Porous aerosol-generating element comprising cut filler

Abstract

A porous aerosol-generating element (40) (114) for generating an inhalable aerosol on heating, the porous aerosol-generating element (40) (114) comprising: a solid binder matrix comprising at least one binder, wherein the porous aerosol-generating element (40) (114) comprises at least 1% by weight of binder on a dry weight basis; and a cut filler dispersed within the solid binder matrix, the cut filler comprising cut plant material impregnated with an aerosol former, wherein the cut plant material has an average cut width of at least 0.75 millimetres, wherein the porous aerosol-generating element (40) (114) comprises at least 10% by weight of aerosol former on a dry weight basis. The porous aerosol-generating element (40) (114) has an average density of less than or equal to 420 mg per cubic centimetre.

Description

Technical Field

[0001] This invention relates to an aerosol generating element for generating inhalable aerosols upon heating, an article comprising the aerosol generating element, and a method for producing the aerosol generating element. Background Technology

[0002] Numerous aerosol-generating articles have been proposed in the art in which an aerosol-generating matrix (such as tobacco) is heated rather than burned. In these aerosol-generating articles, aerosols are typically generated by heating the aerosol-generating matrix to a predetermined temperature. For example, smoking articles have been disclosed in which aerosols are generated by electrically heating a tobacco-containing aerosol-generating matrix or by transferring heat from a combustible fuel element or heat source to the tobacco-containing aerosol-generating matrix. During smoking, volatile compounds are released from the aerosol-generating matrix through heat transfer from the heat source and are entrained in the air inhaled through the smoking article. When the released compounds cool, they condense to form an aerosol inhaled by the consumer.

[0003] Typically, aerosol-generating articles in which tobacco is heated rather than burned also include one or more elements paired with the aerosol-generating matrix. For example, such aerosol-generating articles have been proposed, comprising one or more of the following: a strip of aerosol-generating matrix; a support element adapted to impart increased structural strength to the aerosol-generating article; an aerosol cooling element configured to reduce the temperature of the aerosol before it reaches the mouth end of the aerosol-generating article; and a mouthpiece element.

[0004] In conventionally manufactured aerosol-generating articles, the aerosol-generating matrix is ​​formed from cylindrical strips of tobacco material (such as shredded fillers). However, it has not been found that such cylindrical strips of tobacco material provide ideal aerosol generation when heated rather than burned. Due to the way tobacco material is compacted during manufacturing, shredded filler strips typically have a relatively high density and relatively low porosity. This can pose a challenge to the uniform heating of the tobacco material, and in fact, studies have shown that a significant proportion of the cylindrical strips may not be sufficiently heated to form aerosols during use. Therefore, this proportion of strips is effectively wasted. Furthermore, the fixed size and shape of the cylindrical strips of shredded fillers limits the flexibility of the aerosol-generating matrix in adapting to the design of newer, more efficient aerosol-generating articles and aerosol-generating devices. Summary of the Invention

[0005] The aim is to provide a novel matrix for heated aerosol-generating articles, enabling more efficient aerosol generation and providing an improved consumer experience. In particular, it is desirable to provide a novel matrix that offers greater flexibility for use in different shapes and forms, allowing it to be adapted to a wider variety of aerosol-generating articles and devices. It is also desirable to provide a novel matrix that can be produced using existing methods and equipment with minimal modifications.

[0006] According to this disclosure, a porous aerosol generating element is provided for generating inhalable aerosols upon heating. The porous aerosol generating element may comprise a solid binder matrix. The solid binder matrix may comprise at least one binder. The porous aerosol generating element may comprise at least 1% by weight of binder on a dry weight basis. The aerosol generating element may further comprise shredded filler dispersed within the solid binder matrix. The shredded filler may comprise chopped plant material impregnated with an aerosol forming agent. The chopped plant material may have an average cut width of at least 0.75 mm. The porous aerosol generating element may comprise at least 10% by weight of aerosol forming agent on a dry weight basis. The porous aerosol generating element may have an average density of less than or equal to 420 mg / cm³.

[0007] According to the present invention, a porous aerosol generating element for generating inhalable aerosols upon heating is provided, the porous aerosol generating element comprising: a solid binder matrix comprising at least one binder, wherein the porous aerosol generating element comprises at least 1% by weight of the binder on a dry weight basis; and shredded filler dispersed within the solid binder matrix, the shredded filler comprising chopped plant material impregnated with an aerosol forming agent, wherein the chopped plant material has an average cut width of at least 0.75 mm, and wherein the porous aerosol generating element comprises at least 10% by weight of the aerosol forming agent on a dry weight basis. According to the present invention, the porous aerosol generating element has an average density of less than or equal to 420 mg / cm³.

[0008] According to the present invention, an aerosol generating article is also provided, comprising an aerosol generating element as defined above according to the present invention.

[0009] According to this disclosure, a method for producing a porous aerosol generating element as defined above according to this disclosure is also provided. The method may include the step of: providing plant material. The method may include the step of: conditioning the plant material. Conditioning may include applying an aerosol forming agent to the plant material. Based on the weight of the plant material, the amount of aerosol forming agent applied to the plant material may correspond to at least 15% by weight on a dry weight basis. The method may include the step of: cutting the plant material to provide shredded plant material with an average cut width of at least 0.75 mm. The method may include the step of: drying the conditioned plant material to provide shredded filler having a defined moisture level. The method may include the step of: adding a binder solution comprising one or more binders to the shredded filler and mixing the binder solution with the shredded filler to at least partially coat the shredded filler with the binder solution. The method may include the step of: compacting the mixture of binder solution and shredded filler. The method may include the step of: drying the compacted mixture to form a solid matrix comprising a solid binder matrix having shredded filler dispersed therein. The method may include the step of forming discrete porous aerosol generating elements from the solid matrix.

[0010] According to the present invention, a method for producing a porous aerosol generating element as defined above is provided. The method according to the present invention includes the steps of: providing plant material; conditioning the plant material, wherein the conditioning includes applying an aerosol forming agent to the plant material, wherein the amount of aerosol forming agent applied to the plant material corresponds to at least 15% by weight on a dry weight basis, based on the weight of the plant material; cutting the plant material to provide chopped plant material with an average cut width of at least 0.75 mm; drying the conditioned plant material to provide filamentous filler having a defined moisture level; adding a binder solution comprising one or more binders to the filamentous filler and mixing the binder solution with the filamentous filler to at least partially coat the filamentous filler with the binder solution; compacting the mixture of the binder solution and the filamentous filler; drying the compacted mixture to form a solid matrix comprising a solid binder matrix having filamentous filler dispersed therein; and forming discrete porous aerosol generating elements from the solid matrix.

[0011] As used herein, the term "aerosol generating article" refers to an aerosol generating article for generating aerosols, the aerosol generating article comprising an aerosol generating matrix intended to be heated rather than burned to release volatile compounds that can form aerosols.

[0012] As used herein, the term "aerosol generating element" refers to a discrete aerosol generating matrix in solid form, comprising filamentous fillers dispersed within a solid binder matrix. The structure and composition of aerosol generating elements will be described in more detail below.

[0013] The aerosol generating element according to the present invention can be used as an aerosol generating matrix for aerosol generating articles.

[0014] As used herein, the term "aerosol-generating matrix" refers to a matrix that can release volatile compounds that can form aerosols when heated.

[0015] The porous aerosol generating element of the present invention provides a novel and improved form of aerosol generating matrix for aerosol generating articles. The aerosol generating element provides a porous structure formed from a solid binder matrix, in which shredded plant material and an aerosol forming agent are dispersed. The solid binder matrix carries and holds the shredded filler, enabling the formation of a material with relatively high porosity and relatively low density. This, in turn, allows for very efficient heating of the aerosol generating element during use, optimizes aerosol generation from the aerosol generating element, and minimizes the amount of wasted plant material.

[0016] The form of aerosol generating elements allows for their use in a variety of shapes and forms, providing improved flexibility and versatility for use in a wide range of aerosol generating articles. Aerosol generating elements are particularly suitable for planar or flat aerosol generating articles, as the flat structure of the aerosol generating matrix provides more efficient heating and aerosol generation.

