Aerosol-generating material

Abstract

To provide a method for preparing an aerosol-generating material.SOLUTION: Disclosed herein is a process for preparing an aerosol generating material, comprising the steps for: forming a first composition comprising a first binder and an aerosol former; forming a second composition comprising a tobacco material, a filler and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder and the filler in a total amount of between about 5 wt.% and about 15 wt.% of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol generating material.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates to aerosol-forming materials, methods of making aerosol-forming materials, and articles comprising aerosol-forming materials.

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating material, such as tobacco, to form the aerosol by heating, but not burning, the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol passes and reaches the user's mouth.

[0003] According to a first aspect of the present invention, there is provided a method for preparing an aerosol-forming material, the method comprising: forming a first composition comprising a first binder and an aerosol-forming material; forming a second composition comprising a tobacco material, a filler, and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder, and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol-forming material.

[0004] According to a second aspect of the present invention, there is provided an aerosol-forming material prepared by the method of the first aspect.

[0005] According to a third aspect of the present invention, there is provided an article for use in a non-flammable aerosol delivery system comprising an aerosol-forming material according to the second aspect.

[0006] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1]1A-1D illustrate steps of a method used to produce an aerosol-generating material. [Figure 2] FIG. 1 is a cross-sectional side view of an article comprising an aerosol-forming material. [Figure 3] 3 is a perspective view of a non-combustible aerosol delivery device for generating an aerosol from the aerosol-forming material of the article of FIG. 2. FIG. [Figure 4] 1 is a graph showing the change in the amount of nicotine and glycerol in a mixture of a first composition and a second composition and in an aerosol-forming material. Detailed Description

[0008] The present invention relates to a method for preparing an aerosol-forming material, the method comprising: forming a first composition comprising a first binder and an aerosol-forming material; forming a second composition comprising a tobacco material, a filler, and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the optional second binder, and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and processing the mixture of the first composition and the second composition to form the aerosol-forming material.

[0009] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-generating material may be in solid, liquid, or gel form and may or may not contain active substances and / or flavorings. The aerosol-generating material may be incorporated into an article for use in an aerosol generating system.

[0010] According to one aspect of the present disclosure, there is provided an aerosol-forming material, the aerosol-forming material being configured to generate an aerosol upon heating.

[0011] The water content of the aerosol-forming materials described herein can vary depending on, for example, the temperature, pressure, and humidity conditions under which the compositions are maintained. The water content can be determined by Karl Fischer analysis, as known to those skilled in the art.

[0012] Unless otherwise specified, as used herein, the phrases "volatile components," "volatile matter," "total volatiles," "volatile content," and "total volatiles" are used to refer to volatile compounds, including water. The volatile content of a material can be measured as the mass lost when a sample is dried for 3 hours ± 0.5 minutes in a forced air oven at a controlled temperature of 110°C ± 1°C. After drying, the sample is cooled to room temperature in a desiccator for approximately 30 minutes to allow the sample to cool.

[0013] Figure 1 shows how an aerosol-generating material can be produced. A first composition including a binder and an aerosol-forming material and a second composition including a tobacco material, a filler, and optionally a second binder are formed and mixed. In a subsequent step, the first composition and the second composition are mixed and extruded. Following this, the extruded mixture of the first composition and the second composition may be dried to form a sheet of aerosol-generating material. The sheet may then be shredded to create the aerosol-generating material, which may then be incorporated into a consumable for a non-combustible aerosol delivery system.

[0014] The first composition, also known as a "wet mixture," includes an aerosol-forming material or humectant and a binder. The first composition may also include other liquids or suspensions disclosed herein. The first composition may be in a liquid phase.

[0015] The first composition includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol-forming material is glycerin, glycerol, or propylene glycol.

[0016] The first composition includes a first binder. The binder is configured to bind the components of the first composition together. When combined with the second composition, the binder binds the components of the first and second compositions together to form an aerosol-generating material. The first composition may include two or more binders. In such embodiments, the binders in the first composition may be the same or different.

[0017] The binder may be selected from one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the binder comprises alginate and / or pectin or carrageenan. In some embodiments, the binder comprises CMC.

[0018] The second composition, also known as a "dry mix," comprises a tobacco material, a filler, and optionally a second binder. The second composition may comprise other solids or gels disclosed herein. The second composition may be in a solid phase.

[0019] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0020] The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material may be powder or ground. Alternatively, or in addition, the tobacco material may comprise tobacco strips, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material. In some embodiments, the tobacco material is in particulate or ground form to aid in the formation of the dough-like material that is formed when the first and second compositions are combined.

[0021] In embodiments where tobacco is a particulate tobacco material, each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from any point on the surface of a tobacco particle, or on the surface of a particle, to any other surface point on the same tobacco particle, or on the surface of a particle. The maximum dimension of a particle of a particulate tobacco material can be measured using a scanning electron microscope (SEM).

[0022] In some embodiments, the maximum dimension of each particle of the tobacco material ranges from about 800 μm. In some embodiments, the maximum dimension of each particle of the tobacco material ranges from about 2000 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is between about 200 μm and about 800 μm.

[0023] The particle population of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the particle population of the tobacco material has a particle size distribution (D90) of at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 110 μm, at least about 120 μm, or at least about 130 μm. In some embodiments, the particle population of the tobacco material has a particle size distribution (D90) of at most about 720 μm, at most about 740 μm, at most about 760 μm, at most about 780 μm, at most about 800 μm, at most about 820 μm, at most about 840 μm, or at most about 860 μm. In some embodiments, the particle population of the tobacco material has a particle size distribution (D90) of about 600 μm. A particle size and shape analyzer such as a Camsizer may be used to measure particle size distribution, and sieve analysis may be used to determine the particle size distribution of the tobacco material particles.

