Aerosol-forming material comprising guar gum and starch or modified starch

Abstract

The present invention provides an aerosol-generating material, the aerosol-generating material comprising (a) an aerosol-forming material, (b) a first binder that is guar gum, (c) a second binder that is a starch or modified starch, and (d) a filler. The present invention also provides a method of forming the aerosol-generating material. The present invention also provides a consumable for use with a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating composition, the aerosol-generating composition comprising the aerosol-generating material of the present invention. The present invention also provides a method of generating an aerosol using a non-combustion aerosol delivery system, and the use of the aerosol-generating composition in a consumable for use with a non-combustion aerosol delivery device.

Description

[Technical field]

[0001] The present invention relates to the generation of aerosols. In particular, the present invention relates to aerosol-forming materials, aerosol-forming compositions, consumables, non-combustion aerosol delivery systems, methods of generating aerosols, and methods of forming aerosol-forming materials.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These are sometimes referred to as non-combustion smoking articles, aerosol generating assemblies, or non-combustion aerosol delivery systems.

[0003] One example of such a product is a heating device that releases compounds by heating but not burning a solid aerosolizable material. The solid aerosolizable material may, in some examples, include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products (THPs). A variety of different configurations are known for volatilizing at least one component of a solid aerosolizable material.

[0004] Another example is an e-cigarette / tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosolizable material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Overview

[0005] In a first aspect, an aerosol-forming material is provided, the aerosol-forming material comprising: (a) an aerosol-forming material; (b) a first binder which is guar gum; (c) a second binder which is a starch or a modified starch; and (d) a filler; and Includes.

[0006] In a second aspect, there is provided an aerosol forming composition comprising the aerosol forming material of the first aspect.

[0007] In a third aspect, there is provided a consumable for use in a non-combustion aerosol delivery device, the consumable comprising the aerosol generating composition of the second aspect.

[0008] In a fourth aspect, there is provided a non-combustion aerosol delivery system comprising the consumable of the third aspect and a non-combustion aerosol delivery device.

[0009] In a fifth aspect, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system of the fourth aspect, the method comprising heating an aerosol-generating material to a temperature of less than 350° C.

[0010] In a sixth aspect, there is provided a use of the non-combustion aerosol delivery system of the fourth aspect for generating an inhalable aerosol. In a seventh aspect, a method of making an aerosol-generating material is provided, the method comprising: (i) providing a slurry comprising an aerosol-forming material, a first binder which is guar gum, a second binder which is starch or modified starch, a filler, a solvent, and any further components of the aerosol-forming material; (ii) forming a layer of the slurry; (iii) drying the slurry to form an aerosol-generating material; Includes.

[0011] A further aspect provides a method for making the aerosol-generating materials described herein using a papermaking process, such as an airlaid papermaking process.

[0012] Features described in this specification in connection with one aspect of the invention are expressly disclosed in combination with each of the other aspects, insofar as they are combinable.

[0013] Further characteristics and advantages of the invention will become apparent from the following description, given by way of example only and made with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0014] [Figure 1] FIG. 2 is a cross-sectional view of an example of a consumable item. [Diagram 2] FIG. 2 is a perspective view of the consumable item of FIG. 1. [Diagram 3] FIG. 2 is a cross-sectional elevation view of an example consumable. [Figure 4] FIG. 4 is a perspective view of the consumable item of FIG. 3. [Diagram 5] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 6] FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. Detailed Description

[0015] As mentioned above, (a) an aerosol-forming material; (b) a first binder which is guar gum; (c) a second binder which is a starch or a modified starch; and (d) a filler; and An aerosol-forming material is provided, comprising:

[0016] The aerosol-forming material may form part of an aerosol-forming composition, which is a composition that is capable of generating an aerosol when, for example, heated, irradiated, or supplied with energy in any other way.

[0017] The aerosol-generating material may be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material may be non-fibrous or fibrous. For example, the aerosol-generating material may be substantially non-fibrous. In some embodiments, the aerosol-generating material may be a dry gel. The aerosol-generating material is a solid material that may retain some fluid therein, e.g., a liquid. In some embodiments, the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material) or the retained fluid may be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0018] In some embodiments, the aerosol-forming material is a film.

[0019] In some embodiments, the aerosol-generating material consists essentially of, or consists of, the aerosol-forming material, first and second binders, optionally chitosan, a solvent, such as water, and a bulking agent.

[0020] In some embodiments, the aerosol-generating material consists essentially of or consists of the aerosol-forming material, first and second binders, optionally chitosan, water, and a filler.

[0021] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20% water by weight, calculated on a wet weight basis. In some instances, the hydrogel may contain less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB).

[0022] In some embodiments, the aerosol-forming material may contain less than about 20% water by weight, e.g., less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). For example, the aerosol-forming material may contain between about 1 and 15% water by weight, e.g., between 3 and 12% water by weight, calculated on a wet weight basis (WWB).

[0023] First and second binders The aerosol-forming material includes a first binder that is guar gum and a second binder that is a starch or modified starch.

[0024] The term "gelling agent" may also be used herein in place of "binder."

[0025] The aerosol-generating material has a density of about 80 to about 120 g / m 2 , for example, about 100 g / m 2 Advantageously, the aerosol-forming material has an areal density of about 100 g / m2 or less, so that the mixture of aerosol-forming material and tobacco (such as cut rag tobacco) does not easily separate. It is also desirable for the aerosol-forming material to have sufficient tensile strength to allow the aerosol-forming material to be wound (e.g., in sheet form) onto a bobbin and unwound without breakage. The required areal density (e.g., about 100 g / m2 or less) is preferably about 100 g / m2 or less. 2 It has been found that aerosol-forming materials having a viscosity of about 100 g / m or more and sufficient tensile strength (e.g., about 250 N / m or more) to be wound and unwound on a bobbin can be produced using a guar gum binder in combination with a filler and an aerosol-forming material. However, the viscosity of a liquid (such as a slurry) containing the guar gum binder can be relatively high. By replacing a portion of the guar gum binder with a second binder that is a starch or modified starch, the viscosity of the resulting mixture can be reduced, thereby facilitating handling while still providing a suitable areal density (e.g., about 100 g / m 2 It has been found that it is possible to produce aerosol-forming materials having high molecular weight and sufficient tensile strength.

[0026] In some embodiments, the second binder is a modified starch. The terms "modified starch" and "starch derivatives" may be used interchangeably in this disclosure and are intended to be equivalent.

[0027] Suitable modified starches (sometimes referred to as starch derivatives) include, but are not limited to, hydroxypropyl starch, sodium carboxymethyl starch, carboxymethyl starch, octenyl succinic anhydride-modified starch, acetate starch, phosphate-crosslinked starch, adipate-crosslinked starch, hydroxypropylated phosphate-crosslinked starch, phosphate monoesterified phosphate-crosslinked starch, acetylated phosphate-crosslinked starch, and acetylated adipate-crosslinked starch. In certain embodiments, the modified starch comprises (or is) one or more of hydroxypropyl starch, carboxymethyl starch, and sodium carboxymethyl starch. In certain embodiments, the modified starch comprises (or is) one or more of hydroxypropyl starch, and sodium carboxymethyl starch.

[0028] In some embodiments, the aerosol-forming material comprises a first binder (guar gum) in an amount of about 3%, 5%, 7%, or 10% to about 35%, 30%, 25%, or 20% by weight of the aerosol-forming material on a dry weight basis. For example, in some embodiments, the aerosol-forming material comprises a first binder in an amount of about 3-35%, about 5-30%, about 7-25%, or about 10-20% by weight of the aerosol-forming material.