[0017] Compared to aerosol generating matrices that are in the form of loose fragments such as shredded fillers, the discrete, solid form of aerosol generating elements also facilitates the handling of aerosol generating elements during the manufacture of aerosol generating products.

[0018] In some cases, aerosol generating elements can be used without the need for packaging, which not only simplifies the manufacturing process but also reduces the environmental impact of aerosol generating elements.

[0019] Furthermore, using shredded filler containing chopped plant material minimizes the plant material processing required in the production of aerosol generating elements. In particular, compared to processes using different forms of plant material (such as reconstituted forms) to produce other aerosol generating matrices, the use of shredded filler minimizes the amount of water required for aerosol generating element production and also minimizes the required drying time. Therefore, the production of the aerosol generating element according to the invention can be carried out in an energy- and cost-efficient manner.

[0020] Due to the combination of filament filler and solid binder matrix, the structure of the aerosol generating element is non-uniform, which advantageously allows for better control of airflow through the aerosol generating element. This provides greater flexibility in the ventilation modes that can be used when the aerosol generating element is incorporated into aerosol generating articles.

[0021] Furthermore, most of the production processes for manufacturing the aerosol generating element according to the present invention can be carried out using existing equipment and methods for producing and processing filament fillers, wherein only minor modifications are required to incorporate the binder together with the filament filler into the aerosol generating element.

[0022] As described above, the aerosol generating element according to the invention comprises shredded filler dispersed within a solid binder matrix. As used herein, the term "shredded filler" describes a blend of shredded plant material (such as tobacco plant material), particularly including one or more of leaves, processed stems and ribs, and homogenized plant material. In the production of shredded filler, the shredded plant material is typically conditioned by applying an aerosol forming agent and steam, and then the conditioned plant material is dried to a defined moisture level. Shredded filler may also contain other post-cut filler tobacco or additives, which are typically combined with the dried, conditioned plant material in a post-cutting drum. For the purposes of this invention, the term "shredded filler" refers to shredded plant material that has undergone conditioning and drying steps and has been combined with post-cutting and any other additives in a post-cutting drum.

[0023] The aerosol generating element of the present invention comprises shredded plant material impregnated with an aerosol forming agent. As described above, the aerosol forming agent is applied to the plant material during the conditioning step in the production of the shredded filler. The aerosol forming agent coats the shredded plant material and also penetrates the plant material to a certain extent. The aerosol forming agent will be described in more detail below.

[0024] The aerosol generating element preferably comprises at least 70% by weight of shredded filler on a dry weight basis, more preferably at least 75% by weight of shredded filler, more preferably at least 80% by weight of shredded filler, more preferably at least 85% by weight of shredded filler, and more preferably at least 90% by weight of shredded filler.

[0025] The aerosol generating element may contain less than or equal to 99% by weight, or less than or equal to 98% by weight, of shredded filler on a dry weight basis. The total weight of the shredded filler includes the combined weight of the shredded plant material, the aerosol forming agent applied to the shredded plant material, and any additional additives or add-backs applied during the production of the shredded filler.

[0026] The shredded plant material forming the shredded filler has an average cut width of at least 0.75 mm. Preferably, the shredded plant material has an average cut width of at least 0.8 mm, more preferably at least 0.85 mm, and even more preferably at least 0.9 mm.

[0027] Preferably, the shredded plant material forming the shredded filler has an average cut width of less than or equal to 2 mm, more preferably less than or equal to 1.75 mm, more preferably less than or equal to 1.5 mm, and even more preferably less than or equal to 1.25 mm.

[0028] For example, the shredded plant material may have an average cut width between 0.75 mm and 2 mm, or between 0.8 mm and 1.75 mm, or between 0.85 mm and 1.5 mm, or between 0.9 mm and 1.25 mm. In a preferred embodiment, the shredded plant material has an average cut width of approximately 1 mm.

[0029] Preferably, the shredded filler comprises at least 25% plant leaves, more preferably at least 50% plant leaves, even more preferably at least 75% plant leaves, and most preferably at least 90% plant leaves.

[0030] The shredded plant material in the filler may include shredded tobacco. Referring to this invention, the term "tobacco" describes any plant member of the genus *Nicotiana*. Shredded tobacco may include tobacco material from one or more of light tobacco, dark tobacco, aromatic tobacco, and filler tobacco. The shredded tobacco preferably comprises at least 50% by weight of shredded tobacco leaves, more preferably at least 75% by weight of shredded tobacco leaves, and most preferably at least 90% by weight of shredded tobacco leaves.

[0031] In some embodiments of the invention, the shredded plant material may consist of shredded tobacco material.

[0032] Alternatively, or in addition to chopped tobacco, chopped plant material may include chopped non-tobacco materials. For example, chopped plant material may include one or more of the following: tea, coffee, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seeds, thyme, oregano, and cumin.

[0033] In some embodiments, the shredded filler may comprise a combination of shredded tobacco and shredded non-tobacco materials. In alternative embodiments, the shredded filler may be substantially tobacco-free, such that the aerosol generating element is tobacco-free.

[0034] Based on the total weight of the shredded filler, the shredded filler preferably contains at least 15% by weight of an aerosol forming agent on a dry weight basis. This corresponds to the proportion of aerosol forming agent applied to the shredded plant material during the production of the shredded filler. Additional aerosol forming agents may or may not be added during the step of combining the shredded filler with the binder.

[0035] Preferably, based on the total weight of the shredded filler, the shredded filler contains at least 16% by weight of aerosol forming agent on a dry weight basis, more preferably at least 17% by weight of aerosol forming agent.

[0036] Based on the total weight of the shredded filler, the shredded filler preferably contains less than or equal to 30% by weight of aerosol forming agent on a dry weight basis, more preferably less than or equal to 25% by weight of aerosol forming agent, and even more preferably less than or equal to 20% by weight of aerosol forming agent.

[0037] For example, based on the total weight of the shredded packing, the shredded packing may contain between 16% and 30% by weight of aerosol forming agent on a dry weight basis, or between 17% and 25% by weight of aerosol forming agent, or between 17% and 20% by weight of aerosol forming agent. In a preferred embodiment of the invention, based on the total weight of the shredded packing, the shredded packing contains approximately 18% by weight of aerosol forming agent on a dry weight basis.

[0038] The amount of aerosol forming agent in the aerosol generating element corresponds to at least 10% by weight on a dry weight basis. Preferably, the aerosol generating element contains at least 12% by weight of aerosol forming agent on a dry weight basis, more preferably at least 15% by weight of aerosol forming agent.

[0039] Preferably, the aerosol generating element comprises less than or equal to 40% by weight of aerosol forming agent on a dry weight basis, more preferably less than or equal to 30% by weight of aerosol forming agent, more preferably less than or equal to 25% by weight of aerosol forming agent, and even more preferably less than or equal to 20% by weight of aerosol forming agent.

[0040] For example, the aerosol generating element may contain between 10% and 40% by weight of aerosol forming agent on a dry weight basis, or between 12% and 30% by weight of aerosol forming agent, or between 15% and 25% by weight of aerosol forming agent, or between 15% and 20% by weight of aerosol forming agent.

[0041] Suitable aerosol forming agents for manufacturing aerosol generating elements according to this disclosure include, but are not limited to, glycerol, propylene glycol, and mixtures thereof.

[0042] Preferably, the aerosol generating element contains at least 10% by weight of glycerol on a dry weight basis, more preferably at least 12% by weight of glycerol, and even more preferably at least 15% by weight of glycerol on a dry weight basis.

[0043] Preferably, the aerosol generating element contains less than or equal to 40% by weight of glycerol on a dry weight basis, more preferably less than or equal to 30% by weight of glycerol, more preferably less than or equal to 25% by weight of glycerol, and even more preferably less than or equal to 20% by weight of glycerol.

[0044] For example, the aerosol generating element may contain glycerol in the range of 10% to 40% by weight on a dry weight basis, or glycerol in the range of 12% to 30% by weight, or glycerol in the range of 15% to 25% by weight, or glycerol in the range of 15% to 20% by weight.