[0024] The inventors have found that the particle size distribution (D90) of the tobacco material can be controlled to achieve a desired areal density in the aerosol-generating material and in the sheets, shredded sheets or products made from the material. The areal density of a material is measured in GSM (grams per square meter, g / m 2 ) can be measured. For example, a smaller particle size distribution (D90) is associated with a higher areal density. This higher areal density may reduce the loading value of the tobacco material when the aerosol-forming material is incorporated into an article for use in a non-combustible aerosol delivery system. This particular example is where a particle size distribution (D90) of 300 is 246.6 g / m 2 is predicted to result in an areal density of

[0025] The inventors have also noted that lower areal densities are associated with better taste and sensory properties of the aerosol-generating material and the sheets, shredded sheets, or products made from the material. Because the methods for producing aerosol-generating materials produced by the disclosed methods involve less drying than conventional methods, fewer volatile components (many of which are considered desirable) are lost. Loss of fewer volatile components is associated with better sensory properties, as taste and aroma are better preserved. Furthermore, the present methods require less energy to remove volatile compounds.

[0026] However, the areal density should not be too low, as this reduces the amount of tobacco in the material that consumers perceive as providing positive sensory attributes, resulting in reduced sensory attributes. Furthermore, because materials with higher areal densities can contain more tobacco material, lowering the areal density can reduce the amount of tobacco material required, which can provide additional economic benefits.

[0027] The inventors have found that the particle size distribution (D90) can be controlled to achieve a desired tensile strength in the aerosol-generating material and the sheets, shredded sheets, or products made therefrom. For example, a larger particle size distribution (D90) is associated with a lower tensile strength. Without wishing to be bound by reason, a larger particle size distribution results in less material being bonded together. This can result in a weaker aerosol-generating material and the sheets, shredded sheets, or products made therefrom, and therefore a lower tensile strength. A specific example of this is that a particle size distribution (D90) of 269.2 is predicted to result in a tensile strength of 7.4 N / 15 mm.

[0028] The inventors have discovered that there is an optimum balance between areal density and tensile strength for the aerosol-generating material and the sheets, shredded sheets, or products made therefrom, and that this balance can be achieved by selecting a particle size distribution (D90) that is small enough to provide adequate tensile strength, but large enough to provide an areal density that provides positive sensory attributes to the user and facilitates removal of volatile compounds.

[0029] For example, the particle size distribution (D90) can be selected to provide a sufficiently low areal density to provide positive sensory attributes, but a sufficiently high tensile strength to be within the operating limits of the manufacturing machine. A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of the aerosol-generating material. The inventors have found that a particle size distribution (D90) of less than 100 μm results in an aerosol-generating material with good tensile strength. However, if the aerosol-generating material contains such fine tobacco material particles, the density of the aerosol-generating material may be high. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol delivery system, this high density may reduce the fill value of the tobacco material. Advantageously, the inventors have found that a balance between sufficient tensile strength and suitable areal density (and therefore fill value) can be achieved when the particle size distribution (D90) is at least 100 μm. In some embodiments, the particle size distribution (D90) is between 100 and 800 μm.

[0030] In some embodiments, the particle size distribution (D90) is 160 to 450 μm, In some embodiments, the particle size distribution (D90) is 200 to 450 μm.

[0031] A particle size distribution (D90) of at least about 180 μm is believed to contribute to suitable tensile strength of the aerosol-forming material. The inventors have found that a particle size distribution (D90) of at least about 200 μm results in an aerosol-forming material with good tensile strength. The inclusion of finer particles of tobacco material in the aerosol-forming material can increase its areal density. Selection of the particle size distribution (D90) can result in suitable tensile strength and areal density of the aerosol-forming material that are the same as or improved from those produced by the "band casting" technique. As described in Example 3, compared to aerosol-forming materials produced by band casting, aerosol-forming materials produced by the methods of the present invention have greater areal density and density while maintaining suitable tensile strength.

[0032] The second composition includes a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain any tobacco-derived material or ingredient. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler may be a material containing cellulose or a material containing a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. In some embodiments, the filler is a cellulosic material, cellulose, or CMC. In some embodiments, the filler consists essentially of or consists of cellulose.

[0033] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler can increase the tensile strength of the resulting aerosol-forming material. The use of cellulose as a filler has been found to have a particularly favorable effect on the burst strength of the aerosol-forming material.

[0034] Fillers can also contribute to the texture of the aerosol-generating material. For example, a fibrous filler such as cellulose can provide the aerosol-generating material with a relatively rough first and second surface. Conversely, a non-fibrous particulate filler such as powdered chalk can provide the aerosol-generating material with a relatively smooth first and second surface. In some embodiments, the aerosol-generating material includes a combination of different filler materials. Fillers can help improve the general structural properties of the aerosol-generating material, such as tensile strength and burst strength.

[0035] Incorporating a relatively large amount of first binder into a first composition relative to the aerosol-forming material can result in a highly viscous mixture, making it difficult to blend the first composition with the second composition. The inventors have found that this problem can be solved by reducing the amount of first binder in the first composition and adding a second binder (which may be the same as or different from the first binder) to the second composition.