[0029] In some embodiments, the aerosol-forming material comprises a second binder (starch or modified starch) in a total amount of about 1%, 2%, or 3% to about 20%, 15%, or 10% by weight of the aerosol-forming material on a dry weight basis. For example, in some embodiments, the aerosol-forming material comprises a second binder in a total amount of about 1-20%, about 2-15%, or about 3-10% by weight of the aerosol-forming material.

[0030] In some embodiments, the aerosol-forming material comprises a first and second binder in a total amount of about 5%, 10%, 15%, 17%, or 20% to about 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol-forming material on a dry weight basis. In some such embodiments, the total amount of the first and second binder in the aerosol-forming material is about 5-50%, 10-40%, 15-30%, 15-25%, or 17-25% by weight. In certain embodiments, the total amount of the first and second binder in the aerosol-forming material is about 15 to about 25% by weight.

[0031] More binders As with the first and second binders, the aerosol forming materials may further include one or more additional binders other than guar gum, starch, or modified starch.

[0032] In some embodiments, the additional binder comprises a hydrocolloid.

[0033] In some embodiments, the additional binder comprises (or is) one or more compounds selected from polysaccharide binders, such as alginates, pectins, cellulose or derivatives thereof, pullulan, carrageenan, agar and agarose, gelatin and chitosan, gums, such as xanthan gum, and acacia gum, silica or silicone compounds, such as PDMS and sodium silicate, clays, such as kaolin, and polyvinyl alcohol.

[0034] In some embodiments, the additional binder comprises (or is) one or more polysaccharide binders, hi some embodiments, the polysaccharide binder is selected from alginate, pectin, cellulose or derivatives thereof, and chitosan.

[0035] Examples of cellulose binders (sometimes referred to herein as cellulose derivatives) include, but are not limited to, hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose or its derivatives are selected from hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In certain embodiments, the cellulose derivative is CMC.

[0036] In some embodiments, the additional binder is chitosan, which may improve the retention of certain effective compounds in the aerosol-generating material. For example, the use of chitosan may aid in the retention of glycerol within the aerosol-generating material. This may help reduce the stickiness of the surface of the aerosol-generating material, for example, when the aerosol-generating material contains a high concentration of aerosol-forming material, thereby facilitating the processing and / or handling of the aerosol-generating material (during its manufacture and / or subsequent processing).

[0037] The use of chitosan may also improve the tensile strength of the aerosol-forming material.

[0038] Chitosan is a copolymer of D-glucosamine and N-acetyl-D-glucosamine. Typically, chitosan is produced by N-deacetylation of chitosan by alkaline hydrolysis.

[0039] In some embodiments, the aerosol-forming material comprises chitosan in an amount of about 0.01%, 0.025%, 0.05%, or 0.1% to about 10%, 5%, 4%, 3%, 2%, 1%, or 0.7% by weight of the aerosol-forming material on a dry weight basis. For example, the aerosol-forming material may comprise chitosan in an amount of about 0.01 to 10%, e.g., 0.025 to 5%, 0.05 to 2%, 0.1 to 1%, or 0.1 to 0.7% by weight.

[0040] In some embodiments, the only binders are the first and second binders (ie, guar gum and starch or starch derivative).

[0041] Aerosol-forming materials The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material includes (or is) one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0042] In some embodiments, the aerosol forming material includes (or is) one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0043] In certain embodiments, the aerosol forming material includes (or is) glycerol, optionally in combination with propylene glycol.

[0044] The aerosol-forming material may comprise, on a dry weight basis, a total amount of aerosol-forming material of about 1% to about 80% by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material may comprise about 1%, 10%, 20%, 30%, 35%, 40%, or 45% to about 80%, 70%, 65%, 60%, or 55% by weight of the aerosol-forming material, for example, about 50% by weight of the aerosol-forming material. In certain embodiments, the aerosol-forming material comprises about 35-65%, about 40-60%, or about 45-55%, for example, about 50% by weight of the aerosol-forming material.

[0045] Filler The aerosol-forming material includes a bulking agent. The use of a bulking agent can help, for example, to reduce the stickiness of the aerosol-forming material when high levels of the aerosol-forming material are present.

[0046] In some embodiments, the aerosol-forming material comprises at least 15% by weight, e.g., about 15-40% by weight of the bulking agent on a dry weight basis, for example, in some embodiments, the aerosol-forming material comprises about 20-40% by weight, or about 25-35% by weight of the bulking agent.

[0047] In some embodiments, the filler includes (or is) 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).

[0048] In some embodiments, the filler comprises (or is) one or more organic filler materials, such as wood pulp, tobacco pulp, hemp fiber, cellulose and cellulose derivatives, such as microcrystalline cellulose and / or nanocrystalline cellulose.

[0049] As those skilled in the art will appreciate, crystalline cellulose can be formed by depolymerizing cellulose through a chemical process (e.g., using acid or enzymes). One method for forming crystalline cellulose includes acid hydrolysis of cellulose, using an acid such as HCl. The cellulose produced after this process is crystalline (i.e., no amorphous regions remain). Suitable methods and conditions for forming crystalline cellulose are well known in the art.

[0050] In some embodiments, the aerosol-forming material is free of inorganic fillers.In some embodiments, the aerosol-forming composition is free of inorganic fillers.

[0051] In some embodiments, the aerosol-forming material does not include calcium carbonate, such as chalk.

[0052] In some embodiments, the aerosol forming composition does not include calcium carbonate, such as chalk.

[0053] In certain embodiments, the aerosol-generating material includes a filler, and the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, tobacco pulp, hemp fiber, cellulose, or a cellulose derivative. In some embodiments, the fibrous organic filler material is wood pulp, hemp fiber, cellulose, or a cellulose derivative. In certain embodiments, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, for example, when the sheet of aerosol-generating material surrounds a rod of aerosolizable material.

[0054] In certain embodiments, the filler comprises (or is) wood pulp.

[0055] Any active substance The aerosol-forming material or composition may include an active agent.

[0056] In some examples, the aerosol-forming material may contain from about 1%, 5%, 10%, 15%, 20%, or 25% to about 65%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active material.

[0057] In some examples, the active substance is nicotine. In some examples, the aerosol-forming material may include from about 1%, 2%, 3%, 4%, or 5% to about 20%, 18%, 15%, 12%, or 10% by weight of nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include from about 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0058] As used herein, an active substance is a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active substance may be selected from, for example, functional foods, nootropics, psychoactive substances. The nootropics may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or other botanical substances.

[0059] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0060] As mentioned above, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0061] In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabiersoin (CBE), cannabicitran (CBT).

[0062] The active substance may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0063] The active substance may include cannabidiol (CBD).

[0064] The active substances may include nicotine and cannabidiol (CBD).

[0065] Active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0066] As described herein, the active material may comprise or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, skins, etc. Alternatively, the material may comprise an active compound that is naturally present in the botanical material or obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo leaf extract, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and safflower. orchid, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0067] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0068] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0069] In some embodiments, the additional active material comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0070] In some embodiments, the aerosol-forming material does not include tobacco fibers.

[0071] In some embodiments, the aerosol-forming material does not include tobacco material.

[0072] In some embodiments, the aerosol-forming material is substantially free of tobacco material.

[0073] In some embodiments, the aerosol forming material does not include an active agent.

[0074] fragrance In some embodiments, the aerosol-forming material or composition includes a flavoring.

[0075] In some examples, the aerosol-forming material may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 65%, 60%, 50%, 45%, 40%, 35%, or 30% by weight of flavoring (calculated on a dry weight basis).

[0076] As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sheesh Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the mint genus, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai tea citron, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose,They may contain saccharides such as acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid (such as an oil), a solid (such as a powder), or a gas.

[0077] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0078] In some embodiments, the flavoring may include sensory agents aimed at achieving somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol, WS-3.