[0045] As described above, in the aerosol generating element of the present invention, the filamentous filler is dispersed within a solid binder matrix. The solid binder matrix thus provides a matrix structure to support and bind the filamentous filler. This structure allows the aerosol generating element to have relatively high porosity and relatively low density, as described in more detail below. Preferably, the solid binder matrix is ​​substantially continuous.

[0046] The solid binder matrix is ​​formed from at least one binder. The amount of binder in the aerosol generating element should be sufficient to allow the shredded filler to bond together to form the aerosol generating element. However, the amount of binder can be adjusted according to the properties of the binder and the desired characteristics of the aerosol generating element, such as the desired density.

[0047] According to the present invention, the aerosol generating element comprises at least 1% by weight of binder on a dry weight basis. Preferably, the aerosol generating element comprises at least 2% by weight of binder on a dry weight basis, more preferably at least 5% by weight of binder, more preferably at least 7% by weight of binder, and more preferably at least 10% by weight of binder.

[0048] The aerosol generating element preferably contains less than or equal to 30% by weight of binder on a dry weight basis, more preferably less than or equal to 25% by weight of binder, more preferably less than or equal to 20% by weight of binder, and more preferably less than or equal to 15% by weight of binder.

[0049] For example, the aerosol generating element may contain a binder in the dry weight range of 1% to 30% by weight, or between 2% and 25% by weight, or between 5% and 20% by weight, or between 7% and 15% by weight, or between 10% and 20% by weight.

[0050] Preferably, on a dry weight basis, the weight ratio of filament filler to binder in the aerosol generating element is at least 3, more preferably at least 4, more preferably at least 5, more preferably at least 7, and more preferably at least 10. The weight ratio of filament filler to binder may be less than or equal to 99, preferably less than or equal to 95, and more preferably less than or equal to 90.

[0051] Suitable binders for use in the aerosol generating elements of the present invention will be known to those skilled in the art. The solid binder matrix can be formed using a single binder or a combination of two or more binders.

[0052] In some preferred embodiments of the invention, the binder comprises polyvinyl alcohol. For example, the aerosol generating element of the invention may comprise between 5% and 20% by weight of polyvinyl alcohol on a dry weight basis, or between 5% and 15% by weight of polyvinyl alcohol.

[0053] Alternatively, or in addition to polyvinyl alcohol, the binder may comprise one or more hydrocolloids. Preferably, the one or more hydrocolloids are selected from: starch, modified starch, dextrin, alginate, pectin, cellulose, cellulose derivatives (such as carboxymethyl cellulose), agar, carrageenan, gelatin, natural gums (such as astragalus gum, konjac gum, guar gum, or xanthan gum), and combinations thereof.

[0054] In some preferred embodiments of the invention, the binder comprises nanocellulose, such as cellulose nanocrystals (also known as nanocrystalline cellulose) or microfibrillated cellulose.

[0055] The aerosol generating element of the present invention may contain nanocellulose at a dry weight of between 1% and 15% by weight, or between 2% and 10% by weight, or between 2% and 8% by weight.

[0056] For example, an aerosol generating element may contain cellulose nanocrystals at a dry weight of between 1% and 15% by weight, or between 2% and 10% by weight, or between 2% and 8% by weight.

[0057] Alternatively or additionally, the aerosol generating element may contain between 1% and 10% by weight of microfibrillated cellulose on a dry weight basis, or between 2% and 8% by weight of microfibrillated cellulose, or between 2% and 6% by weight of microfibrillated cellulose, or between 2% and 4% by weight of microfibrillated cellulose.

[0058] In some embodiments, the binder comprises a combination of polyvinyl alcohol and nanocellulose. The ratio of polyvinyl alcohol to nanocellulose may be at least 1, at least 2, or at least 3.

[0059] The aerosol generating element according to the invention may further comprise one or more active agents. For example, the aerosol generating element may comprise exogenous nicotine. The term "exogenous nicotine" refers to nicotine added to the aerosol generating element as a component different from any nicotine inherently present in the chopped plant material, for example, said chopped plant material comprising chopped tobacco.

[0060] The total nicotine content of the aerosol generating element is preferably between 1% and 5% by weight on a dry weight basis, more preferably between 1% and 3% by weight. The total nicotine content corresponds to the total amount of endogenous nicotine that may be present in the tobacco material and any exogenous nicotine added in place of chopped tobacco or added in addition to chopped tobacco.

[0061] Alternatively or additionally, the aerosol generating element of the present invention may further comprise one or more flavoring agents. Suitable flavoring agents will be known to those skilled in the art. The one or more flavoring agents may comprise one or more of the following: one or more essential oils, such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; one or both of anethole and linalool.

[0062] The aerosol generating element preferably has a total water content of less than or equal to 30% by weight, more preferably less than or equal to 20% by weight, and even more preferably less than or equal to 15% by weight.

[0063] The aerosol generating element preferably has a total water content of at least 1% by weight, more preferably at least 2% by weight, and even more preferably at least 5% by weight.

[0064] For example, the aerosol generating element may have a total water content between 1% and 30% by weight, or between 2% and 20% by weight, or between 5% and 15% by weight.

[0065] Preferably, the aerosol generating element has a moisture content of less than or equal to 30% oven volatiles (OV), more preferably less than or equal to 20% oven volatiles (OV), and even more preferably less than or equal to 15% oven volatiles (OV).

[0066] Preferably, the aerosol generating element has a moisture content of at least 1% oven volatiles (OV), more preferably at least 2% oven volatiles (OV), and even more preferably at least 5% oven volatiles (OV).

[0067] For example, the aerosol generating element may have a moisture content between 1% and 30% OV, or between 2% and 20% OV, or between 5% and 15% OV.

[0068] The term "%Oven Volatile Matter" (% OV) is used to refer to the moisture content of a material. This is determined by measuring the percentage of weight loss from the tested material when a sample of the material is dried in an oven at 100 ± 1°C (°C) for 3 hours ± 0.5 minutes. In practice, it is presumed that the vast majority of the weight loss from plant material is due to moisture evaporation. It should be noted that, on an absolute basis, the moisture content value obtained by oven drying may be higher than that analyzed using a specific method (Karl Fischer method) such as ISO 6488. This difference is related to the sample type and is attributed to the loss of volatile substances, rather than water (e.g., aerosol forming agents), from the tested material during oven drying.

[0069] According to the present invention, the aerosol generating element has an average density of less than or equal to 420 mg / cm³. Preferably, the aerosol generating element has an average density of less than or equal to 400 mg / cm³, more preferably less than or equal to 375 mg / cm³, more preferably less than or equal to 350 mg / cm³, more preferably less than or equal to 325 mg / cm³, and even more preferably less than or equal to 300 mg / cm³.

[0070] The aerosol generating element preferably has an average density of at least 200 mg / cm³, more preferably at least 225 mg / cm³, and even more preferably at least 250 mg / cm³.

[0071] For example, the aerosol generating element may have an average density between 200 mg / cm³ and 420 mg / cm³, or between 200 mg / cm³ and 400 mg / cm³, or between 225 mg / cm³ and 375 mg / cm³, or between 225 mg / cm³ and 350 mg / cm³, or between 250 mg / cm³ and 325 mg / cm³, or between 250 mg / cm³ and 300 mg / cm³.

[0072] Average density can be calculated by measuring the weight of the aerosol generating element and dividing that weight by the volume occupied by the aerosol generating element.

[0073] Due to the porous structure of the filamentous filler dispersed within the solid binder matrix, the porous aerosol generating element advantageously possesses a relatively low density. This relatively low density allows for more efficient heat transfer through the aerosol generating element during use. This, in turn, enables more efficient aerosol generation from the filamentous filler during heating. The relatively low density also allows for a greater airflow through the aerosol generating element, which further improves the heating uniformity of the aerosol generating element during use.

[0074] The aerosol generating element of the present invention has a porous structure, wherein there are a plurality of air-filled pores within a structure defined by a solid binder matrix and filament filler.