[0036] Thus, the second composition may include an optional second binder. In some embodiments of the present invention, the first binder and the second binder are the same. In some embodiments of the present invention, the first binder and the second binder are different. The binder may be selected from one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the binder includes alginate and / or pectin or carrageenan. In some embodiments, the binder includes CMC.

[0037] As mentioned above, by incorporating a second binder into the second composition, the amount of the first binder in the first composition can be reduced, thus reducing the viscosity of the first composition and making it easier to form a mixture of the first composition and the second composition. The binder may at least partially coat the surface of the tobacco material. When the tobacco material is in particulate form, the binder may at least partially coat the surface of the tobacco particles and bind the particles together.

[0038] The total volatile content of the second composition may be about 10-15% by weight of the second composition. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, 35%, or 40% by weight of the second composition.

[0039] The first composition and the second composition described herein can be mixed to provide a mixture of the first composition and the second composition. The mixture of the first composition and the second composition can be formed by homogenizing the first composition and the second composition. The mixture of the first composition and the second composition can be in the form of a "dough". Advantageously, to provide a homogeneous dough suitable for subsequent processing steps, it is necessary to add minimal water or no water at all to the mixture. For example, the dough can then be extruded through a die, and preferably the homogeneous dough can pass through the die without adding additional water or with the addition of a small amount of water.

[0040] The inventors have found that mixing the first binder, aerosol-forming material, tobacco material, filler, and optional second binder in a single step (i.e., without forming the first and second compositions separately and then combining them) can result in a viscous mixture that is difficult to process and handle. By forming the first and second compositions separately and then combining these compositions, the resulting "dough"-like mixture can be more easily processed.

[0041] The tobacco material may be present in an amount of about 50% to about 80% by weight of the mixture of the first and second compositions. For example, the tobacco material may be present in an amount of about 50%, 60%, 70%, 80%, or 90% by weight of the mixture of the first and second compositions. In some embodiments, the tobacco material is present in an amount of about 75% by weight of the mixture of the first and second compositions.

[0042] The filler component may be present in an amount of 0-20% by weight of the mixture of the first and second compositions, or in an amount of 1-10% by weight of the mixture of the first and second compositions. For example, the filler may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the mixture of the first and second compositions. In some embodiments, the filler component is present in an amount of 5% by weight of the mixture of the first and second compositions, as the inventors have found that including 5% filler improves the burst strength and reduces brittleness of the aerosol-forming material.

[0043] The aerosol-forming material may be present in an amount of about 10% to about 25% by weight of the mixture of the first and second compositions, or in an amount of 1 to about 10% by weight of the mixture of the first and second compositions. For example, the aerosol-forming material may be present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% by weight of the mixture of the first and second compositions. In some embodiments, the aerosol-forming material is present in an amount of about 15% by weight of the mixture of the first and second compositions.

[0044] The binder may be present in an amount of about 1 to about 20% by weight of the mixture of the first and second compositions, or in an amount of 1 to about 10% by weight of the mixture of the first and second compositions. For example, the binder may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the mixture of the first and second compositions. In some embodiments, the binder is present in an amount greater than about 2% by weight of the mixture of the first and second compositions. In some embodiments, the binder is present in an amount of about 5% by weight, or up to about 5% by weight of the mixture of the first and second compositions. The amount of binder in the first composition, the second composition, and the mixture of the first and second compositions is important because it alters the consistency of the compositions and mixtures. If the amount of binder is too high, the composition / mixture may become too viscous to be processed, for example, by pumps and machines.

[0045] In embodiments of the present invention in which first and second binders are provided, the ratio of the first binder to the second binder may be between 1:1 and 1:10. This ratio is advantageously selected to provide adequate binding of the mixture and / or aerosol-generating materials while maintaining the physical properties of the sheet and without compromising the texture of the composition. The ratio of the first binder to the second binder may be approximately 1:10, 2:8, 3:7, 4:6, 5:5, 10:1, 8:2, 7:3, or 6:4, respectively. In some embodiments, the ratio of the first binder to the second binder is 4:6, respectively, to maintain the physical properties of the sheet or shredded sheets. If the first composition contains all of the binder, the viscosity of the first composition may be too high to process, for example, by pumps and machines. Providing a binder in both the first and second compositions facilitates processing of the compositions.

[0046] The inventors have unexpectedly discovered that incorporating a first binder, an optional second binder, and a filler in a total amount of about 5% to about 15% by weight of a mixture of a first composition and a second composition beneficially affects the burst strength, strength, and flexibility of the aerosol-generating material. The mixture of a first composition and a second composition may contain a total of about 2%, about 5%, about 8%, about 10%, about 12%, or about 15% of the first binder, optional second binder, and filler on a dry weight basis. In some embodiments, the mixture of a first composition and a second composition contains 5% of the first binder, optional second binder, and 5% of the filler. Incorporation of the first binder, optional second binder, and filler in this manner can reduce the tackiness, increase the burst strength, and improve the flexibility of the aerosol-generating material.

[0047] In certain embodiments, the first binder and the optional second binder are both CMC, with a total binder content of 5%, and the filler is cellulose, with a total cellulose content of 5%. Thus, in such embodiments, the mixture of the first composition and the second composition contains 5% CMC and 5% cellulose. The inventors have found that the presence of these amounts of binder and filler has a particularly beneficial effect on the physical properties of the aerosol-forming material, including improved strength and flexibility. The cellulose filler improves the burst strength and reduces brittleness of the aerosol-forming material.

[0048] The aerosol-forming material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the aerosol-forming material may have a burst strength of at least 150 g.