[0079] Other functional materials In some embodiments, the aerosol-forming material or composition may further comprise one or more other functional materials, which may include one or more of a pH adjusting agent, a coloring agent, a preservative, a stabilizer, and / or an antioxidant.

[0080] The aerosol-generating material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0081] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0082] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0083] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

[0084] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colorant to the aerosol-generating material, the aerosol-generating material can match the color of other components of the aerosol-generating composition or other components of a consumable comprising the aerosol-generating material.

[0085] Various colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (such as tobacco materials) in the aerosol-generating composition that includes the aerosol-generating material. In some embodiments, the addition of a colorant to the aerosol-generating material renders the aerosol-generating material visually indistinguishable from other components in the aerosol-generating composition.

[0086] The colorant may be incorporated during the formation of the aerosol-generating material (e.g., when forming a slurry with the materials that will form the aerosol-generating material), or the colorant may be applied to the aerosol-generating material after its formation (e.g., by spraying the colorant onto the aerosol-generating material).

[0087] In some embodiments, the aerosol-generating material is formed as a sheet. In some examples, the sheet of aerosol-generating material may be incorporated into a non-combustion aerosol delivery system or consumable in sheet form. The sheet of aerosol-generating material may be incorporated as a flat sheet, as a gathered or pleated sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some such examples, the aerosol-generating material of these embodiments may be included in the system / consumable as a sheet, for example, as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). For example, the sheet of aerosol-generating material may be formed on a wrapping paper that surrounds the aerosolizable material, such as tobacco. In other examples, the sheet may be shredded and then incorporated into an assembly, preferably mixed into the aerosolizable material, such as cut rag tobacco.

[0088] In some instances, the aerosol-generating material may be in the form of a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, or 0.3 mm, for example, 0.1 to 3 mm, or 0.15 to 0.3 mm. Materials having a thickness of 0.2 mm may be particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

[0089] If the aerosol-generating material is too thick, heating efficiency may be compromised, which negatively impacts power consumption during use. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle; that is, very thin materials are more difficult to cast and may be more fragile, which may impair aerosol formation during use.

[0090] The thicknesses specified herein are the average thickness of the material. In some instances, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0091] In some embodiments, the aerosol generating material in sheet form may have sufficient tensile strength so that it can be wound or unwound on a bobbin without breaking, hi some examples, the aerosol generating material in sheet form has a tensile strength of about 250 N / m or greater.

[0092] The aerosol-forming material may be of any suitable areal density, for example, 30 g / m 2 ~120g / m 2 In some examples, the aerosol-forming material may have a density of about 80 to 120 g / m 2 , or about 70 to 110 g / m 2 , or in particular, about 90 to 110 g / m 2 , or preferably about 100 g / m 2 (so that the aerosol-forming material does not easily separate when mixed with tobacco, e.g., cut rag tobacco). Such areal densities may be particularly suitable when the aerosol-forming material is included in the consumable / system in sheet form or as shredded sheets (described further herein below).

[0093] Aerosol-forming compositions One aspect provides an aerosol-forming composition comprising an aerosol-forming material as defined herein.

[0094] In some embodiments, the aerosol-forming composition further comprises a tobacco material. In these embodiments, the tobacco material does not form part of the aerosol-forming material, i.e., the tobacco material is present in the aerosol-forming composition separate from the aerosol-forming material.

[0095] As used herein, the term "tobacco material" refers to any material that contains tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract.

[0096] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. It may also be "fines" or dust of tobacco particles, expanded tobacco, stems, expanded stems, and other processed stem materials (such as rolled cut stems). The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may include tobacco fibers and may be formed by casting, a Fourdrinier-type approach with back-addition of tobacco extract, or extrusion.

[0097] In some embodiments, the amount of aerosol-forming material in the aerosol-forming composition is about 5 to about 30% by weight of the aerosol-forming composition on a dry weight basis. For example, in some embodiments, the aerosol-forming composition includes an amount of aerosol-forming material of about 10 to about 20% by weight, or about 13 to about 17% by weight. In some embodiments, the aerosol-forming composition includes an amount of aerosol-forming material of about 15% by weight. This amount includes any aerosol-forming material present in the aerosol-forming composition, for example, aerosol-forming material provided in the aerosol-forming material and any aerosol formers loaded into the tobacco material.

[0098] Typically, it has been found that cut rag tobacco blends that can be used alone in conventional combustion smoking articles such as cigarettes are not suitable for use in non-combustion aerosol delivery devices. Without wishing to be bound by theory, it is believed that cut rag tobacco blends used in cigarettes typically cannot be loaded with enough aerosol-forming material to provide the desired inhalable aerosol when heated by a non-combustion aerosol delivery device.

[0099] Previous attempts to address this problem have included replacing some or all of the cut rag tobacco in typical combustible tobacco blends with reconstituted tobaccos, such as paper reconstituted tobaccos. Paper reconstituted tobaccos typically contain a higher percentage of aerosol-forming materials. However, tobacco blends that contain a high percentage of paper reconstituted tobaccos may have undesirable sensory characteristics when heated by a non-combustible aerosol delivery device.

[0100] By providing an aerosol-generating material having a high aerosol-forming material content in combination with a tobacco material, it is possible to generate an acceptable aerosol without requiring the presence of large amounts of reconstituted tobacco (thereby reducing the undesirable sensory characteristics associated with reconstituted tobacco).

[0101] In some embodiments, the tobacco material comprises or consists of laminar tobacco (eg, cut rag tobacco), which provides desirable sensory characteristics.

[0102] In some embodiments, the tobacco material comprises reconstituted tobacco in an amount of less than about 50%, 30%, 10%, 5%, or 1% by weight of the dry weight of the tobacco material. In some embodiments, the tobacco material is substantially free of reconstituted tobacco.

[0103] The tobacco material may be present in any form, but is typically fine cut (e.g., chopped into small pieces). Fine cut tobacco material may be advantageously blended with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and aerosol-forming material throughout the aerosol-forming composition.

[0104] In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract. It is possible to use relatively large amounts of laminar tobacco in the aerosol-generating composition and still produce an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material. In certain examples, the tobacco material comprises shredded tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material.

[0105] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0106] The tobacco material may typically be present in the aerosol forming composition in an amount of about 50-95%, or about 60-95%, or about 70-90%, or about 80-90% by weight of the aerosol forming composition.

[0107] In some embodiments, the aerosol-generating material is present in the aerosol-generating composition in an amount of about 5-40%, 5-30%, 5-25%, or 10-25%, or 10-20% by weight. Surprisingly, by configuring the aerosol-generating material to have a relatively high aerosol-forming material content, a relatively small amount of the aerosol-generating material (e.g., about 10-20% by weight) can be used in the aerosol-generating composition and still achieve a desired aerosol for use with a non-combustion type aerosol delivery system.

[0108] In some embodiments, the aerosol-forming composition consists or consists essentially of an aerosol-forming material and a tobacco material.

[0109] In some embodiments, the tobacco material itself comprises the aerosol-forming material. Typically, the tobacco material comprises fine-cut tobacco, and the aerosol-forming material is loaded onto the tobacco fragments. In an example, the tobacco material comprises the aerosol-forming material in an amount of about 1-10% by weight, such as about 3-6% by weight, of the tobacco material. The aerosol-forming materials defined above with respect to the aerosol-generating material are also suitable for use in the tobacco material.