[0075] Preferably, the aerosol generating element has a total porosity of at least 0.3, more preferably at least 0.35, and even more preferably at least 0.4. Preferably, the aerosol generating element has a total porosity of less than or equal to 0.7, preferably less than or equal to 0.65, and preferably less than or equal to 0.6.

[0076] For example, the aerosol generating element may have a total porosity between 0.3 and 0.7, or between 0.35 and 0.65, or between 0.4 and 0.6.

[0077] As used herein, the term "total porosity" refers to the ratio of the total pore space in a porous body to the total volume of that porous body. Specifically, the total porosity of an aerosol generating element corresponds to the total volume of pores within the aerosol generating element divided by the total volume of the aerosol generating element. Total pore volume takes into account both open and closed pores, which will be discussed below.

[0078] The porous structure of the aerosol generating element includes open pores connected to the external environment of the aerosol generating element and closed pores not connected to the external environment. Both types of pores are considered when measuring the total porosity as described above.

[0079] Preferably, the open porosity of the aerosol generating element is at least 0.3, more preferably at least 0.35, and even more preferably at least 0.4. Preferably, the open porosity of the aerosol generating element is less than or equal to 0.6, more preferably less than or equal to 0.55, and even more preferably less than or equal to 0.5. For example, the open porosity of the aerosol generating element may be between 0.3 and 0.6, or between 0.35 and 0.55, or between 0.4 and 0.5.

[0080] "Open porosity" refers to the ratio of the total open pore space within a porous body to the total volume of the porous body. This porosity value can be measured and calculated as described above regarding total porosity, but only the open pores within the structure are considered.

[0081] The total porosity and open porosity of an aerosol-generating element can be determined using an industrial computed tomography (CT) system. For the purposes of this invention, the total porosity and open porosity of an aerosol-generating element are measured using a Nikon XTH 225 ST industrial CT system from Nikon Metrology NV, which operates with the following parameters:

[0082] Beam energy: 150kV

[0083] Beam current: 36 microamps

[0084] Power: 5.4W

[0085] Number of projections: 3141

[0086] Exposure time: 708 ms

[0087] The scans obtained from the system were reconstructed in 3D using "CT Pro 3D" software from Nikon Metrology NV, and the 3D data were analyzed using "VG Studio Max" software from Volume Graphics. This software is capable of calculating the total volume of open pores, the total volume of closed pores, and thus the total volume of pores. Using the volume of the aerosol generating element, the total porosity and open porosity can then be calculated as described above.

[0088] The aerosol generating element may optionally include one or more perforations to provide a greater degree of airflow through the aerosol generating element.

[0089] The size and shape of the aerosol generating element can be adjusted according to the intended use of the aerosol generating element, for example, depending on the construction of the aerosol generating element into which the aerosol generating element can be incorporated.

[0090] Preferably, the aerosol generating element according to the invention has a weight of at least 50 mg, more preferably at least 100 mg, more preferably at least 125 mg, and even more preferably at least 150 mg.

[0091] Preferably, the weight of the aerosol generating element is less than or equal to 300 mg, more preferably less than or equal to 250 mg, and even more preferably less than or equal to 200 mg.

[0092] For example, the weight of the aerosol generating element may be between 50 mg and 300 mg, or between 100 mg and 250 mg, or between 125 mg and 250 mg, or between 100 mg and 200 mg, or between 125 mg and 200 mg, or between 150 mg and 200 mg.

[0093] The aerosol generating element is defined by a length measured in the x-direction, a width measured in the y-direction, and a thickness measured in the z-direction. The length is typically greater than or equal to the width. The thickness is typically less than or equal to both the length and width. Preferably, the thickness is less than both the length and width.

[0094] For the purposes of this invention, the thickness of the aerosol generating element should be considered as the smallest of the three dimensions measured in the x, y, and z directions.

[0095] Preferably, the length and width of the aerosol generating element are at least twice the thickness of the aerosol generating element.

[0096] Preferably, the average thickness of the aerosol generating element according to the invention is at least 1 mm, more preferably at least 1.5 mm, and even more preferably at least 2 mm. Preferably, the average thickness of the aerosol generating element is less than or equal to 15 mm, more preferably less than or equal to 10 mm, and even more preferably less than or equal to 5 mm. For example, the average thickness of the aerosol generating element may be between 1 mm and 15 mm, or between 1.5 mm and 10 mm, or between 2 mm and 5 mm. In a preferred embodiment, the aerosol generating element has an average thickness of approximately 3 mm.

[0097] The thickness of the aerosol generating element can be substantially constant along its entire length and width. Alternatively, the thickness of the aerosol generating element can be varied.

[0098] Preferably, the average thickness of the aerosol generating element is at least twice the average cut width of the shredded filler as defined above, more preferably at least 2.5 times the average cut width of the shredded filler, and even more preferably at least three times the average cut width of the shredded filler. This ensures that the aerosol generating element has sufficient structural integrity and strength for use in aerosol generating articles.

[0099] Preferably, the length of the aerosol generating element according to the invention is at least 10 mm, more preferably at least 12 mm, and even more preferably at least 15 mm. Preferably, the length of the aerosol generating element is less than or equal to 40 mm, more preferably less than or equal to 30 mm, and even more preferably less than or equal to 20 mm. For example, the length of the aerosol generating element may be between 10 mm and 40 mm, or between 12 mm and 30 mm, or between 15 mm and 20 mm.

[0100] Preferably, the width of the aerosol generating element according to the invention is at least 4 mm, more preferably at least 5 mm, and even more preferably at least 6 mm. Preferably, the width of the aerosol generating element is less than or equal to 15 mm, more preferably less than or equal to 12 mm, and even more preferably less than or equal to 10 mm. For example, the length of the aerosol generating element may be between 4 mm and 15 mm, or between 5 mm and 12 mm, or between 6 mm and 10 mm.

[0101] Preferably, the length of the aerosol generating element is at least twice the thickness, more preferably at least three times the thickness, and even more preferably at least four times the thickness.

[0102] Preferably, the width of the aerosol generating element is at least 1.5 times the thickness, more preferably at least 1.75 times the thickness, and even more preferably at least twice the thickness.

[0103] The aerosol generating element can therefore preferably have a relatively flat form, with its thickness being significantly smaller than its length and width.

[0104] In some preferred embodiments, the aerosol generating element includes opposing planar surfaces. For example, the aerosol generating element may include a planar upper surface and a lower surface, wherein the separation between the upper and lower surfaces corresponds to the thickness of the aerosol generating element. Providing opposing planar surfaces may be advantageous if the aerosol generating element is intended for use in an aerosol generating apparatus that includes a planar heating element, in order to maximize the contact between the planar heating element and the aerosol generating element.

[0105] When the aerosol generating element comprises opposing planar surfaces, the exposed surface area of ​​each planar surface is preferably at least 100 square millimeters, more preferably at least 125 square millimeters, and even more preferably at least 150 square millimeters. The exposed surface area of ​​each exposed planar surface may be less than or equal to 600 square millimeters, or less than or equal to 500 square millimeters.

[0106] The total exposed surface area of ​​the aerosol generating element according to the present invention is preferably at least 150 square millimeters, more preferably at least 250 square millimeters, even more preferably at least 350 square millimeters, and even more preferably at least 400 square millimeters. The total exposed surface area of ​​the aerosol generating element may be less than or equal to 2500 square millimeters, or less than or equal to 1500 square millimeters, or less than or equal to 1000 square millimeters.

[0107] Depending on the intended application, the aerosol generating element can have any suitable shape. It can be rectangular or rhomboid in shape. Alternatively, the aerosol generating element...

[0108] As defined above, the present invention also provides a method for producing an aerosol generating element according to the present invention as defined above. The method according to the present invention includes the steps of:

[0109] Provide plant materials;

[0110] The plant material is conditioning, wherein the conditioning includes applying an aerosol forming agent to the plant material, wherein the amount of aerosol forming agent applied to the plant material corresponds to at least 15% by weight on a dry weight basis, based on the weight of the plant material.