[0049] If the burst strength is too low, the aerosol-generating material may be relatively brittle. As discussed herein, the aerosol-generating material may be formed into sheets or shredded sheets. As a result, breakage of the sheets or shredded sheets may occur during the manufacturing process of the aerosol-generating material. For example, when a sheet is shredded to form shredded sheets by a cutting process, the sheet may crumble or break into pieces upon cutting. Incorporating a first binder, an optional second binder, and a filler may help improve the general structural properties of the aerosol-generating material, such as tensile strength and burst strength.

[0050] The volatile content of the mixture of the first and second compositions may be greater than 20% by weight of the mixture of the first and second compositions. The volatile content may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight of the mixture of the first and second compositions. In some embodiments, about 20 to about 30% water is added to the mixture of the first and second compositions. In some embodiments, about 26% water is added.

[0051] The total volatile content of the mixture of the first and second compositions may be about 22-29% by weight. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight of the mixture of the first and second compositions.

[0052] The amount of water in the mixture of the first and second compositions may be greater than 20% by weight of the mixture of the first and second compositions. The amount of water may be greater than about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight of the mixture of the first and second compositions. In some embodiments, about 20 to about 30% water is added to the mixture of the first and second compositions. In some embodiments, about 26% water is added.

[0053] The total water content of the mixture of the first composition and the second composition may be about 22 to 29% by weight, or about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight of the mixture of the first composition and the second composition.

[0054] The present invention has the additional advantage that less water is required to prepare a dough-like mixture of the first and second compositions than with other conventional compositions. Therefore, the mixture of the first and second compositions can be easily mixed without the need to add additional water or chemicals to form a homogeneous mixture suitable for extrusion. An additional advantage of the low amount of water required is that it improves the reliability of the manufacturing process. As a result, the manufacturing process is also repeatable, which also has cost-saving implications. Therefore, the total water content of the mixture of the first and second compositions is relatively low.

[0055] As a result of this lower moisture content, less water needs to be removed during processing. For example, the "band casting" process uses a slurry with a target moisture content of about 75% to about 80%. This slurry then needs to be dried to a target moisture content of about 13%, thus requiring a water reduction of about 67%. In the inventions disclosed herein, minimal water is incorporated into the mixture of the first and second compositions. For example, the resulting dough may only require a water reduction of about 16% in the final product. Thus, compared to methods of forming aerosol-generating materials that involve slurries, such as the band casting process, the methods described herein may require a water reduction of about 50% or about 60%. Advantageously, because less water needs to be removed during processing, less energy is consumed. Less energy consumption is more environmentally friendly, faster, and cost-effective. Furthermore, less drying is required, resulting in better flavor and aroma retention.

[0056] The aerosol-generating material produced by the methods disclosed herein has a volatile content of between about 5% and about 15%, which allows the aerosol-generating material to be cut into strips relatively easily. If the volatile content, particularly the water content, is too high, the aerosol-generating material may tear during the cutting process, which is undesirable. If the volatile content is too low, the aerosol-generating material may be too brittle and may shatter during the cutting process.

[0057] The present invention has the additional advantage that the amount of certain volatile components, particularly nicotine and glycerol, lost during drying of the mixture of the first composition and the second composition is smaller. Without wishing to be bound by the reason, the mixture of the first composition and the second composition contains a relatively low amount of water, and therefore requires less drying than slurries known to those skilled in the art. For example, lower temperatures and shorter drying times can be used to achieve the desired volatile content of the aerosol-forming material. This also reduces the amount of loss of certain valuable volatile components, improving the flavor, taste, and mouthfeel characteristics of the aerosol produced in the final product.

[0058] In an exemplary embodiment, the mixture of the first and second compositions comprises about 75% tobacco material (tobacco), about 15% aerosol-forming material (glycerin), about 5% filler (cellulose), and about 5% binder (CMC, about 2% in the first composition and about 3% in the second composition). In this embodiment, the composition does not contain guar gum. The inventors have discovered that the mixture of the first and second compositions provides the advantages disclosed herein.

[0059] Once formed and mixed, the mixture of the first and second compositions can be extruded to form the aerosol-forming material using any extrusion technique or device known in the art.

[0060] Extrusion involves feeding the precursor composition through an orifice to produce an extruded mass. The process combines pressure and shear forces on the precursor composition to produce a cohesive structure, which may be sheet-like.

[0061] Extrusion can be carried out using one of the major classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. Forming a sheet structure by extrusion has the advantage that this process combines mixing, conditioning, homogenizing, and shaping of the mixture of the first and second compositions.

[0062] Other materials such as bases, diluents, solid aerosol formers, solid flavor modifiers, leavening agents, and other additives known in the art can also be added during the extrusion process, which has the advantage of dispersing the additives evenly throughout the agglomerated structure being formed.

[0063] The resulting extruded mixture of the first and second compositions can be dried using any suitable drying technique known in the art. For example, microwave drying, infrared drying, air drying, and oven drying are suitable techniques for drying aerosol-forming materials. The temperature of the drying step can be less than 100°C, and in some embodiments of the present invention, less than 90°C. The drying temperature utilized can be up to about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C.

[0064] The resulting extruded mixture of the first and second compositions may be processed by forming a layer of the mixture on a surface, and the mixture may then be dried to remove at least a portion of the water and form a sheet of aerosol-generating material.

[0065] Water can be removed by evaporating it from the extruded mixture at ambient temperature and pressure (e.g., 25°C and 101 kPa). Alternatively, water may be removed by applying heat to the extruded mixture (e.g., heating above about 25°C) and / or reducing the atmospheric pressure surrounding the extruded mixture of the first and second compositions (e.g., to less than 101 kPa).