[0110] The aerosol-generating material may be present in the aerosol-generating composition in any suitable form. In examples, the aerosol-generating material is present in sheet form. In examples, the aerosol-generating material is present as a shredded sheet (e.g., the aerosol-generating composition includes pieces of the aerosol-generating material). In examples, the aerosol-generating material is present as a shredded sheet and is blended with tobacco material that is fine cut and / or shredded, e.g., the aerosol-generating material and the tobacco material are in a similar form. Advantageously, providing both the aerosol-generating material and the tobacco material as pieces / fine cut portions allows for an aerosol-generating composition blend with a uniform distribution of the aerosol-generating material and the tobacco material throughout the aerosol-generating composition.

[0111] In examples, the aerosol-generating material has a surface density that is about 90-110% of the surface density of any tobacco material in the aerosol-generating composition. That is, the aerosol-generating material and the tobacco material have similar surface densities. Configuring the aerosol-generating material and the tobacco material to have similar surface densities allows for better blending of the aerosol-generating material and the tobacco material, typically when provided as shredded sheets. For example, aerosol-generating material in the form of shredded sheets and cut rag tobacco having similar surface densities can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition).

[0112] Fine cut tobacco (e.g., cut rag tobacco) has a cut width, typically expressed as CPI (cuts per inch), which refers to the width of the cut in the tobacco. In some instances where the tobacco material is fine cut (e.g., where the tobacco material includes cut rag tobacco) and the aerosol-generating material is a shredded sheet, the cut width of the aerosol-generating material is about 90-110% of the cut width of the cut rag tobacco. That is, the aerosol-generating material and the tobacco material have similar cut widths, or shred widths. Configuring the aerosol-generating material and the tobacco material to have similar cut widths allows for better blending of the aerosol-generating material and the tobacco material. For example, aerosol-generating material sheets and cut rag tobacco having similar cut widths can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition). The tobacco material may have a length of 1-4 cm.

[0113] support The aerosol-generating material used to generate the aerosol may be on or in a support to form a substrate. The support may be or include, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is incorporated within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0114] The aerosol-generating composition may include a carrier on which the aerosol-generating material is disposed. The carrier acts as a support on which the layer of aerosol-generating material is formed, facilitating manufacturing. The carrier may provide tensile strength to the layer of aerosol-generating material, facilitating handling.

[0115] In some examples, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some examples, the carrier may include or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the carrier itself is a laminated structure comprising multiple layers of materials selected from the aforementioned list. In some examples, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with flavor or tobacco extract.

[0116] In some examples, the carrier may be magnetic. This feature may be used to secure the carrier to a non-combustion aerosol delivery device during use, or to generate a particular aerosol-generating material shape. In some examples, the aerosol-generating composition may include one or more magnets that can be used to secure the material to an induction heater during use.

[0117] In some instances, the carrier may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the carrier layer, thereby controlling the flow and ensuring that the aerosol or gas is delivered to the user. This may also be utilized to prevent the gas / aerosol from condensing or otherwise depositing during use, for example on the surface of a heater provided in the aerosol generation assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

[0118] In some instances, the surface of the carrier that abuts the aerosol-generating material may be porous. For example, in one instance, the carrier comprises paper. A porous carrier such as paper has been found to be particularly suitable, where a porous (e.g., paper) layer abuts a layer of the aerosol-generating material and forms a strong bond. The aerosol-generating material may be formed by drying a slurry, and, without being limited by theory, it is believed that the slurry partially impregnates the porous carrier (e.g., paper), such that the carrier is partially bonded to the aerosol-generating material. This results in a strong bond between the aerosol-generating material and the carrier.

[0119] In some embodiments, the aerosol-forming material may be laminated to a carrier, such as a paper sheet.

[0120] In some embodiments, when the aerosol-forming material is formed from a slurry as described herein, a layer of the slurry may be formed on a carrier, such as a paper sheet.

[0121] In addition, surface roughness may contribute to the strength of the bond between the aerosol-generating material and the carrier. The roughness of the paper (the surface that abuts the carrier) may preferably be in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specific pressure is forced between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

[0122] Conversely, the surface of the carrier that does not face the aerosol-forming material may be placed in contact with the heater, and the smoother surface may provide more efficient heat transfer. Thus, in some examples, the carrier is positioned to have a rougher surface that abuts the aerosol-forming material and a smoother surface that does not face the aerosol-forming material.

[0123] In one particular example, the carrier may be a paper-backed foil, where the paper layer abuts the aerosol-generating material, providing the properties discussed in the previous paragraphs. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also act to transfer heat to the aerosol-generating material.

[0124] In another example, a foil layer of a paper-backed foil abuts the aerosol-generating material, the foil being substantially impermeable to prevent moisture provided in the aerosol-generating material from being absorbed by the paper, which could weaken the structural integrity of the paper.

[0125] In some cases, the carrier is formed from or includes a metal foil, such as aluminum foil. A metal carrier may allow for better transfer of thermal energy to the aerosol-generating material. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0126] In some examples, the carrier may have a thickness of from about 0.010 mm to about 2.0 mm, preferably from about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0127] consumables In another aspect of the present disclosure, a consumable for use in a non-combustion aerosol delivery device is provided, the consumable comprising an aerosol generating composition as defined herein, the aerosol generating composition comprising an aerosol forming material.

[0128] In some embodiments, the present disclosure relates to consumables that include an aerosol generating composition and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0129] The consumables may be used with any suitable non-combustion aerosol delivery device.

[0130] A consumable is an article that includes or consists of an aerosol-generating composition that is intended to be consumed in part or in whole during use by a user. A consumable may include one or more other components, such as an aerosol-generating composition storage area, an aerosol-generating composition transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that generates heat upon use to cause the generation of an aerosol from the aerosol-generating composition. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0131] A susceptor is a material that can be heated by the penetration of a varying magnetic field, for example an alternating magnetic field. The susceptor may be an electrically conductive material, in which case its penetration with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, in which case its penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, in which case the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0132] An aerosol modifier is a substance, typically located downstream of the aerosol-generation region, configured to modify the aerosol generated, for example by altering the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be included in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0133] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in powder, thread, or granular form. The aerosol modifier may not include a filtration material.

[0134] An aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating composition. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating composition to thermal energy to release one or more volatile substances from the aerosol-generating composition to form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating composition without heating. For example, the aerosol generator may be configured to subject the aerosol-generating composition to one or more of vibration, high pressure, or electrostatic energy.

[0135] Non-combustion aerosol delivery system In another aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising a consumable and a non-combustion aerosol delivery device as described herein.

[0136] According to this disclosure, a "non-combustion" aerosol delivery system is one in which a component aerosol generating composition (or a component thereof) of the aerosol delivery system is not combusted or burned during use to facilitate delivery of at least one substance to a user.

[0137] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example a powdered non-combustion aerosol delivery system.

[0138] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating composition heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0139] In some embodiments, the non-combustion aerosol delivery device is non-combustion heated.

[0140] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol generating compositions, one or more of which may be heated. In some embodiments, the hybrid system comprises an aerosol generating composition described herein that comprises or consists of an aerosol generating material and an additional liquid or gel aerosol generating composition.

[0141] In some embodiments, the non-combustion aerosol delivery device is an e-cigarette hybrid device.

[0142] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0143] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute power in the form of heat to the aerosol generating composition or to a heat conducting material in proximity to the heat generating power source.

[0144] In some embodiments, a non-combustion aerosol delivery system, e.g., a non-combustion aerosol delivery device, may include a consumable receiving region, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0145] A non-combustion aerosol delivery system or device may include a heater configured to heat but not combust the aerosol-forming composition / material. The heater may, in some examples, be a thin-film electrical resistance heater. In other examples, the heater may include an induction heater or other heater. In still further examples, the heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat when in use.