[0111] The plant material is cut to provide shredded plant material with an average cut width of at least 0.75 mm;

[0112] Drying and conditioning plant materials to provide shredded filler with a defined moisture level;

[0113] Add an adhesive solution containing one or more binders to the filament filler and mix the adhesive solution with the filament filler to at least partially coat the filament filler with the adhesive solution;

[0114] Compact the mixture of the binder solution and the shredded filler;

[0115] The dried and compacted mixture is used to form a solid matrix comprising a solid binder matrix having shredded filler dispersed therein; and

[0116] Discrete porous aerosol generating elements are formed from the solid matrix.

[0117] As mentioned above, the plant material can be tobacco or non-tobacco material or a combination thereof.

[0118] In the conditioning step, an aerosol forming agent is applied to the plant material. The aerosol forming agent is preferably applied at an elevated temperature, for example, between 40°C and 100°C. The aerosol forming agent can be applied with a mixture of steam. Additional additives, such as feedstock, may be applied to the plant material during the conditioning step. The conditioning step can be carried out in a direct conditioning feed roller (DCCC) under the same conditions used in conventional filament filler production processes.

[0119] The amount of aerosol forming agent applied to the plant material is adjusted so that the final shredded filler contains at least 15% by weight of aerosol forming agent on a dry weight basis.

[0120] In the cutting step, the plant material is cut to provide shredded plant material with an average cut width of at least 0.75 mm. The cutting step is preferably performed after the conditioning step, but it can alternatively be performed before the conditioning step. The cutting step can be performed using conventional methods, such as those used in conventional shredded filler production processes.

[0121] The conditioned plant material is then dried to a defined moisture level. This can be done by conventional means, such as in a flash tower dryer. The drying temperature will depend on the properties of the plant material and the desired moisture level. It can be between 100°C and 350°C, for example, between 150°C and 250°C.

[0122] Preferably, the conditioned plant is dried to a moisture content between 1% oven volatiles (OV) and 20% OV, more preferably between 5% OV and 15% OV, and even more preferably between 5% OV and 10% OV.

[0123] Following the drying step, the dried and conditioned plant material can be mixed with at least one additive or reinforcing agent (e.g., a flavoring agent or additive). This mixing can be carried out in a post-cutting drum, as used in conventional shredded filler production processes.

[0124] The product obtained from these steps is the shredded filler as described above, comprising shredded plant material impregnated with an aerosol forming agent.

[0125] To provide an aerosol-generating element with a solid binder matrix as defined above, a filament filler is combined with a binder solution containing at least one binder. For example, the binder solution is applied to the filament filler by spraying, and the filament filler is mixed with the binder solution to at least partially coat the filament filler with the binder solution. The binder solution can be a solution of the binder in water, an aerosol forming agent, or another solvent. The concentration of the binder in the binder solution can be adjusted according to the properties of the binder. Preferably, the amount of water or other solvent used in the binder solution is minimized to reduce the time and energy requirements of subsequent drying steps.

[0126] Advantageously, the binder solution can be applied to the filament filler in the post-cutting roller, allowing this step to be performed without significant alteration to existing filament filler production processes and equipment. Alternatively, the binder solution can be applied to the filament filler in a separate step downstream of the post-cutting roller. For example, the filament filler can be deposited from the post-cutting roller as a layer on a continuous surface, and the binder solution can be sprayed onto the layer of filament filler.

[0127] The mixture of shredded filler and binder solution is then compacted and dried to form a solid matrix comprising a solid binder matrix having shredded filler dispersed therein. The compaction of the shredded filler and binder solution mixture can be performed by any suitable means. In some embodiments, compaction can be performed, for example, by pressing the mixture with a pressure plate or by passing the mixture through one or more pairs of rollers. Alternatively, compaction can be performed by extruding the mixture.

[0128] Adjust the compaction degree to provide aerosol generating elements with the desired density and porosity.

[0129] After the mixture of shredded filler and binder solution is dried, the binder forms a solid matrix around the shredded filler, which binds the shredded filler together to form a solid matrix. From this solid matrix, one or more discrete aerosol generating elements can be formed. This can be done, for example, by cutting the solid matrix into the desired shape and size. In an alternative method, the mixture of shredded filler and binder solution can be formed into the desired shape and size (e.g., by extrusion) prior to the final drying step.

[0130] The aerosol generating elements according to the present invention can be used in a variety of different aerosol generating articles. As defined below, the present invention provides an aerosol generating article comprising an aerosol generating matrix, said aerosol generating matrix comprising one or more porous aerosol generating elements according to the present invention as described above.

[0131] Preferably, the aerosol generating matrix comprises a plurality of porous aerosol generating elements as described above.

[0132] Preferably, the average bulk density of the aerosol generating matrix is ​​less than or equal to 420 mg / cm³. More preferably, the aerosol generating matrix has an average bulk density of less than or equal to 400 mg / cm³, more preferably less than or equal to 375 mg / cm³, more preferably less than or equal to 350 mg / cm³, more preferably less than or equal to 325 mg / cm³, and even more preferably less than or equal to 300 mg / cm³.

[0133] The aerosol generating matrix preferably has an average bulk density of at least 200 mg / cm³, more preferably at least 225 mg / cm³, and even more preferably at least 250 mg / cm³.

[0134] For example, the aerosol generating matrix may have an average bulk density between 200 mg / cm³ and 420 mg / cm³, or between 200 mg / cm³ and 400 mg / cm³, or between 225 mg / cm³ and 375 mg / cm³, or between 225 mg / cm³ and 350 mg / cm³, or between 250 mg / cm³ and 325 mg / cm³, or between 250 mg / cm³ and 300 mg / cm³.

[0135] The average bulk density of the aerosol generating matrix can be calculated by measuring the total weight of the aerosol generating matrix and dividing that weight by the volume occupied by the aerosol generating matrix in the aerosol generating article.

[0136] The aerosol generating matrix advantageously possesses a relatively low bulk density. This relatively low bulk density allows for more efficient heat transfer through the aerosol generating matrix during use. This, in turn, enables more efficient aerosol generation from the aerosol generating element upon heating. The relatively low bulk density also allows for a greater airflow through the aerosol generating matrix, which further improves the heating uniformity of the aerosol generating matrix during use.

[0137] An aerosol generating matrix containing one or more porous aerosol generating elements can be combined with one or more elements upstream or downstream of the aerosol generating matrix.

[0138] The aerosol-generated article has an article length, an article width, and an article thickness, wherein the article length and article width are preferably at least twice the article thickness.

[0139] Preferably, the aerosol-generating article according to the invention is substantially flat or substantially planar. This means that the article has a relatively large base area relative to its volume. As mentioned above, the aerosol-generating element of the invention has been found to be particularly suitable for use in flat aerosol-generating articles because it can be easily shaped into a flat form with a relatively large relative surface area. This form will optimize the heating of the aerosol-generating element and the generation of aerosols. The thickness of the aerosol-generating element can be relatively small, thereby allowing for a small temperature gradient across the thickness of the aerosol-generating element during heating.

[0140] In certain preferred embodiments of the invention, the aerosol generating article includes: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first and second planar outer surfaces, the frame at least partially defining the cavity; an air inlet and an air outlet; and an airflow passage extending through the cavity between the air inlet and the air outlet. One or more porous aerosol generating elements are positioned between the first and second planar outer surfaces, typically within the cavity.

[0141] The cavity may contain a single aerosol generating element having a size and shape suitable for location within the cavity. Alternatively, the cavity may contain multiple aerosol generating elements, wherein the size of each aerosol generating element is significantly smaller than the size of the cavity.

[0142] In an alternative preferred embodiment of the invention, the aerosol generating article includes a container comprising a first wall and a second wall that together define a matrix compartment, wherein one or more porous aerosol generating elements are disposed in the matrix compartment.

[0143] The first wall can contain a different material than the second wall. This design advantageously allows the first and second walls to have different properties tailored for different functions. For example, the first and second walls can be configured to have different porosities, different thermal conductivity, or different stiffness.

[0144] The first wall may contain a flexible material, such as a flexible cellulose material. The second wall may have higher stiffness than the first wall.

[0145] At least a portion of the first or second wall may be porous.

[0146] As defined above, containers can take the form of bags.