[0066] The use of lower drying temperatures is advantageous because it reduces the loss of volatile components, such as nicotine, glycerol, and flavorings, which contribute to the flavor, taste, and mouthfeel of the final product. In some embodiments of the present invention, the combined loss of nicotine and glycerol is less than about 10%, less than about 8%, less than about 5%, less than about 4%, less than about 2%, or less than about 1%. In some embodiments, the combined loss of volatile materials is less than 5%. In some embodiments of the present invention, the combined loss of glycerol and nicotine is less than about 10%, less than about 8%, less than about 5%, less than about 4%, less than about 2%, or less than about 1%. In some embodiments, the combined loss of glycerol and nicotine is less than 5%. Thus, the aerosol-forming material has a lower total volatile content than a mixture of the first and second compositions.

[0067] The aerosol-forming material may comprise less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the total volatiles by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material comprises between about 0% and about 15%, or between about 5% and about 15% by weight of the total volatiles by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material may have a total volatile content of between about 9% and 13% by weight.

[0068] The aerosol-forming material may contain water. The aerosol-forming material may contain less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the aerosol-forming material. In some embodiments, the aerosol-forming material contains between about 0% and about 15%, or between about 5% and about 15% by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material contains between about 5% and about 15% by weight of the aerosol-forming material. Thus, the aerosol-forming material has a lower water content than a mixture of the first and second compositions.

[0069] In some embodiments, the amount of water lost from the mixture of the first and second compositions and the aerosol-forming material is between 10 and 50%. In some embodiments of the invention, the amount of water lost is about 10%, about 15%, about 25%, about 30%, about 40%, or about 50%. In some embodiments, the amount of water lost is about 26%.

[0070] The sheet or chopped sheet of aerosol-generating material may contain water and aerosol-forming material in a total amount of less than about 30% by weight of the sheet or chopped sheet of aerosol-generating material, or less than about 25% by weight of the aerosol-generating material. Incorporating water and aerosol-forming material into the sheet or chopped sheet of aerosol-generating material in an amount less than about 30% by weight of the sheet or chopped sheet of aerosol-generating material may advantageously reduce the stickiness of the sheet, making it easier to handle the aerosol-generating material during processing. For example, it may be easier to roll a sheet of aerosol-generating material to form a bobbin of material and then unroll the bobbin without the layers of the sheet sticking to each other. Reducing stickiness also reduces the tendency of the chopped strands or strips of material to clump or stick together, further improving processing efficiency and final product quality.

[0071] After drying, the sheet of aerosol-generating material may be cut into strips or strands of aerosol-generating material. A single-thickness sheet of aerosol-generating material may be fed to a shredding device. This may be achieved, for example, by providing a bobbin of sheet material that can be continuously fed to the shredding device. Alternatively, discrete portions of sheet-like aerosol-generating material, such as sheets known to those skilled in the art as flags, may be fed to the shredding device. The strips or strands of aerosol-generating material may be gathered and formed into articles for use in non-combustible aerosol delivery systems. Optionally, the aerosol-generating material may be crimped before being gathered and formed into an article. Optionally, the aerosol-generating material may be subjected to a second cutting step, such as a cross-cut shredding process, to obtain a defined cut length.

[0072] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth) or may be uneven or irregular. For example, the first and / or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second surfaces are relatively rough.

[0073] The smoothness of the first and second surfaces can be affected by many factors, such as the areal density of the sheet or shredded sheet, the nature of the components that make up the aerosol-generating material, or whether the surface of the material has been treated, for example, embossed, scored, or otherwise treated to impart a pattern or texture.

[0074] The sheet or chopped sheet of aerosol-forming material has a thickness of at least about 100 μm. The sheet or chopped sheet may have a thickness of at least about 100 μm, 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm, 280 μm, 290 μm, or 300 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 100 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 μm to about 270 μm, about 190 μm to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm. In some embodiments, the thickness of the sheet or shredded sheet is about 200 μm.

[0075] The thickness of the sheet or chopped sheet may vary between the first and second surfaces. In some embodiments, each strip or piece of aerosol-generating material has a minimum thickness across its area of ​​about 100 μm. In some cases, each strip or piece of a sheet or chopped sheet of aerosol-generating material has a minimum thickness across its area of ​​about 0.05 mm or about 0.1 mm. In some cases, each strip, strand, or piece of a sheet or chopped sheet of aerosol-generating material has a maximum thickness across its area of ​​about 1.0 mm. In some cases, each strip or piece of aerosol-generating material has a maximum thickness across its area of ​​about 0.5 mm or about 0.3 mm.

[0076] ISO 534:2011 "Paper and Board - Determination of Thickness" can be used to determine the thickness of the sheet.

[0077] The inventors have determined that if the sheet or shredded sheet of aerosol-generating material is too thick, heating efficiency may be compromised. This may adversely affect power consumption during use, for example, power consumption to release flavor from the aerosol-generating material. Conversely, if the sheet or shredded sheet of aerosol-generating material is too thin, it may be difficult to manufacture and handle. Very thin materials may be difficult to cast, may be prone to breakage, and may impair aerosol formation during use.

[0078] It is contemplated that if the sheet or chopped sheet of aerosol-generating material is too thin (e.g., less than 100 μm), it may be necessary to increase the cut width of the chopped sheet to achieve sufficient packing when the sheet or chopped sheet of aerosol-generating material is incorporated into an article. Increasing the cut width of the chopped sheet can increase pressure loss, which is undesirable.