[0146] In some examples, the heater, in use, may heat the aerosolizable material to between 120° C. and 350° C. without burning the aerosolizable material. In some examples, the heater, in use, may heat the aerosolizable material to between 140° C. and 250° C. without burning the aerosolizable material. In some examples, in use, substantially the entire aerosol-generating material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some examples, the solid is disposed between about 0.017 mm and 2.0 mm, preferably between about 0.1 mm and 1.0 mm, from the heater. These minimum distances may in some examples reflect the thickness of a carrier supporting the aerosol-generating material. In some examples, a surface of the aerosol-generating material may directly abut the heater.

[0147] In some instances, the heater may be incorporated into the aerosol-forming composition / material. In some such instances, the heater may be an electrical resistance heater (with exposed contacts for connection to an electrical circuit). In other such instances, the heater may be an inductively heated susceptor incorporated into the aerosol-forming composition.

[0148] The non-combustion aerosol delivery system may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components so that they condense to form the aerosol. The cooling element may also act to move hot parts of the device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0149] In some examples, the non-combustion aerosol delivery system may be a non-combustion heated system, i.e., the non-combustion aerosol delivery system may include a solid material (and not a liquid aerosolizable material). A non-combustion heated device is disclosed in WO2015 / 062983A2, the entirety of which is incorporated herein by reference.

[0150] In some examples, the non-combustion aerosol delivery system may be an e-cigarette hybrid device. That is, the non-combustion aerosol delivery system may include a solid aerosolizable material and a liquid aerosol-generating material. These separate aerosolizable materials may be heated by separate heaters or may be heated by the same heater, and in some examples, the downstream aerosolizable material may be heated by the hot aerosol generated from the upstream aerosolizable material. An e-cigarette hybrid device is disclosed in WO2016 / 135331A1, the entirety of which is incorporated herein by reference.

[0151] The consumable may also be referred to herein as a cartridge. The consumable may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some examples, the consumable may further comprise a filter and / or a cooling element as previously described. In some examples, the consumable may be surrounded by a packaging material, such as paper.

[0152] The consumable product may further comprise vent holes. These may be provided in the sidewalls of the article. In some instances, the vent holes may be provided in the filter and / or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0153] The ventilation facilitates the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by a process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation) and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of newly formed droplets from the heated volatiles.

[0154] In some instances, the ratio of cold air to the sum of heated volatiles and cold air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0155] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0156] 1 and 2, there is shown a partial cutaway cross-sectional view and a perspective view of an example of an article consumable 101 ("Article"). The Article 101 is adapted for use with a device having a power source and a heater. The Article 101 of this embodiment is particularly suited for use with the device 51 shown in Figures 5-7, described below. In use, the Article 101 can be removably inserted into the device at an insertion point 20 of the device 51 shown in Figure 5.

[0157] The example article 101 is in the form of a generally cylindrical rod including an aerosol-generating composition body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition includes an aerosol-generating material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol-generating composition as described herein may be incorporated in both sheet form and chopped form.

[0158] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The aerosol generating composition body 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the aerosol generating composition body 103 between the aerosol generating composition body 103 and the filter segment 109 such that the cooling segment 107 is in an abutting relationship with the aerosol generating composition 103 and the filter segment 109. In another example, there may be a separation between the aerosol generating composition body 103 and the cooling segment 107 and between the aerosol generating composition body 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed toward proximal end 113 of article 101 and is adjacent filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0159] In one example, the rod of aerosol forming composition 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably has a length of 42 mm.

[0160] In one example, the overall length of the article 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0161] One axial end of the aerosol-generating composition body 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers one axial end of the aerosol-generating composition body 103.

[0162] The aerosol generating composition body 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the aerosol generating composition body 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0163] In one example, cooling segment 107 is an annular tube that is disposed around and defines a cavity within the cooling segment. The cavity provides a chamber through which heated volatile components generated from aerosol generating composition body 103 flow. Cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 101 during insertion into device 51. In one example, the wall thickness of cooling segment 107 is about 0.29 mm.

[0164] The cooling segment 107 provides a physical displacement between the aerosol-generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating composition 103 when the aerosol-generating composition 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the aerosol generating composition body 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may become damaged during use and may no longer effectively perform its required function.

[0165] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0166] The cooling segment 107 is made from paper, meaning that it is constructed from a material that does not generate compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 51 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness and straightness.

[0167] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 101 during insertion into device 51.

[0168] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol generating composition. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0169] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be substantially centered within the filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, if a capsule is present, the capsule may contain a volatile component, such as a flavoring or an aerosol-forming material.

[0170] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to draw of the article 101. Thus, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the article 101. Additionally, the filter segment performs a filtration function in the article 101.

[0171] In one example, the filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0172] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the temperature of the contact of the user's lips with the surface of filter segment 109.

[0173] In one example, the filter segment 109 is between 6 mm and 10 mm in length, preferably 8 mm.

[0174] The mouth end segment 111 is an annular tube that is disposed around and defines a cavity within the mouth end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacture and insertion into the device 51. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0175] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outside diameter, roundness and straightness.

[0176] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0177] It should be appreciated that in one example, the oral end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 disposed within the tube to separate the oral end segment 111 and the cooling segment 107.

[0178] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0179] In the example of article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in article 301 to allow air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of article 301. The vent holes may be located in cooling segment 307 to aid in cooling article 301. In one example, ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

[0180] In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

[0181] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

[0182] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is such that the vent holes 317 are not blocked by a user when the article 301 is in use.

[0183] By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 51 when the article 301 is fully inserted into the device 51, as seen in Figures 6 and 7. By locating the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 51 through the vent holes to help cool the article 301.

[0184] The length of the cooling segment 307 is such that when the item 301 is fully inserted into the device 51, the cooling segment 307 is partially inserted into the device 51. This length of the cooling segment 307 serves a first function of providing a physical gap between the heating device and the heat-sensitive filter device 309 of the device 51, and a second function of allowing the vent hole 317 to be located within the cooling segment while also being located outside the device 51 when the item 301 is fully inserted into the device 51. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 51.

[0185] 5-7 in more detail, an example of a device 51 is shown that is configured to heat an aerosol-generating composition to volatilize at least one component of said aerosol-generating composition, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, but not combusting, the aerosol-generating composition.

[0186] The first end 53 may be referred to herein as the oral or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on / off button 57, allowing the entire device 51 to be activated / deactivated as desired by the user.

[0187] The device 51 includes a housing 59 for arranging and protecting various internal components of the device 51. In the illustrated example, the housing 59 includes a unitary sleeve 11 that surrounds the outer periphery of the device 51 and is capped with a top panel 17 that generally forms the "top" of the device 51 and a bottom panel 19 that generally forms the "bottom" of the device 51. In another example, the housing includes, in addition to the top panel 17 and bottom panel 19, a front panel, a rear panel, and a pair of opposing side panels.

[0188] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 51, or may be "permanently" secured to unitary sleeve 11, for example to prevent a user from accessing the interior of device 51. In one example, panels 17 and 19 are made of a plastic material (including glass-filled nylon formed by injection molding, etc.) and unitary sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

[0189] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51 through which a user can insert and remove an article 101, 301 containing an aerosol-generating composition into and from the device 51 during use.

[0190] Housing 59 has disposed therein or secured thereto heating device 23, control circuitry 25, and power source 27. In this example, heating device 23, control circuitry 25, and power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuitry 25 generally located between heating device 23 and power source 27, although other arrangements are possible.

[0191] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol generating composition within the article 101, 301, as discussed further below.

[0192] Power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and provides power when needed under the control of control circuitry 25 to heat the aerosol-forming composition within the article (to volatilize the aerosol-forming composition without burning it, as discussed above).

[0193] An advantage of locating the power source 27 laterally adjacent to the heating apparatus 23 is that a physically larger power source 25 can be used without making the overall device 51 excessively long. Of course, a physically larger power source 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore may provide a longer battery life for the device 51.