[0147] The following is a non-exhaustive list of non-limiting examples. 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.

[0148] EX1. A porous aerosol generating element for generating an inhalable aerosol upon heating, the porous aerosol generating element comprising:

[0149] A solid adhesive matrix, the solid adhesive matrix comprising at least one adhesive; and

[0150] The shredded filler dispersed within the solid binder matrix comprises shredded plant material impregnated with an aerosol forming agent.

[0151] EX2. A porous aerosol generating element according to Example EX1, wherein the shredded plant material has an average cut width of at least 0.75 mm.

[0152] EX3. A porous aerosol generating element according to Example EX1 or EX2, wherein the chopped plant material has an average cut width of at least 0.8 mm, for example at least 0.85 mm, for example at least 0.9 mm.

[0153] EX4. A porous aerosol generating element according to any of the foregoing examples, wherein the shredded plant material has an average cut width of less than or equal to 2 mm, for example less than or equal to 1.75 mm, for example less than or equal to 1.5 mm, for example less than or equal to 1.25 mm.

[0154] EX5. A porous aerosol generating element according to any of the foregoing examples, wherein the chopped plant material comprises chopped tobacco.

[0155] EX6. A porous aerosol generating element according to Example EX5, wherein the shredded tobacco comprises at least 50% by weight of shredded tobacco leaves.

[0156] EX7. A porous aerosol generating element according to any of the foregoing examples, wherein the chopped plant material comprises chopped non-tobacco plant material.

[0157] EX8. The porous aerosol generating element according to Example EX7, wherein the chopped non-tobacco plant material comprises one or more of the following: tea, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seeds, thyme, oregano, and cumin.

[0158] EX9. A porous aerosol generating element according to any of the foregoing examples, wherein, based on the total weight of the filament packing, the filament packing contains at least 15% by weight of an aerosol forming agent on a dry weight basis, such as at least 16% by weight, such as at least 17% by weight.

[0159] EX10. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises at least 70% by weight of the shredded filler, for example at least 80% by weight of the shredded filler, for example at least 90% by weight of the shredded filler, on a dry weight basis.

[0160] EX11. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises at least 10% by weight of the aerosol forming agent on a dry weight basis.

[0161] EX12. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises at least 12% by weight of the aerosol forming agent on a dry weight basis, for example at least 15% by weight of the aerosol forming agent.

[0162] EX13. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises less than or equal to 40% by weight of the aerosol forming agent on a dry weight basis, for example less than or equal to 30% by weight of the aerosol forming agent, for example less than or equal to 25% by weight of the aerosol forming agent, for example less than or equal to 20% by weight of the aerosol forming agent.

[0163] EX14. A porous aerosol generating element according to any of the foregoing examples, wherein the aerosol forming agent comprises glycerol, propylene glycol, or a combination thereof.

[0164] EX15. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises at least 1% by weight of the binder on a dry weight basis.

[0165] EX16. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises at least 2% by weight of the binder on a dry weight basis, for example at least 5% by weight of the binder, for example at least 7% by weight of the binder, for example at least 10% by weight of the binder.

[0166] EX17. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises less than or equal to 30% by weight of the binder on a dry weight basis, for example less than or equal to 25% by weight of the binder, for example less than or equal to 20% by weight of the binder, for example less than or equal to 15% by weight of the binder.

[0167] EX18. A porous aerosol generating element according to any of the foregoing examples, wherein the weight ratio of the filament filler to the binder, on a dry weight basis, is at least 3, for example at least 4, for example at least 5, for example at least 7, for example at least 10.

[0168] EX19. A porous aerosol generating element according to any of the foregoing examples, wherein the binder comprises polyvinyl alcohol.

[0169] EX20. A porous aerosol generating element according to Example EX19, wherein the porous aerosol generating element comprises between 5% and 20% by weight of polyvinyl alcohol on a dry weight basis, for example, between 5% and 15% by weight of polyvinyl alcohol.

[0170] EX21. A porous aerosol generating element according to any of the foregoing examples, wherein the binder comprises one or more hydrocolloids.

[0171] EX22. A porous aerosol generating element according to Example EX21, wherein the one or more hydrocolloids are selected from: starch, modified starch, alginate, pectin, cellulose, cellulose derivatives, dextrin, agar, carrageenan, gelatin, natural gums, and combinations thereof.

[0172] EX23. A porous aerosol generating element according to any of the foregoing examples, wherein the binder comprises nanocellulose.

[0173] EX24. A porous aerosol generating element according to Example EX23, wherein the porous aerosol generating element comprises between 1% and 15% by weight of nanocellulose on a dry weight basis, for example, between 2% and 10% by weight of nanocellulose, for example, between 2% and 8% by weight of nanocellulose.

[0174] EX25. A porous aerosol generating element according to any of the foregoing examples, wherein the binder comprises polyvinyl alcohol, nanocellulose, or a combination thereof.

[0175] EX26. A porous aerosol generating element according to Example EX23, wherein the binder comprises microfibrillated cellulose.

[0176] EX27. A porous aerosol generating element according to Example EX23, wherein the porous aerosol generating element comprises cellulose nanocrystals.

[0177] EX28. A porous aerosol generating element according to any of the foregoing examples, wherein the solid binder matrix is ​​substantially continuous.

[0178] EX29. The porous aerosol generating element according to any of the foregoing examples further comprises an active agent, such as exogenous nicotine.

[0179] EX30. The porous aerosol generating element according to any of the foregoing examples further comprises a flavoring agent.

[0180] EX31. A porous aerosol generating element according to any of the foregoing examples, wherein the total water content of the porous aerosol generating element is less than or equal to 30% by weight, for example less than or equal to 15% by weight, for example less than or equal to 12% by weight.

[0181] EX32. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has a moisture content of less than or equal to 30% oven volatiles, for example less than or equal to 15% oven volatiles, for example less than or equal to 12% oven volatiles.

[0182] EX33. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has a total nicotine content between 1% and 5% by weight, for example between 1% and 3% by weight, on a dry weight basis.

[0183] EX34. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has an average density of less than or equal to 420 mg / cm³.

[0184] EX35. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has an average density of less than or equal to 400 mg / cm³, for example less than or equal to 375 mg / cm³, for example less than or equal to 350 mg / cm³, for example less than or equal to 325 mg / cm³, for example less than or equal to 300 mg / cm³.

[0185] EX36. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has an average density of at least 200 mg / cm³.

[0186] EX37. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has a total porosity of at least 0.3, for example at least 0.35, for example at least 0.4.

[0187] EX38. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has an open porosity of at least 0.3, for example at least 0.35, for example at least 0.4.

[0188] EX39. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises one or more perforations.

[0189] EX40. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element comprises a non-uniform cross section.

[0190] EX41. A porous aerosol generating element according to any of the foregoing examples, wherein the weight of the porous aerosol generating element is at least 50 mg, for example at least 100 mg, for example at least 125 mg, for example at least 150 mg.

[0191] EX42. A porous aerosol generating element according to any of the foregoing examples, wherein the weight of the porous aerosol generating element is less than or equal to 300 mg, for example less than or equal to 250 mg, for example less than or equal to 200 mg.

[0192] EX43. A porous aerosol generating element according to any of the foregoing examples, wherein the average thickness of the porous aerosol generating element is at least 1 mm, for example at least 1.5 mm, for example at least 2 mm.

[0193] EX44. A porous aerosol generating element according to any of the foregoing examples, wherein the average thickness of the porous aerosol generating element is at least twice, for example at least 2.5 times, or for example at least 3 times, the average cutting width of the filament filler.

[0194] EX45. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has a length between 10 mm and 25 mm, for example between 15 mm and 20 mm.

[0195] EX46. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element has a width between 5 mm and 15 mm, for example between 6 mm and 10 mm.

[0196] EX47. A porous aerosol generating element according to any of the foregoing examples, wherein the length of the porous aerosol generating element is at least twice the thickness, for example at least three times the thickness, for example at least four times the thickness.

[0197] EX48. A porous aerosol generating element according to any of the foregoing examples, wherein the width of the porous aerosol generating element is at least 1.5 times the thickness, for example, at least twice the thickness.