[0079] having a thickness of at least about 100 μm and about 100 g / m 2 ~approximately 240 or 250 g / m 2 It is anticipated that aerosol-generating materials having an areal density of about 100 g / m are less likely to tear, rip, or otherwise deform during manufacturing. 2 ~approximately 240 or 250 g / m 2 Aerosol-generating materials having an areal density of at least about 100 μm are less likely to tear, rip, or otherwise deform during manufacturing. A thickness of at least about 100 μm can favorably affect the overall structural integrity and strength of the sheet or chopped sheet. For example, sheets or chopped sheets of such thickness may have good tensile strength and therefore be relatively easy to process. In some embodiments, the areal density is from about 170 to about 240 or 250 g / m. 2 In some embodiments, the areal density is between about 180 g / m 2 is.

[0080] It is also believed that the thickness of the sheet or shredded sheets is related to its areal density, i.e., increasing the thickness of the sheet or shredded sheets can increase the areal density of the sheet or shredded sheets.

[0081] Conversely, reducing the thickness of the sheet or chopped sheet may reduce the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, the term refers to the average areal density calculated for a given strip, strand, piece, or sheet of aerosol-forming material, where the areal density is calculated by measuring the surface area and weight of the given strip, strand, piece, or sheet of aerosol-forming material.

[0082] The sheet or shredded sheet of aerosol-forming material has a mass of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 In some embodiments, the sheet or shredded sheet has an areal density of about 180 g / m 2 It has an areal density of

[0083] Surface density is approximately 100g / m 2 ~about 250g / m 2It is believed that this contributes to the strength and flexibility of the sheet or shredded sheet. Furthermore, the inventors have found that a rod comprising a shredded sheet of aerosol-forming material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm can be loaded such that the aerosol-forming material remains in place within the rod while maintaining a desired weight of tobacco material (e.g., about 300 mg) and delivering acceptable organoleptic properties (e.g., taste and odor) when heated in a non-combustible aerosol delivery device.

[0084] The flexibility of the sheet or shredded sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Additionally, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. It is believed that the combination of thickness and areal density of the aerosol-generating materials described herein results in a relatively flexible sheet or shredded sheet. This flexibility may provide various advantages when the aerosol-generating material is incorporated into an article for use in a non-flammable aerosol delivery device. For example, the strands or strips can easily deform and bend when an aerosol generator is inserted into the aerosol-generating material, thereby facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosol-generating material.

[0085] The inventors have found that the areal density of the sheet or chopped sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second surfaces can be adjusted.

[0086] The sheet or shredded sheet may have a tensile strength of at least 4 N / 15 mm. The inventors have found that if the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, the sheet or shredded sheet may be prone to tearing, breaking, or other deformation during manufacture and / or subsequent incorporation into an article for use in a non-flammable aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0087] The sheet or chopped sheet of aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the sheet or chopped sheet of aerosol-generating material has a burst strength of at least 150 g. As disclosed and discussed above, burst strength affects the strength of the material.

[0088] The sheet or shredded sheet of aerosol-forming material may have a total volatile content of about 9-13% by weight. The total volatile content may be about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight. As disclosed herein, the present invention advantageously preserves the amount of volatile compounds, thereby improving the flavor, taste, and mouthfeel characteristics of the aerosol generated in the final product.

[0089] The aerosol-forming material may include a substance to be delivered to a user. In some embodiments, the substance to be delivered includes an active agent.

[0090] As used herein, an active substance may be a physiologically active substance, which is a substance intended to obtain or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant material.

[0091] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0092] As described herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0093] As described herein, an active substance may include or be derived from one or more botanical substances or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, and the like. Alternatively, the material may include synthetically derived active compounds naturally occurring in the plant. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, and ginkgo biloba. biloba), hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, teas such as green tea and black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, Beefsteak plant, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.Mint can be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citratac.v., Mentha piperita cv, Mentha piperitac.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0094] 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.

[0095] 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.

[0096] 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 rooibos and fennel.

[0097] In some embodiments, an additive may be incorporated into the first composition, the second composition, the mixture of the first and second compositions, or the aerosol-forming material before or after the extrusion, drying, or shredding step. In some embodiments, the additive comprises the substance to be delivered.

[0098] In some embodiments, the substance to be delivered comprises a flavoring, which can be added at any stage in the manufacture of the aerosol-forming material.

[0099] In some embodiments, the fragrance is added to the first composition. This embodiment has the advantage that the liquid fragrance is added to the liquid composition before mixing the first composition with the second composition, and the fragrance is uniformly dispersed throughout at least the first composition. This embodiment has the disadvantage that the fragrance may be lost during the drying operation.

[0100] In some embodiments, flavoring may be added after the chopping operation. For example, the machine may be equipped with a flavoring nozzle to deposit a flavoring on the surface of the strip of aerosol-forming material.

[0101] As used herein, the terms "flavoring" and "flavoring agent" refer to materials that can be used to produce a desired taste, aroma, or other somatic sensation in products for adult consumers, as permitted by local regulations. These materials include naturally occurring flavor substances, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). Gho, 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 quid, shisha, pine, honey essence, rose oil, vanilla La, 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 derived from any species of Mentha, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green tea and black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, blackcurrant, valerian, bell pepper, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugar and / or sugar substitutes (e.g., sucralose, acesulfame potassium,The materials may include other additives such as cellulose, cellulose acetate, cellulose esters (aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol), as well as charcoal, chlorophyll, minerals, botanicals, breath fresheners, etc. These materials may be imitation, synthetic, natural, or blends thereof. These materials may be in any suitable form, e.g., liquid such as an oil, solid such as a powder, or gas.