[0194] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 containing the aerosol generating composition is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride ceramics, as well as silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), resistive heating elements formed by resistive electrical windings, and the like.

[0195] In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the article 101, 301 is inserted into the device 51, substantially the entire body of the article 101, 301, which comprises the aerosol-forming composition 103, 303, is inserted into the heating device 23.

[0196] The or each heating element may be arranged so as to allow selected zones (regions) of the aerosol-forming composition to be heated independently, e.g., sequentially (over time as described above) or together (simultaneously), as desired.

[0197] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heating device 23 to the exterior of the device 51. This generally reduces heat loss and therefore helps to keep the power requirements of the heating device 23 low. The insulation 31 also helps to keep the exterior of the device 51 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (including, for example, a suitable foam-type material) in addition to or in place of the double-walled sleeve.

[0198] The housing 59 may further include various internal support structures 37 for supporting all of the internal components as well as the heating device 23 .

[0199] The device 51 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along an outer surface of the chamber 35, each fin being disposed to circumscribe the outer surface of the chamber 35. When the article 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the article 101, 301. The gap 36 circumscribes the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

[0200] The collar 33 includes a number of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage an article 101, 301 inserted within the device to help secure it within the device 51. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the article 101, 301 form ventilation paths around the outer surface of the article 101, 301. These ventilation paths allow hot steam escaping from the article 101, 301 to exit the device 51, and allow cooling air to flow within the gap 36 around the article 101, 301 into the device 51.

[0201] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. Referring specifically to Figure 6, in one example, the aerosol generating composition body 103, 303 (which is disposed at the distal end 115, 315 of the article 101, 301) is completely contained within the heating arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and functions as a mouthpiece assembly for the user.

[0202] During operation, the heating device 23 heats the article 101 , 301 to volatilize at least one component of the aerosol-forming composition from the aerosol-forming composition body 103 , 303 .

[0203] The primary flow path for heated volatile components from the aerosol-generating composition body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating composition body is between 60° C. and 250° C., which may be above an acceptable inhalation temperature for a user. The heated volatile components cool as they travel through the cooling segment 107, 307, and some of the volatile components condense on the interior surface of the cooling segment 107, 307.

[0204] In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0205] Method for Producing Aerosol-Generating Materials Another aspect of the present invention provides a method of making the aerosol-forming materials described herein, the method comprising: (i) providing a slurry comprising an aerosol-forming material, a first binder which is guar gum, a second binder which is starch or modified starch, a filler, a solvent, and any further components of the aerosol-forming material; (ii) forming a layer of the slurry; (iii) drying the slurry to form an aerosol-generating material; may include:

[0206] The disclosures herein regarding the components of the aerosol-forming material apply equally to the slurry, which may include these components in any of the proportions indicated herein for the composition of the aerosol-forming material.

[0207] If the aerosol-generating material includes an additional binder, which is alginate and / or pectin, the slurry may further include a solidifying agent and / or a solidifying agent may be applied to the slurry. In this case, the method may further include solidifying the slurry. In some examples, forming the layer of the slurry, solidifying the slurry, and / or drying the slurry are performed at least partially simultaneously (e.g., during electrostatic spraying). In some examples, forming the layer of the slurry, solidifying the slurry with an optional solidifying agent, and drying the slurry are performed sequentially in that order.

[0208] Another aspect of the invention provides a method (hereinafter referred to as the second method) of making an aerosol-forming composition comprising the aerosol-forming material described herein. The method may include providing an aerosol-forming material and combining the aerosol-forming material and a tobacco material to provide an aerosol-forming composition.

[0209] In some examples, the aerosol forming composition may comprise an aerosol-forming material in an amount from about 5 to about 30% by weight of the aerosol forming composition on a dry weight basis.

[0210] The second method typically includes the steps of providing an aerosol-forming material as described herein above, providing a tobacco material as described herein above, and combining the aerosol-forming material and the tobacco material in a ratio such that an aerosol-forming composition is obtained having an aerosol-forming material content of about 5-30% by weight of the aerosol-forming composition.

[0211] In examples, the aerosol-generating material is provided as a shredded sheet. In particular examples, providing the aerosol-generating material includes shredding a sheet of the aerosol-generating material to provide the aerosol-generating material as a shredded sheet. In examples, the tobacco material is fine cut, and combining the aerosol-generating material and the tobacco material includes blending the shredded sheet of the aerosol-generating material with the fine cut tobacco material.

[0212] In an example, the step of preparing the aerosol-generating material includes (i) forming a slurry including components of the aerosol-generating material or precursors thereof, (ii) forming a layer of the slurry, and (iii) drying the slurry to form the aerosol-generating material.

[0213] (ii) The step of forming the layer of the slurry typically involves spraying, casting, or extruding the slurry. In examples, the slurry layer is formed by electrostatically spraying the slurry. In examples, the slurry layer is formed by casting the slurry.

[0214] In some instances, the slurry is applied to a substrate, and the layer may be formed on the substrate.

[0215] In examples, the drying step (iii) removes from about 50%, 60%, 70%, 80%, or 90% to about 80%, 90%, or 95% (wet weight basis, WWB) of the water in the slurry.

[0216] In examples, the drying step (iii) reduces the cast material thickness by at least 80%, preferably 85% or 87%. For example, if the slurry is cast to a thickness of 2 mm, the resulting dry aerosol-generating material may have a thickness of 0.2 mm.

[0217] In embodiments, the dry aerosol-forming material forms a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, or 0.3 mm, for example 0.05 to 0.3, or 0.15 to 0.3 mm. Materials having a thickness of 0.2 mm may be particularly suitable.

[0218] The slurry itself is an embodiment of the present invention. In some instances, the slurry solvent consists essentially of water or consists of water. In some instances, the slurry comprises about 50%, 60%, 70%, 80%, or 90% solvent by weight (WWB).

[0219] A further aspect provides a method for making the aerosol-generating materials described herein using a papermaking process. In certain embodiments, the papermaking process is an airlaid papermaking process. The use of an airlaid papermaking process reduces water consumption. A suitable airlaid papermaking process is discussed in US9901112B2, the disclosure of which is incorporated herein by reference.

[0220] In an embodiment, the airlaid process comprises: (a) optionally mixing a filler with optional chitosan; (b) forming a layer of the mixture (or filler) on a surface, such as a moving surface, to form a base layer; (c) applying a slurry comprising the aerosol-forming material and the first and second binders by spraying the slurry onto the base layer; (d) drying; Includes.

[0221] In one embodiment, the spraying step (c) and drying step (d) are repeated, for example, two or three times.

