, it can have excellent tensile strength and is therefore relatively easy to process. In some embodiments, the areal density is from about 170 to about 240 or 250 g / m³. 2 Between. In some embodiments, the areal density is approximately 180 g / m³. 2 .

[0128] It is also believed that the thickness of the sheet or shredded material affects its areal density. In other words, increasing the thickness of the sheet or shredded material can increase its areal density.

[0129] Conversely, reducing the thickness of sheets or shreds can reduce the areal density of the sheets or shreds. For the avoidance of doubt, when areal density is mentioned herein, it refers to the average areal density calculated for a given strip, strand, sheet, or plate of aerosol generating material, by measuring the surface area and weight of the given strip, strand, sheet, or plate of aerosol generating material.

[0130] The sheet or shredded material of the aerosol generating material has a density of approximately 100 g / m³. 2 Approximately 250 g / m 2 The areal density. Sheets or shredded materials can have an areal density of approximately 110 g / m³. 2 Approximately 240 g / m 2 Approximately 120 g / m 2 Approximately 230 g / m 2 Approximately 130 g / m 2 Approximately 220 g / m 2 Or approximately 140 g / m 2 Approximately 210 g / m 2The areal density. In some embodiments, the sheet or shredded material has an areal density of approximately 130 g / m². 2 Approximately 190 g / m 2 Approximately 140 g / m 2 Approximately 180 g / m 2 Approximately 150 g / m 2 Approximately 170 g / m 2 The areal density. In some embodiments, the sheet or shredded material has an areal density of approximately 180 g / m². 2 Surface density.

[0131] It is estimated to be approximately 100 g / m 2 Approximately 250 g / m 2 The areal density contributes to the strength and flexibility of the sheet or shredded material. Furthermore, a rod containing shredded material with an areal density of approximately 180 gsm and a minimum thickness of 220-230 μm can be packaged, thereby holding the aerosol-generating material in place within the rod while maintaining the desired weight of tobacco material (e.g., approximately 300 mg) within the rod and delivering acceptable sensory properties (e.g., taste and odor) when heated in a non-flammable aerosol supply device.

[0132] The flexibility of sheet or shredded material is considered to depend at least in part on its thickness and areal density. Thicker sheets or shredded materials may be less flexible than thinner ones. Furthermore, the greater the areal density of the sheet, the less flexible it is. The thickness and areal density of the combination of aerosol generating materials described herein are considered to provide relatively flexible sheets or shredded materials. This flexibility can offer several advantages when the aerosol generating material is incorporated into articles used in non-flammable aerosol supply devices. For example, the strands or strips can easily deform and bend when an aerosol generator is inserted into the aerosol generating material, thus facilitating insertion of the aerosol generator (e.g., a heater) into the material and also improving the retention of the aerosol generating material in the aerosol generator.

[0133] The areal density of the sheet or shredded material used to generate aerosols can affect the roughness of the first and second surfaces. By changing the areal density, the roughness of the first and / or second surfaces can be adjusted.

[0134] Sheets or shredded materials may have a tensile strength of at least 3 N / 15 mm. The tensile strength may be at least about 4 N / 15 mm.

[0135] When sheet or shredded material has a tensile strength of less than 3 N / 15 mm, it may tear, break, or otherwise deform during its manufacture and / or subsequent incorporation into articles intended for use in non-flammable aerosol supply systems. Tensile strength can be measured using ISO 1924:2008.

[0136] The sheet or shredded material of the aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the burst strength of the sheet or shredded material of the aerosol-generating material is at least 150 g. As disclosed and discussed above, burst strength affects the material strength.

[0137] The total volatile matter content can be about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight. Sheets or shreds of the aerosol-generating material can have a total volatile matter content of about 5-15% by weight. As disclosed herein, the present invention advantageously retains the amount of volatile compounds. This improves the flavor, taste, and mouthfeel properties of the aerosol produced in the final product.

[0138] Aerosol-generating materials contain substances to be delivered to users. The substances to be delivered include active ingredients, also referred to herein as active substances.

[0139] The composition of aerosols contributes to user experience and satisfaction. One attribute contributing to user experience and satisfaction is the presence of active ingredients in the aerosol, specifically its nicotine content. Another attribute contributing to user experience and satisfaction is the perceived irritation of the aerosol. Therefore, controlling the nicotine content and irritation of aerosols is important.