[0198] EX49. A porous aerosol generating element according to any of the foregoing examples, wherein the porous aerosol generating element includes opposing planar surfaces.

[0199] EX50. A porous aerosol generating element according to Example EX49, wherein the exposed surface area of ​​each planar surface is at least 100 square millimeters, for example at least 125 square millimeters, for example at least 150 square millimeters.

[0200] EX51. A porous aerosol generating element according to any of the foregoing examples, wherein the exposed surface area of ​​the porous aerosol generating element is at least 150 square millimeters, for example at least 250 square millimeters, for example at least 350 square millimeters, for example at least 400 square millimeters.

[0201] EX52. An aerosol generating article comprising an aerosol generating matrix, said aerosol generating matrix comprising one or more porous aerosol generating elements according to any of the foregoing examples.

[0202] EX53. An aerosol-generating article according to Example EX52, wherein the aerosol-generating article is substantially flat.

[0203] EX54. An aerosol-generating article according to Example EX53, the aerosol-generating article comprising:

[0204] First plane outer surface;

[0205] Second plane outer surface;

[0206] cavity;

[0207] A frame positioned between a first planar outer surface and a second planar outer surface, the frame at least partially defining the cavity, wherein one or more porous aerosol generating elements are positioned between the first planar outer surface and the second planar outer surface;

[0208] Air inlet and air outlet; and

[0209] An airflow passage that extends through the cavity between the air inlet and the air outlet.

[0210] EX55. An aerosol-generating article according to Example EX52, the aerosol-generating article comprising: a container, the container comprising...

[0211] A first wall and a second wall together define a matrix compartment, wherein one or more porous aerosol generating elements are disposed in the matrix compartment.

[0212] EX56. A method for producing a porous aerosol generating element according to any one of Examples EX1 to EX51, the method comprising the steps of:

[0213] Provide plant materials;

[0214] The plant material is conditioning, wherein the conditioning includes applying an aerosol forming agent to the plant material, wherein the amount of aerosol forming agent applied to the plant material corresponds to at least 15% by weight on a dry weight basis, based on the weight of the plant material.

[0215] The plant material is cut to provide shredded plant material with an average cut width of at least 0.75 mm;

[0216] Drying and conditioning plant materials to provide shredded filler with a defined moisture level;

[0217] Add an adhesive solution containing one or more binders to the filament filler and mix the adhesive solution with the filament filler to at least partially coat the filament filler with the adhesive solution;

[0218] Compact the mixture of the binder solution and the shredded filler;

[0219] The dried and compacted mixture is used to form a solid matrix comprising a solid binder matrix having shredded filler dispersed therein; and

[0220] Discrete porous aerosol generating elements are formed from the solid matrix.

[0221] EX57. The method according to Example EX56, wherein the conditioning step includes applying a mixture of the aerosol forming agent and steam to the plant material.

[0222] EX58. According to the method of Example EX56 or EX57, wherein after the drying step, the shredded filler is mixed with at least one additive in a post-cutting drum.

[0223] EX59. The method according to Example EX58, wherein the adhesive solution is applied in the cut roller.

[0224] EX60. According to the method of Example EX58, the adhesive solution is applied downstream of the cut roller.

[0225] EX61. The method according to Example EX58, wherein a feeding solution is applied to the filament packing in the cutting roller.

[0226] EX62. The method according to any one of Examples EX56 to EX61, wherein the step of compacting the mixture of the filament filler and the binder solution is carried out by pressing the mixture, for example using one or more pairs of rollers.

[0227] EX63. The method according to any one of Examples EX56 to EX61, wherein the step of compacting the mixture of the filament filler and the binder solution is carried out by extruding the mixture. Attached Figure Description

[0228] The examples will now be described further with reference to the accompanying drawings, in which:

[0229] Figure 1 A perspective view of an aerosol-generated article according to a first embodiment of the present invention is shown;

[0230] Figure 2 It shows Figure 1 An exploded perspective view of the aerosol-generated product;

[0231] Figure 3 It shows Figure 1 A cross-sectional view of the aerosol-generated product;

[0232] Figure 4 A schematic cross-sectional view of an aerosol-generated article according to a second embodiment of the present invention is shown. Detailed Implementation

[0233] Figure 1 An aerosol-generating article 10 is shown, comprising a first outer plane layer 24 forming a first outer plane surface 21, a second outer plane layer 25 forming a second outer plane surface 22, and a frame 50 positioned between the first outer plane layer 24 and the second outer plane layer 25. The first outer plane layer 24 and the second outer plane layer 25 may be formed of a non-aerosol-generating material such as paper or cardboard. Alternatively, either the first outer plane layer 24 or the second outer plane layer 25 may include an aerosol-generating matrix comprising an aerosol-generating material, such as tobacco.

[0234] The aerosol generating article 10 has a length extending in the x-direction, a width extending in the y-direction, and a thickness extending in the z-direction. The aerosol generating article 10 has a length of 30 mm, a width of 10 mm, and a thickness of 3.1 mm.

[0235] The first planar outer surface 21 and the second planar outer surface 22 extend in the x and y directions. That is, the first planar outer surface 21 and the second planar outer surface 22 extend in the x / y plane. The first planar outer surface 21 is positioned parallel to the second planar outer surface 22, and the first planar outer surface 21 is spaced apart from the second planar outer surface 22 in the z or lateral direction. The distance between the first planar outer surface 21 and the second planar outer surface 22 in the z or lateral direction corresponds to the thickness of the aerosol-generating article 10.

[0236] The aerosol-generating article 10 is a substantially flat or substantially planar aerosol-generating article. Specifically, the thickness of the aerosol-generating article 10 is less than 50% of both its length and width. The aerosol-generating article 10 has a generally rectangular cuboid shape and a laminated structure formed by a first planar outer layer 24, a frame 50, and a second planar outer layer 25. The first planar outer layer 24, the frame 50, and the second planar outer layer 25 are bonded together with an adhesive, particularly guar gum.

[0237] Figure 2 It shows Figure 1 An exploded view of the aerosol-generated product 10.

[0238] Frame 50 has a length of 30 mm, a width of 10 mm, and a thickness of 2.7 mm. Frame 50 is made of cardboard and defines a frame opening extending through the thickness of frame 50. The frame opening at least partially forms cavity 30. Cavity 30 has a length of 26 mm, a width of 6 mm, and a thickness of 2.7 mm. Therefore, cavity 30 has a volume of approximately 421.2 cubic millimeters. Cavity contains a porous aerosol generating element 40 positioned within cavity 30. The porous aerosol generating element 40 will be described in more detail below.

[0239] The first outer plane layer 24 and the second outer plane layer 25 have a thickness of 200 micrometers and are in physical contact with the frame 50. The first outer plane layer 24 and the second outer plane layer 25 are bonded to the frame with adhesive 15. The first outer plane layer 24 covers the end of the cavity 30 and forms a first cavity end wall 31. The second outer plane layer 25 covers the opposite end of the cavity 30 and forms a second cavity end wall 32. That is, the frame 50, the first outer plane layer 24 and the second outer plane layer 25 together define the cavity 30.

[0240] The frame 50 includes a peripheral wall 51 that defines the cavity 30. The outer peripheral wall 51 has a radial thickness of about 2 mm.

[0241] An air inlet (not visible) and an air outlet 12 are defined by and extend through the outer peripheral wall 51 of the frame 50. The air inlet and air outlet 12 are positioned opposite each other on opposite walls of the frame 50. Each air inlet and air outlet 12 has a rectangular cross-section, a width of 2 mm, and a thickness of 0.9 mm. An airflow passage extends through the cavity 30 between the air inlet and air outlet 12.

[0242] The porous aerosol generating element 40 is cuboid in shape, with a length of approximately 16 mm, a width of approximately 7 mm, and a thickness of approximately 3 mm. The porous aerosol generating element 40 weighs approximately 120 mg and has a density of approximately 350 mg / cm³. Although the porous aerosol generating element 40 is shown as filling the cavity 30, the actual dimensions of the element 40 are slightly smaller than the corresponding dimensions of the cavity 30, thereby providing an airflow path through the cavity when the aerosol generating element 40 is present.