[0222] Further embodiments of the present invention are described below. 1. The aerosol-forming material of claim 1, comprising a total amount of aerosol-forming materials of about 1-80% by weight of the aerosol-forming material on a dry weight basis. 2. The aerosol-forming material of embodiment 1, comprising a total amount of aerosol-forming material of about 35-65% by weight of the aerosol-forming material on a dry weight basis. 3. The aerosol-forming material of embodiment 2, comprising a total amount of aerosol-forming materials of about 40-60% by weight of the aerosol-forming material on a dry weight basis. 4. The aerosol-forming material of embodiment 3, comprising a total amount of aerosol-forming materials of about 45-55% by weight of the aerosol-forming material on a dry weight basis. 5. The aerosol generating material of claim 1 or any preceding embodiment, wherein the aerosol forming material comprises (or is) one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. 6. The aerosol-generating material of claim 1 or any preceding embodiment, wherein the aerosol-forming material comprises (or is) glycerol, optionally in combination with propylene glycol. 7. The aerosol-forming material of claim 1 or any preceding embodiment, wherein the second binder is a modified starch. 8. The aerosol-forming material of claim 1 or any preceding embodiment, wherein the modified starch is one or more of hydroxypropyl starch, sodium carboxymethyl starch, carboxymethyl starch, octenylsuccinic anhydride-modified starch, starch acetate, phosphate-crosslinked starch, adipate-crosslinked starch, hydroxypropylated phosphate-crosslinked starch, phosphate monoesterified phosphate-crosslinked starch, acetylated phosphate-crosslinked starch, and acetylated adipate-crosslinked starch. 9. The aerosol-forming material of embodiment 8, wherein the modified starch comprises (or is) one or more of hydroxypropyl starch, carboxymethyl starch, and sodium carboxymethyl starch. 9A. The aerosol-forming material of embodiment 9, wherein the modified starch comprises (or is) one or more of: hydroxypropyl starch, and sodium carboxymethyl starch. 10. The aerosol-forming material of claim 1 or any preceding embodiment, comprising the first binder in an amount of about 3-35% by weight of the aerosol-forming material on a dry weight basis. 11. The aerosol-forming material of embodiment 10, comprising a first binder in an amount of about 5 to 30% by weight of the aerosol-forming material on a dry weight basis. 12. The aerosol-forming material of embodiment 11, comprising a first binder in an amount of about 7-25% by weight of the aerosol-forming material on a dry weight basis. 13. The aerosol-forming material of embodiment 12, comprising the first binder in an amount of about 10-20% by weight of the aerosol-forming material on a dry weight basis. 14. The aerosol-generating material of claim 1 or any preceding embodiment, comprising a second binder in a total amount of about 1-20% by weight of the aerosol-forming material on a dry weight basis. 15. The aerosol-forming material of embodiment 14, comprising a second binder in a total amount of about 2 to 15% by weight of the aerosol-forming material on a dry weight basis. 16. The aerosol-forming material of embodiment 15, comprising a second binder in a total amount of about 3 to 10% by weight of the aerosol-forming material on a dry weight basis. 17. The aerosol-forming material of claim 1 or any preceding embodiment, comprising first and second binders in a total amount of about 5-50% by weight of the aerosol-forming material on a dry weight basis. 18. The aerosol-forming material of embodiment 17, comprising first and second binders in a total amount of about 10 to 40% by weight of the aerosol-forming material on a dry weight basis. 19. The aerosol-forming material of embodiment 18, comprising first and second binders in a total amount of about 15-30% by weight of the aerosol-forming material on a dry weight basis. 20. The aerosol-forming material of embodiment 19, comprising first and second binders in a total amount of about 15 to 25 percent by weight of the aerosol-forming material on a dry weight basis. 21. The aerosol-forming material of embodiment 20, comprising first and second binders in a total amount of about 17-25% by weight of the aerosol-forming material on a dry weight basis. 22. The aerosol forming material of claim 1 or any preceding embodiment, further comprising one or more additional binders other than guar gum, starch, or modified starch. 23. The aerosol-forming material of embodiment 22, wherein the further binder comprises (or is) one or more compounds selected from polysaccharide binders, gelatin, gums, silica or silicone compounds, clays, and polyvinyl alcohol. 24. The aerosol-forming material of embodiment 23, wherein the gum is selected from xanthan gum and gum acacia. 25. The aerosol-generating material of any of embodiments 23-24, wherein the silica or silicone compound is selected from PDMS and sodium silicate. 26. The aerosol-forming material of any of embodiments 23-25, wherein the clay is kaolin. 27. The aerosol-forming material of embodiment 22, wherein the further binder comprises (or is) one or more polysaccharide binders. 28. The aerosol-forming material of any of embodiments 23-27, wherein the polysaccharide binder is selected from alginate, pectin, cellulose or a derivative thereof, pullulan, carrageenan, agar, agarose, and chitosan. 29. The aerosol-forming material of embodiment 28, wherein the polysaccharide binder is selected from alginate, pectin, cellulose or derivatives thereof, and chitosan. 30. The aerosol generating material of any of embodiments 28-29, wherein the cellulose derivative is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). 31. The aerosol-forming material of any of embodiments 22-30, wherein the further binder (or polysaccharide binder) comprises (or is) chitosan. 32. The aerosol-forming material of embodiment 31, comprising chitosan in an amount of about 0.01 to 10% by weight of the aerosol-forming material on a dry weight basis. 33. The aerosol-forming material of embodiment 32, comprising chitosan in an amount of about 0.025 to 5% by weight of the aerosol-forming material on a dry weight basis. 34. The aerosol-forming material of embodiment 33, comprising chitosan in an amount of about 0.05 to 2% by weight of the aerosol-forming material on a dry weight basis. 35. The aerosol-forming material of embodiment 34, comprising chitosan in an amount of about 0.1 to 1% by weight of the aerosol-forming material on a dry weight basis. 36. The aerosol-forming material of embodiment 35, comprising chitosan in an amount of about 0.1 to 0.7% by weight of the aerosol-forming material on a dry weight basis. 37. The aerosol-forming material of claim 1 or any preceding embodiment, wherein the filler comprises one or more organic filler materials. 38. The aerosol-forming material of embodiment 37, wherein the organic filler material is selected from wood pulp, tobacco pulp, hemp pulp, starch and starch derivatives, such as maltodextrin, cellulose and cellulose derivatives, such as microcrystalline cellulose and / or nanocrystalline cellulose. 39. The aerosol-forming material of claim 1 or any preceding claim, wherein the filler comprises (or is) wood pulp. 40. The aerosol-generating material of claim 1 or any preceding embodiment, comprising a total amount of filler of at least 15% by weight of the aerosol-generating material on a dry weight basis. 41. The aerosol-forming material of embodiment 40, comprising a total amount of filler of about 15-40% by weight of the aerosol-forming material on a dry weight basis. 42. The aerosol-forming material of embodiment 41, comprising a total amount of filler of about 20-40% by weight of the aerosol-forming material on a dry weight basis. 43. The aerosol-forming material of embodiment 42, comprising a total amount of filler of about 25-35% by weight of the aerosol-forming material on a dry weight basis. 44. The aerosol-forming material of claim 1 or any preceding embodiment, which is free of inorganic fillers. 45. The aerosol-forming material of claim 1 or any preceding claim, which does not contain calcium carbonate, such as chalk. 46. ​​The aerosol-forming material of claim 1 or any preceding embodiment, which is free of an active agent. 47. The aerosol-forming material of claim 1 or any preceding embodiment, which does not contain tobacco material. 48. An aerosol-forming composition comprising an aerosol-forming material as defined in claim 1 or any preceding embodiment. 49. The aerosol forming composition of embodiment 48, further comprising a tobacco material. 50. The aerosol generating composition of embodiment 48 or 49, wherein the amount of aerosol-forming material in the aerosol generating composition is from about 5 to about 30% by weight of the aerosol generating composition on a dry weight basis. 51. The aerosol generating composition of embodiment 50, wherein the amount of aerosol-forming material in the aerosol generating composition is from about 10 to about 20% by weight of the aerosol generating composition on a dry weight basis. 52. The aerosol generating composition of embodiment 51, wherein the amount of aerosol-forming material in the aerosol generating composition is from about 13 to about 17% by weight of the aerosol generating composition on a dry weight basis. 53. The aerosol-forming composition of any of embodiments 48-52, comprising, on a dry weight basis, the aerosol-forming material in an amount of about 5-40% by weight of the aerosol-forming composition. 54. The aerosol-forming composition of embodiment 53, comprising the aerosol-forming material in an amount of about 5-30% by weight of the aerosol-forming composition on a dry weight basis. 55. The aerosol-forming composition of embodiment 54, comprising the aerosol-forming material in an amount of about 5-25% by weight of the aerosol-forming composition on a dry weight basis. 56. The aerosol-forming composition of embodiment 55, comprising the aerosol-forming material in an amount of about 10-25% by weight of the aerosol-forming composition on a dry weight basis. 57. The aerosol-forming composition of embodiment 56, comprising the aerosol-forming material in an amount of about 10-20% by weight of the aerosol-forming composition on a dry weight basis. 58. The aerosol-forming composition of any of embodiments 49-57, comprising tobacco material in an amount of about 50-95% by weight of the aerosol-forming composition, on a dry weight basis. 59. The aerosol-forming composition of embodiment 58, comprising tobacco material in an amount of about 60-95% by weight of the aerosol-forming composition, on a dry weight basis. 60. The aerosol-forming composition of embodiment 59, comprising tobacco material in an amount of about 70-90% by weight of the aerosol-forming composition, on a dry weight basis. 61. The aerosol-forming composition of embodiment 60, comprising tobacco material in an amount of about 80-90% by weight of the aerosol-forming composition, on a dry weight basis. 62. The aerosol-forming composition of any of embodiments 49-61, wherein the tobacco material comprises an aerosol-forming material in an amount of about 1-10% by weight of the tobacco material. 63. The aerosol forming composition of any of embodiments 49-62, wherein the tobacco material is fine cut. 64. The aerosol forming composition of any of embodiments 49-63, wherein the tobacco material comprises laminar tobacco. 65. The aerosol forming composition of any of embodiments 49-64, wherein the tobacco material comprises cut rag tobacco. 66. The aerosol-forming composition of any of embodiments 49-65, wherein the aerosol-forming material is in the form of shredded sheets and blended with the tobacco material. 67. The aerosol forming composition of any of embodiments 49-66, which does not contain an inorganic filler. 68. The aerosol forming composition of any of embodiments 49-67, which does not contain calcium carbonate, such as chalk.