[0102] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco. In some embodiments, the flavoring agent comprises flavor components extracted from cannabis.

[0103] In some embodiments, the substance to be delivered may comprise a sensory agent, typically chemically induced, intended to produce a somatosensory sensation perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and may include chemicals that produce a warming, cooling, tingling, or numbing effect. Suitable warming agents include, but are not limited to, vanillyl ethyl ether, and suitable cooling agents include, but are not limited to, eucoliptol and WS-3.

[0104] In some embodiments, the first composition, the second composition, or the mixture of the first and second compositions may contain one or more functional materials. The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0105] In some embodiments, the substance to be delivered may be an aerosol-generating material as described herein, or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agents, and / or one or more other functional materials.

[0106] According to one aspect of the present disclosure, there is provided a consumable comprising the aerosol-generating material described herein. A consumable is an article comprising an aerosol-generating material, some or all of which is intended to be consumed during use by a user. The consumable may include one or more components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat upon use to generate an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be of any shape or size suitable for a smoking device. In some embodiments of the present invention, the consumable is rod-shaped.

[0107] In one embodiment, the aerosol-forming material is delivered to an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product.

[0108] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, pipe tobacco, hand-rolled or make-your-own cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; and Non-combustible aerosol delivery systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as e-cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol-generating materials to generate the aerosol.

[0109] According to this disclosure, a "combustible" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that is a component of the aerosol delivery system is combusted or burned during use to facilitate delivery of at least one substance to a user.

[0110] In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0111] In some embodiments, the present disclosure relates to components for use in combustible aerosol delivery systems, such as filters, filter rods, filter segments, tobacco rods, spills, or aerosol modifier-releasing components such as capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper.

[0112] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system are not burned or caused to burn to facilitate delivery of at least one substance to a user.

[0113] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0114] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vape device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0115] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0116] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-forming materials, one or more of which may be heated. Each aerosol-forming material may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

[0117] Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

[0118] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-generating materials and are configured for use with non-flammable aerosol delivery devices.

[0119] In some embodiments, a non-combustible aerosol delivery system, such as a non-combustible aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat source. In some embodiments, the heat source includes a carbon substrate capable of generating energy to power an aerosol-generating material or a heat transfer material in the form of heat in proximity to the heat source.

[0120] In some embodiments, the non-flammable aerosol delivery system may include an area for containing consumables, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0121] In some embodiments, consumables for use with a non-flammable aerosol delivery device may include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0122] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming agents, and / or one or more other functional materials.

[0123] As disclosed herein, a non-flammable aerosol delivery system may include an aerosol-generating material, as illustrated in Figures 2 and 3.

[0124] 2 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. Article 1 comprises a mouthpiece segment 2 and an aerosol generation segment 3.

[0125] The aerosol-generating segment 3 is in the form of a cylindrical rod and contains an aerosol-generating material 4. The aerosol-generating material can be any of the materials discussed herein.

[0126] Although described above as a rod, the aerosol-generation segment 3 may be provided in other forms, for example in the form of a plug, pouch or packet of material within the article.

[0127] The mouthpiece segment 2 in the illustrated embodiment includes a body of material 5, such as fibrous or filamentary tow.

[0128] The rod-shaped consumable 1 further comprises a wrapper 6 , for example a paper wrapper, surrounding the mouthpiece segment 2 and the aerosol-generation segment 3 .

[0129] 3 shows an example of a non-combustible aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material of the consumables 110 described herein. Broadly speaking, device 100 may be used to heat a replaceable article 110 containing an aerosol-generating medium, such as article 1 as shown in FIG. 2 or an article as described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0130] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 may be inserted for heating by the heating assembly. In use, the item 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heating assembly.

[0131] The device 100 of this example includes a first end member 106 with a lid 108 that is movable relative to the first end member 106 to close the opening 104 when no item 110 is placed therein. In Figure 3, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

[0132] Device 100 may include a user-operable control element 112, such as a button or switch, that, when pressed, operates device 100. For example, a user can turn device 100 on by operating switch 112.

[0133] Device 100 may also include an electrical component, such as a socket / port 114, that can accept a cable for charging a battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0134] In some embodiments, the consumable 110 may include an aerosol modifier. The aerosol modifier is a substance typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0135] 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 coloring, 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 the form of a powder, a string, or granules. The aerosol modifier may be free of a filtration material.

[0136] In some embodiments, the device may also include an aerosol generator. The aerosol generator is an apparatus configured to generate an aerosol from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy such that the aerosol-generating material releases one or more volatile substances to form an aerosol. In some embodiments, the aerosol generator is configured to generate the aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy. [Example]

[0137] Example 1 Two aerosol-generating materials were prepared. Each material was prepared by forming a first composition ("liquid phase") containing at least one binder (CMC, optionally guar) and an aerosol-forming material; forming a second composition ("dry phase") containing tobacco material, filler, and a second binder (CMC); and combining the first and second compositions to form a dough-like mixture of the first and second compositions. The mixture was then extruded and dried below 100°C to form a sheet of aerosol-generating material. The burst strength of the two materials was measured and compared. Burst strength was measured using a calibrated Texture Analyser (50 kg load cell, 20 mm probe height calibration, 1 g contact force) from Stable Micro Systems and Exponent software. Burst strength was measured using a 3 cm 2 aerosolizable material. 2 The sheets were measured using a 5 mm stainless steel ball probe. The composition and burst strength of each material are shown in Table 1.