[0140] As explained earlier, non-tobacco plant materials can provide a neutral flavor spectrum, which can enhance the sensory properties of the active ingredients present. Therefore, they can also increase the irritation of the aerosol.

[0141] In some cases, aerosol-generating materials containing nicotine and organic acids have been found to produce aerosols with favorable perceived irritation. Aerosol-generating materials containing pure nicotine, such as free nicotine base, produce relatively irritating aerosols. Adding organic acids reduces the perceived irritation to a favorable level. Alternatively, aerosol-generating materials containing nicotine salts can produce aerosols with favorable perceived irritation.

[0142] For example, compared to aerosol-generating materials containing tobacco and nicotine or nicotine salts, aerosol-generating materials containing non-tobacco plant materials, nicotine and acids, or aerosol-generating materials containing non-tobacco plant materials and nicotine salts can exhibit a relatively smooth and enhanced flavor profile.

[0143] The first composition and / or the second composition may contain an active ingredient. Preferably, the active ingredient is added to the first composition. This has the advantage that the active ingredient will be uniformly distributed at least throughout the first composition.

[0144] As used herein, active substances can be physiologically active materials, which are materials intended to achieve or enhance physiological responses. Active substances can be, for example, selected from nutrients, nootropics, and psychoactive agents. Active substances can be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6, B12, or C), melatonin, or components, derivatives, or combinations thereof. Active substances may include one or more components, derivatives, or extracts of tobacco or another plant material.

[0145] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0146] As mentioned in this article, active substances may contain or be derived from one or more plant materials or their components, derivatives or extracts.

[0147] In some embodiments, the active substance comprises or is derived from one or more plant materials or their components, derivatives or extracts, and the plant material is tobacco.

[0148] In some embodiments, the active substance comprises or is derived from one or more plant materials or their components, derivatives or extracts, and the plant materials are selected from eucalyptus, star anise and cocoa.

[0149] In some embodiments, the active substance comprises or is derived from one or more plant materials or their components, derivatives or extracts, and the plant materials are selected from rooibos tea and fennel.

[0150] In some embodiments, the method includes adding an acid to a first composition or a second composition. The acid may be selected from the group consisting of levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid.

[0151] The term lactic acid is synonymous with the term 2-hydroxypropionic acid and separately covers both or mixtures of the D and L enantiomers. For example, lactic acid can be a mixture of D-2-hydroxypropionic acid and L-2-hydroxypropionic acid (e.g., a racemic mixture). The term levulinic acid is synonymous with the term 4-oxovalerate.

[0152] In some implementations, the active ingredient comprises a flavoring agent. The flavoring agent can be added at any stage of the production of the aerosol-generating material.

[0153] As used herein, the terms “flavoring agent” and “spice” refer to materials that, where permitted by local regulations, may be used in products intended for adult consumers to produce a desired taste, aroma, or other bodily sensation. These may include naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise seed, cinnamon, turmeric, Indian spices, Asian spices, vanilla, wintergreen, cherry, berries, cranberries, blueberries, peach, apple, orange, mango, citrus, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, honey whiskey, bourbon whiskey, Scotch whiskey, whiskey). Avoid alcohol, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, quinoa, nutmeg, sandalwood, bergamot, geranium, arabesque, naswar, areca nut, hookah, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wild jasmine, allspice, ginger, coriander, coffee, and more. Peppermint oil from any species of the genus *Mentha*, eucalyptus, star anise, cocoa, lemongrass, rooibos tea, flax, ginkgo, hazelnut, hibiscus, laurel, wintergreen tea, orange peel, rose, tea (such as green or black tea), thyme, juniper, elderflower, basil, bay leaf, fennel, oregano, red pepper, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander leaf, myrtle, blackcurrant, valerian, chili pepper, nutmeg, sprig salsa, marjoram, olive, bees Flowers, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclosulfonates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as activated charcoal, chlorophyll, minerals, botanical materials, or breath fresheners. These can be analogous, synthetic, or natural ingredients or blends thereof. They can be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0154] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises flavor components of cucumber, blueberry, citrus fruits, and / or cranberries. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco.

[0155] In some embodiments, the active ingredient may include a sensate intended to induce somatic sensations, which are typically chemically induced and perceived through stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or in place of olfactory or gustatory nerves, and these may include agents that provide hot, cool, tingling, or numbing effects. Suitable thermal agents may be, but are not limited to, vanillyl ethyl ether, and suitable coolants may be, but are not limited to, eucalyptol and WS-3.