[0223] The above embodiments defining the characteristics of the aerosol-forming material apply equally to the slurries of the present invention.

[0224] Similarly, the above embodiments apply equally to the consumables, non-combustion aerosol delivery systems, methods of generating aerosols, and methods of forming aerosol-forming materials of the present invention. EXAMPLES

[0225] An aerosol-forming material (AGM) having the following components was produced using an airlaid papermaking process. Percentage amounts are given on a dry weight basis unless otherwise stated. The thickness, areal density, tensile strength, and moisture content of the aerosol-forming material were measured.

[0226] The thickness was measured using an L&W Micrometre (A-2 version) with the settings in the following table: The conditions during the measurements were a temperature of 22±2° C. and a relative humidity of 60±5%.

[0227] [Table 1] 100cm 2 Use a cutter to cut 100 cm of aerosol-generating material. 2 The areal density was determined by cutting the samples and then weighing the cut samples on an analytical balance (resolution 0.01 g). The conditions during the measurements were a temperature of 22±2° C. and a relative humidity of 60±5%.

[0228] Samples for tensile strength measurements were prepared as follows. A sample measuring 15 mm wide and 140 mm long was cut from the sheet material. Fold 25 mm of the sample at either end to prepare a sample with a total length of 90 mm and a single thickness of 40 mm at the center.

[0229] The water content was determined by Karl Fischer titration.

[0230] [Table 2]

[0231] [Table 3]

[0232] [Table 4]

[0233] [Table 5] All weight percentages (indicated as weight %) described herein are calculated on a dry weight basis (DWB) unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights indicated on a dry weight basis refer to the totality of the extract, slurry or material other than water, and may include ingredients that are liquid by themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages indicated on a wet weight basis (WWB) refer to all ingredients, including water.

[0234] For the avoidance of doubt, where the term "comprising" is used herein in defining the invention or features of the invention, there are also disclosed embodiments in which the invention or features may be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material "comprising" certain features means that those features are contained in, contained in, or retained within the material.

[0235] The above embodiments should be understood as illustrative of the present invention. It should be understood that any feature described in connection with any one embodiment, aspect, or example may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other embodiment, aspect, or example, or any combination of any other embodiment, aspect, or example. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the present invention, as defined in the appended claims.

[0236] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein are not to be considered as limitations on the scope of the invention as defined by the claims or to the equivalents of the claims, and that other embodiments may be utilized and changes may be made without departing from the scope of the invention as claimed. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of elements, components, features, parts, steps, means, etc. of the present disclosure other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. (a) an aerosol-forming material; (b) a first binder that is guar gum; and (c) a second binder which is a starch or modified starch; (d) a filler; and 1. An aerosol-generating material comprising:

2. The aerosol-generating material of claim 1, wherein the filler comprises one or more organic filler materials.

3. 10. The aerosol-forming material of claim 1, wherein the second binder is a modified starch.

4. 2. The aerosol-forming material of claim 1, wherein the modified starch is one or more of hydroxypropyl starch, sodium carboxymethyl starch, carboxymethyl starch, octenylsuccinic anhydride-modified starch, starch acetate, phosphated starch, cross-linked starch phosphate, cross-linked starch adipate, hydroxypropylated cross-linked starch phosphate, phosphorylated distarch phosphate, acetylated cross-linked starch phosphate, and acetylated cross-linked starch adipate.

5. 10. The aerosol-forming material of claim 1, wherein the modified starch comprises (or is) one or more of hydroxypropyl starch, carboxymethyl starch, and sodium carboxymethyl starch.

6. 10. The aerosol-forming material of claim 1, comprising the first binder in an amount of about 3 to 35 percent by weight of the aerosol-forming material on a dry weight basis.

7. 10. The aerosol-forming material of claim 1, comprising the second binder in a total amount of about 1 to 20% by weight of the aerosol-forming material on a dry weight basis.

8. 10. The aerosol-forming material of claim 1, wherein the aerosol-forming material comprises (or is) one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

9. 10. The aerosol-forming material of claim 1, comprising a total amount of aerosol-forming materials of about 1 to 80% by weight of the aerosol-forming material on a dry weight basis.

10. 10. The aerosol-forming material of claim 1, comprising a total amount of aerosol-forming materials of about 40 to 60% by weight of the aerosol-forming material on a dry weight basis.

11. 10. The aerosol-forming material of claim 1, wherein the filler comprises (or is) wood pulp.

12. 10. The aerosol-forming material of claim 1, comprising a total amount of filler of at least 15% by weight of the aerosol-forming material on a dry weight basis.

13. An aerosol-forming composition comprising the aerosol-forming material of claim 1.

14. 14. The aerosol forming composition of claim 13, further comprising a tobacco material.

15. 15. The aerosol-forming composition of claim 14, wherein the aerosol-forming material is in the form of shredded sheets and blended with the tobacco material.

16. A consumable for use in a non-combustion type aerosol delivery device, the consumable comprising the aerosol forming composition of any one of claims 13 to 15.

17. 17. A non-combustion aerosol delivery system comprising the consumable of claim 16 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

18. 20. A method of generating an aerosol using the non-combustion aerosol delivery system of claim 17, comprising heating the aerosol-forming material to a temperature less than 350°C.

19. 16. Use of the aerosol generating composition of any one of claims 13 to 15 in a consumable product for use with a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable product when the consumable product is used with the non-combustion aerosol delivery device.

20. A method of forming the aerosol-forming material of any one of claims 1 to 12, comprising the steps of: (i) providing a slurry comprising an aerosol-forming material, a first binder that is guar gum, a second binder that is starch or modified starch, a filler, a solvent, and any additional components of the aerosol-forming material; (ii) forming a layer of said slurry; (iii) drying the slurry to form the aerosol-forming material; A method comprising:

21. A method for making the aerosol-forming material of any one of claims 1 to 12 using a papermaking process, such as an airlaid papermaking process.

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