[0243] The porous aerosol generating element 40 comprises a solid binder matrix and filamentous filler dispersed within the solid binder matrix. Examples of suitable compositions for the porous aerosol generating element 40 are provided below.

[0244] The porous aerosol generating element has a total porosity of about 0.5 and an open porosity of about 0.45, as determined using the aforementioned equipment.

[0245] Figure 4 An aerosol generating article 100 according to a second embodiment of the present invention is shown. The aerosol generating article 100 includes a container 110. The container 110 includes a first wall 111 and a second wall 112, which together define a matrix compartment 113. An aerosol generating element 114 is disposed in the matrix compartment 113. The matrix compartment 113 has a length of 17 mm, a width of 8 mm, and a depth of 3.5 mm.

[0246] The first wall 111 is formed of nonwoven cotton material. The first wall 111 contains between 85% and 90% by weight of cellulose, between 7% and 16% by weight of hemicellulose, and between 1% and 3% by weight of lignin. The first wall 111 is porous.

[0247] The second wall 112 contains paper. The second wall 112 has a weight of approximately 35 gsm per square meter. The second wall is non-porous.

[0248] The second wall 112 can be substantially planar. The second wall 112 has higher stiffness than the first wall 111. In this way, the first wall 111 can generally form a bag shape closed by the second wall 112.

[0249] The first wall 111 and the second wall 112 meet at the contact area 116. The contact area 116 extends around the circumference of the container 110. The contact area 116 has a thickness of 3.5 mm. The first wall 111 and the second wall 112 are joined at the contact area 116 by an adhesive to form a sealed area. The adhesive is a polyvinyl alcohol adhesive.

[0250] The first wall 111 and the second wall 112 are thermally stable at a temperature of at least 280 degrees Celsius or below.

[0251] The aerosol-generating article 100 also includes a ring element 115 covering the sealing area. The ring element 115 is formed of paper with a basis weight of 100 gsm per square meter. The ring element 115 has higher stiffness than the first wall 111 and the second wall 112. The ring element 115 covers the entire sealing area. The ring element 115 is adhered to the first wall 111. In this way, a portion of the first wall 111 is sandwiched between the ring element 115 and the second wall 112. The ring element 115 is adhered to the first wall 111 by a polyvinyl alcohol adhesive. The ring element 115 has a thickness of 3.5 mm corresponding to the thickness of the contact area 116.

[0252] Aerosol generating element 114 is disposed in matrix compartment 113. Aerosol generating element 114 is cuboid in shape, having a length of approximately 16 mm, a width of approximately 7 mm, and a thickness of approximately 3 mm. Aerosol generating element 114 weighs approximately 120 mg and has a density of approximately 350 mg / cm³. Aerosol generating element 114 comprises a solid binder matrix and filament filler dispersed within the solid binder matrix. An example of a suitable composition of aerosol generating element 114 is provided below.

[0253] Example

[0254] Table 1 below shows suitable compositions for forming the aerosol generating element according to the present invention:

[0255]

[0256] Table 1

[0257] All quantities are on dry weight and are shown as a weight percentage based on the total weight of the aerosol generating elements.

[0258] To prepare aerosol-generating elements with compositions according to samples A through E, the tobacco raw material is first conditioned in a direct conditioning feed roller (DCCC) by applying glycerol and steam at approximately 60 degrees Celsius. The conditioned tobacco material is cut to an average cut width of 1 mm and then dried in a flash tower dryer (FTD) at 200 degrees Celsius to provide a moisture content of approximately 9% oven volatiles (OV). The dried, conditioned tobacco material is added to a post-cut roller, where a backfill comprising tobacco stems and optional clove particles is added to form a shredded filler. An aqueous solution of a binder is then applied to the shredded filler in the post-cut roller. The binder solution is mixed with the shredded filler to at least partially coat the shredded filler in the binder solution. The mixture of shredded filler and binder solution is then compacted by passing the mixture through a series of rollers. The resulting compacted mixture is dried to a moisture content of approximately 10% oven volatiles and then cut to form aerosol-generating elements of the desired size and shape.

[0259] When the aerosol generating element is heated in the article described above with reference to the accompanying drawings, it is found that the aerosol generating element generates an aerosol providing suitable levels of nicotine and glycerin throughout the heating duration.

[0260] To prepare an aerosol generating element with the composition according to sample F, dried chamomile granules are used instead of tobacco raw materials. The remainder of the process described above can then be followed, including conditioning the chamomile granules, mixing the chamomile granules with a binder solution, compacting the resulting mixture, and drying it.

[0261] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Thus, in this context, the figure A is understood to be A ± 10% of A. In this context, the figure A may be considered to include a value within the general standard error for the measurement of the property modified by the figure A. In certain instances used in the appended claims, the figure A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or may not be listed herein.

Claims

1. A porous aerosol generating element for generating an inhalable aerosol upon heating, the porous aerosol generating element comprising: A solid binder matrix comprising at least one binder, wherein the porous aerosol generating element comprises at least 1% by weight of the binder on a dry weight basis; and The shredded filler dispersed within the solid binder matrix comprises shredded plant material impregnated with an aerosol forming agent, wherein the shredded plant material has an average cut width of at least 0.75 mm, and wherein the porous aerosol generating element comprises at least 10% by weight of the aerosol forming agent on a dry weight basis; and The porous aerosol generating element has an average density of less than or equal to 420 mg / cm³.

2. The porous aerosol generating element according to claim 1, wherein the shredded plant material in the shredded filler comprises shredded tobacco.

3. The porous aerosol generating element according to claim 1 or 2, comprising at least 15% by weight of an aerosol forming agent.

4. The porous aerosol generating element according to any of the preceding claims, comprising less than or equal to 30% by weight of the binder on a dry weight basis.

5. The porous aerosol generating element according to any of the preceding claims, wherein the weight ratio of the filament filler to the binder is at least 3 on a dry weight basis.

6. The porous aerosol generating element according to any of the preceding claims, wherein the binder comprises polyvinyl alcohol, nanocellulose, or a combination thereof.

7. The porous aerosol generating element according to any of the preceding claims, having a moisture content of less than or equal to 20% of oven volatiles.

8. The porous aerosol generating element according to any of the preceding claims, having a total porosity of at least 0.

3.

9. The porous aerosol generating element according to any of the preceding claims, wherein the aerosol generating element has a length, a width, and a thickness, and the length and the width are at least twice the thickness of the aerosol generating element.

10. The porous aerosol generating element according to claim 9, wherein the average thickness of the aerosol generating element is at least 2 mm.

11. The porous aerosol generating element according to claim 9 or 10, wherein the average thickness of the porous aerosol generating element is at least three times the average cutting width of the filament filler.

12. An aerosol generating article comprising an aerosol generating matrix, said aerosol generating matrix comprising one or more aerosol generating elements according to any of the preceding claims.

13. The aerosol-generating article according to claim 12, wherein the aerosol-generating article has an article length, an article width, and an article thickness, wherein the article length and the article width are at least twice the article thickness.

14. A method for producing a porous aerosol generating element according to any preceding claim, the method comprising the steps of: Provide plant materials; The plant material is conditioning, wherein the conditioning includes applying an aerosol forming agent to the plant material, wherein the amount of aerosol forming agent applied to the plant material corresponds to at least 15% by weight on a dry weight basis, based on the weight of the plant material. The plant material is cut to provide shredded plant material with an average cut width of at least 0.75 mm; Drying and conditioning plant materials to provide shredded filler with a defined moisture level; Add an adhesive solution containing one or more binders to the filament filler and mix the adhesive solution with the filament filler to at least partially coat the filament filler with the adhesive solution; Compact the mixture of the binder solution and the shredded filler; The dried and compacted mixture is used to form a solid matrix comprising a solid binder matrix having filament fillers dispersed therein. as well as Discrete porous aerosol generating elements are formed from the solid matrix.

15. The method of claim 14, wherein the binder solution is applied to the filament filler in the post-cutting roller.

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