[0156] In some implementations, the active ingredient can be added after the chopping operation. For example, a flavoring nozzle can be installed on the machine to deposit the flavoring agent onto the surface of the aerosol-generating material strip.

[0157] In some embodiments, the additive may be incorporated into the second composition, a mixture of the first and second compositions, or the aerosol-generating material before or after the extrusion, drying, or shredding processing steps. In some embodiments, the additive comprises the substance to be delivered.

[0158] Active ingredients can be selected to enhance the fundamental properties of the aerosol-generating material. For example, as described herein, the aerosol-generating material may preferably not contain tobacco. In these cases, for example, when rooibos tea, fennel, star anise, and / or peppermint are used in the aerosol-generating material, the plant-based material can produce a particularly neutral aroma spectrum. When using one or more of these plant-based materials, the aroma can be enhanced when combined with flavoring agents such as menthol, spearmint, and / or peppermint; berry fruits, citrus fruits, and / or tropical fruits, or any combination of these flavoring agents.

[0159] In some embodiments, the first composition, the second composition, or a mixture of the first and second compositions may contain one or more functional materials. One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0160] In some embodiments, the substance to be delivered may be an aerosol-generating material, such as those described herein, or a material not intended for aerosolization. Depending on the circumstances, any material may comprise one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agents, and / or one or more other functional materials.

[0161] According to one aspect of this disclosure, a consumable comprising an aerosol-generating material as described herein is provided. The consumable is an article comprising an aerosol-generating material, some or all of which is intended to be consumed by a user during use. The consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also comprise an aerosol generator, such as a heater, which generates heat during use to induce the aerosol-generating material to generate an aerosol. The heater may, for example, comprise a combustible material, a material that can be heated by electrical conductivity, or a base. The consumable may have any shape or size suitable for a smoking device. In some embodiments of the invention, the consumable is rod-shaped.

[0162] In one aspect, aerosol generating materials are provided in aerosol generating devices, such as heated tobacco products (THP) or hybrid electronic cigarette products.

[0163] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes: Combustible aerosol supply systems, such as cigarettes, cigarettes, and tobacco for pipes or hand-rolled or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokeable materials); and Non-flammable aerosol supply systems that release compounds from aerosol generating materials without burning the aerosol generating materials, such as electronic cigarettes, heated tobacco products, and hybrid systems that use a combination of aerosol generating materials to generate aerosols.

[0164] According to this disclosure, a "combustible" aerosol supply system is a system in which the components of the aerosol supply system, aerosol generating materials (or components thereof), are burned or ignited during use to facilitate the delivery of at least one substance to the user.

[0165] In some implementations, the delivery system is a combustible aerosol supply system, such as a system selected from the group consisting of cigarettes, cigarettes, and cigars.

[0166] In some embodiments, this disclosure relates to components used in combustible aerosol supply systems, such as filters, filter rods, filter sections, tobacco stalks, sprinkles, aerosol modifiers for releasing components, such as capsules, threads or beads, or paper, such as plug wrap, tipping paper or cigarette paper.

[0167] According to this disclosure, a "non-flammable" aerosol supply system is a system in which the aerosol generating material (or components thereof) of the aerosol supply system does not burn or ignite to facilitate the delivery of at least one substance to a user.

[0168] In some implementations, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0169] In some implementations, the non-flammable aerosol supply system is an electronic cigarette, also known as an electronic vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a necessary condition.

[0170] In some implementations, the non-flammable aerosol supply system is an aerosol-generating material heating system, also known as a non-burning heating system. An example of such a system is a tobacco heating system.

[0171] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to produce aerosols, one or more of which can be heated. Each aerosol-generating material may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system comprises liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may comprise, for example, tobacco or non-tobacco products.

[0172] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0173] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. Throughout the disclosure, these consumables may sometimes be referred to as articles.

[0174] In some embodiments, the non-flammable aerosol supply system, such as its non-flammable aerosol supply device, may include a power source and a controller. The power source may be, for example, an electric power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be energized to distribute energy in the form of heat to the aerosol-generating material or heat transfer material adjacent to the exothermic power source.

[0175] In some embodiments, a non-flammable aerosol supply system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0176] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery assembly, an aerosol generator, an aerosol generating area, a housing, a package, a filter, a mouthpiece, and / or an aerosol modifier.

[0177] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended for aerosolization. Depending on the circumstances, any material may contain one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agents, and / or one or more other functional materials.