[0138] [Table 1]

[0139] As can be seen from Table 1, using 2% CMC in the first composition and 3% CMC in the second composition (for a total of 5% CMC in the mixture of the first and second compositions) resulted in an aerosol-forming material (Aerosol-Forming Material 2) with a burst strength of at least 150 g. Furthermore, the inventors found that processing the material in an apparatus or machine posed no significant challenges, and that the burst strength was suitable for subsequent use in an article for use in a non-flammable aerosol delivery system.

[0140] Example 2 4 is a graph showing the reduction in the volatile compound nicotine (shown in a dashed line pattern as "nicotine (nic) delta") and the reduction in the volatile compound glycerol (shown in a dotted line pattern as "glycerol delta") in three exemplary aerosol-generating materials formed using the method for preparing aerosol-generating material 2 in Example 1. The changes in the amount of glycerol and nicotine were measured by gas chromatography (GC) from the dough-like mixture to the final product. The changes in total volatile content, including moisture, were measured as the percent weight loss when the samples were dried for exactly three hours in a ventilated hot air oven thermostated at 110°C.

[0141] The combined nicotine and glycerol content was reduced by only 0-2%. Furthermore, the moisture content was reduced by only approximately 16%. This demonstrates an efficient, targeted drying process that removed only unwanted moisture and minimized the loss of the volatile compounds nicotine and glycerol. Nicotine is an example of an active substance as described herein, and glycerol is an example of an aerosol-forming material as described herein.

[0142] Example 3 In this example, the physical properties of aerosol-forming materials produced by band casting and by the method of the present invention were compared.

[0143] [Table 2]

[0144] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as representative examples of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be construed as limitations on the scope of the invention as defined by the claims or equivalents of the claims, and it is understood that other embodiments may be utilized and changes may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but that may be claimed in the future.

Claims

1. forming a first composition comprising a first binder and an aerosol forming material; forming a second composition comprising a tobacco material, a filler, and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition, the mixture comprising the first binder, the second binder, and the filler in a total amount of between about 5% and about 15% by weight of the mixture; and Processing the mixture of the first composition and the second composition to form an aerosol-forming material. A method for preparing an aerosol-generating material, comprising:

2. 10. The method of claim 1, wherein the step of processing the mixture of the first composition and the second composition comprises extruding the mixture to form a sheet of the aerosol-generating material.

3. The method of claim 2 , comprising the step of drying the sheet of aerosol-generating material.

4. The method of any one of claims 1 to 3, wherein the mixture of the first composition and the second composition has a volatile content of greater than about 20% by weight.

5. 5. The method of claim 1, wherein the aerosol-forming material has a volatile content that is less than a volatile content of the mixture of the first composition and the second composition.

6. The method of any one of claims 1 to 5, wherein the aerosol-forming material has a volatile content of less than about 20% by weight.

7. The method of any one of claims 1 to 6, wherein the tobacco material comprises particulate tobacco.

8. 8. The method according to any one of claims 1 to 7, wherein the tobacco material has a particle size distribution (D90) of 160 to 450 μm.

9. The method of any one of claims 1 to 8, wherein the first binding agent and the second binding agent are the same or different.

10. The method of any one of claims 1 to 9, wherein the ratio of the first binder to the second binder is from 1:1 to about 1:

10.

11. 11. The method of any one of claims 1 to 10, wherein the mixture of the first composition and the second composition comprises the binder in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

12. 12. The method of any one of claims 1 to 11, wherein the mixture of the first composition and the second composition comprises the first binder, the second binder, and the filler in a total amount between 5 and 15% by weight of the mixture of the first composition and the second composition.

13. The method according to any one of claims 1 to 12, wherein the first composition is in a liquid phase and the second composition is in a solid phase.

14. 14. The method of any one of claims 1 to 13, wherein the mixture of the first composition and the second composition comprises the filler in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

15. A method according to any one of claims 2 to 14, comprising chopping the sheet to form strips of the aerosol-forming material.

16. The method of any one of claims 3 to 15, wherein the drying is carried out at a temperature of less than about 100°C.

17. 17. The method of any one of claims 1 to 16, wherein the mixture of the first composition and the second composition is formed by homogenizing the first composition and the second composition.

18. 18. An aerosol-forming material prepared by the method of any one of claims 1 to 17.

19. 20. The aerosol-forming material of claim 18 in the form of a sheet or chopped sheets.

20. 20. The aerosol-forming material of claim 19, wherein the sheet or chopped sheet has a burst strength of at least 150 g.

21. The sheet or shredded sheet has a thickness of about 170 g / m ２ ~Approx. 240g / m ２ 21. The aerosol-forming material of any one of claims 18 to 20, having an areal density of

22. 22. The aerosol-forming material of any one of claims 18 to 21, wherein the sheet or chopped sheet has a tensile strength of about 4 N / 15 mm to about 20 N / 15 mm.

23. 23. The aerosol generating material of any one of claims 18 to 22, comprising glycerol and / or nicotine in an amount that is 0 to 5% by weight less than the amount of glycerol and / or nicotine contained in the mixture of the first composition and the second composition.

24. An article for use in a non-flammable aerosol delivery system comprising the aerosol generating material of any one of claims 18 to 23.

25. 25. A non-flammable aerosol delivery system comprising the article of claim 24.

26. Use of an aerosol-forming material according to any one of claims 18 to 25 in an article for use in a non-flammable aerosol delivery system.

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