[0178] As disclosed herein, non-flammable aerosol supply systems may include aerosol-generating materials. This is in Figure 2 and Figure 3 Examples were provided in the text.

[0179] Figure 2 This is a side cross-sectional view of a consumable or article 1 used in an aerosol delivery system. Article 1 includes a mouthpiece section 2 and an aerosol generation section 3.

[0180] The aerosol generating section 3 is in the form of a cylindrical rod and contains aerosol generating material 4. The aerosol generating material can be any material discussed herein.

[0181] Although it is in rod form as described above, the aerosol generating section 3 can be provided in the article in other forms, such as a material plug, material bag or material package.

[0182] In the illustrated embodiment, the mouthpiece segment 2 includes a material body 5, such as fibers or filament bundles.

[0183] The rod-shaped consumable 1 also includes a covering 6, such as wrapping paper, that surrounds the mouthpiece section 2 and the aerosol generating section 3.

[0184] Figure 3 An example of a non-flammable aerosol supply device 100 for generating aerosols from an aerosol generating medium / material, such as the aerosol generating material of consumable 110, as described herein, is shown. Generally, device 100 can be used to heat a replaceable article 110 containing an aerosol generating medium, for example, as... Figure 2 Article 1, as shown or described elsewhere herein, is used to generate an aerosol or other inhalable medium for inhalation by a user through device 100. Device 100 and replaceable article 110 together form a system.

[0185] The device 100 includes a housing 102 (in the form of an outer casing) that surrounds and houses multiple components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by a heating assembly. In use, the article 110 can be fully or partially inserted into the heating assembly, where it can be heated by one or more components of the heating assembly.

[0186] The device 100 of this example includes a first end member 106, which includes a cover 108 movable relative to the first end member 106, thereby closing the opening 104 when no article 110 is in place. Figure 3 The image shows the cover 108 in the open configuration; however, the cover 108 can be moved to the closed configuration. For example, a user can slide the cover 108 in the direction of arrow "B".

[0187] The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, by operating the switch 112, a user can turn on the device 100.

[0188] Device 100 may also include electrical components, such as a socket / port 114, which can accept a power cord to charge the battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0189] In some embodiments, consumable 110 may include an aerosol modifier. An aerosol modifier is a substance typically located downstream of the aerosol generation zone that is configured to alter the generated aerosol, for example, by changing its taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier release assembly, which is operable to selectively release the aerosol modifier.

[0190] Aerosol modifiers can be, for example, additives or adsorbents. Aerosol modifiers can, for example, contain one or more of fragrances, colorants, water, and carbon adsorbents. Aerosol modifiers can be, for example, solids, liquids, or gels. Aerosol modifiers can be in powder, filament, or granule form. Aerosol modifiers may not contain filter materials.

[0191] In some embodiments, the apparatus may further include an aerosol generator. An aerosol generator is a device configured to induce the formation of aerosols from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy, thereby releasing one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to induce the formation of aerosols from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

[0192] Example

[0193] Referring to Table 1, an aerosol-generating material can be prepared by forming a first composition (“liquid phase”) comprising a binder, an active ingredient (optional), an acid (optional), an aerosol-forming agent, and water, forming a second composition (“dry phase”) comprising plant-based materials and fillers, and combining the first and second compositions. The mixture is then extruded, rolled between a pair of rollers to form a sheet, and the sheet is dried at below 100°C to form a sheet of dried aerosol-generating material. The composition of each material is provided in Table 1.

[0194] Table 1

[0195] “dwb” = based on dry weight

[0196] Four mixtures (mixtures A1 to A4) were prepared based on mixture A. The amount of water in mixture A was varied by increasing the amount of water added to the first composition. The relative amounts of water and other components (plant-based materials, aerosol forming agents, fillers, and binders) are shown in Table 2.

[0197] Table 2 “wb” = based on wet weight Mixture A1 is too dry and has the consistency of loam, making it difficult to extrude and form into sheets. Mixture A2 is too sticky to be extruded and formed into sheets. Mixture A3 can be processed, but is difficult to handle due to its relatively high viscosity. Mixture A4 has lower viscosity and can be processed into sheets.

Claims

1. A method for preparing aerosol-generating materials, the method comprising: A first composition is formed, the first composition comprising a binder and optionally an aerosol forming agent; A second composition is formed, the second composition comprising a non-tobacco plant material and a filler; The first composition and the second composition are combined to form a mixture of the first composition and the second composition; and The mixture of the first composition and the second composition is processed to form an aerosol-generating material, wherein, optionally, the first composition and / or the second composition contains an active ingredient.

2. The method according to claim 1 or claim 2, wherein, Processing a mixture of the first composition and the second composition includes: extruding the mixture to form a sheet of the aerosol-generating material.

3. The method according to claim 2, wherein, Processing a mixture of the first composition and the second composition includes: extruding the mixture to form an extrudate.

4. The method according to claim 3, wherein, Processing a mixture of the first composition and the second composition includes forming the extrudate into a sheet of aerosol-generating material.

5. The method according to claim 4, wherein, The extrudate is formed into a sheet of aerosol generating material by rolling the extrudate with at least one roller.

6. The method according to any one of claims 2 to 5, wherein, The mixture of the first composition and the second composition and / or the sheet of the aerosol generating material contains water in an amount of about 40% to about 90%.

7. The method according to any one of claims 2 to 6, wherein, The method includes drying sheets of the aerosol-generating material.

8. The method according to any one of claims 1 to 7, wherein, The aerosol forming agent is selected from the group consisting of: glycerol, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, triacetin, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and any mixture thereof.

9. The method according to any one of claims 1 to 8, wherein, The mixture of the first composition and the second composition has a volatile content of about 30% to about 90%.

10. The method according to any one of claims 1 to 9, wherein, The volatile content of the aerosol generating material is less than that of the mixture of the first composition and the second composition.

11. The method according to any one of claims 1 to 10, wherein, The aerosol generating material has a volatile content of about 25% to about 35%.

12. The method according to any one of claims 1 to 11, wherein, The plant material is selected from the list of the following: fennel, star anise, rooibos tea and any mixture thereof, optionally wherein the active ingredient is nicotine or nicotine salt.

13. The method according to any one of claims 1 to 12, wherein, The first composition and / or the second composition contain an acid, optionally wherein the acid is selected from the group consisting of nicotine benzoate, nicotine lactate, nicotine citrate, nicotine levulinate, and any mixture thereof.

14. The method according to any one of claims 1 to 13, wherein, The aerosol generating material does not contain tobacco materials.

15. The method according to any one of claims 1 to 14, wherein, The non-tobacco plant material has a particle size distribution (D90) of 250 μm to about 400 μm.

16. The method according to any one of claims 1 to 15, wherein, The second composition comprises a second adhesive, and the first adhesive and the second adhesive may be the same or different. Optionally, the ratio of the first adhesive to the second adhesive is from 1:1 to about 1:

10. Optionally, the mixture of the first composition and the second composition comprises the first adhesive, the second adhesive, and the filler in a total amount of 5 to 40% by weight of the mixture of the first composition and the second composition.

17. The method according to any one of claims 1 to 16, wherein, The mixture of the first composition and the second composition contains the binder in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

18. The method according to any one of claims 1 to 17, wherein, The first composition is a liquid phase, and the second composition is a solid phase.

19. The method according to any one of claims 1 to 18, wherein, The mixture of the first composition and the second composition contains the filler in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

20. The method according to any one of claims 1 to 19, wherein, The method includes shredding the sheet to form strands or strips of the aerosol generating material.

21. The method according to any one of claims 1 to 20, wherein, Drying is carried out at a temperature below approximately 100°C.

22. The method according to any one of claims 1 to 21, wherein, By homogenizing the first composition and the second composition, a mixture of the first composition and the second composition is formed.

23. The method according to any one of claims 1 to 22, wherein, The aerosol generating material is incorporated into an article for use with a non-flammable aerosol supply system.

24. An aerosol-generating material, which is obtained or can be obtained by the method of any one of claims 1 to 23, optionally wherein, The aerosol generating material is in the form of sheets or shredded material, optionally wherein the sheets or shredded material has a burst strength of at least 150 g, optionally wherein the sheets or shredded material has a burst strength of about 170 g / m³. 2 Approximately 240 g / m 2 The areal density, optionally, wherein the sheet or shredded material has a tensile strength of about 4 N / 15 mm to about 20 N / 15 mm, optionally, wherein the aerosol generating material contains 0 to 15 wt less glycerol and / or nicotine than the amount of glycerol and / or nicotine contained in the mixture of the first composition and the second composition.

25. An article for use in a non-flammable aerosol supply system, the article comprising the aerosol generating material of claim 24.

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