Smoking substitute consumable

Abstract

To provide an aerosol-forming article (e.g. a HNB consumable) comprising an aerosol-forming substrate dosed with a coating of flavourant.SOLUTION: An aerosol-forming substrate is a slurry-type reconstituted plant material, and the flavourant content is up to 20 wt.% of the aerosol-forming substrate.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present disclosure relates to consumables for use in smoking substitution systems, and particularly but not exclusively to heat-not-burn (HNB) consumables. [Background technology]

[0002] During the manufacturing process of tobacco products, such as cigarettes, tobacco waste is produced. The tobacco waste is usually in the form of tobacco dust, leaves, or stems. The tobacco waste can be collected and processed to provide what is known as reconstituted tobacco, or "recon."

[0003] Two distinct methods are most commonly used to produce reconstituted tobacco: i) papermaking (i.e., providing a "paper recon"), and ii) slurry casting (providing a "slurry-type recon"). The products resulting from these distinct processes have significantly different properties and characteristics. For example, while slurry-type recons generally have improved aroma / flavor and nicotine content compared to paper recons, slurry-type recons are typically more prone to breaking and often have less uniform quality.

[0004] In slurry casting, tobacco waste is ground into a fine powder, mixed with an aqueous solvent, usually water, and combined with a binder. The resulting slurry can undergo further grinding to further reduce the particle size of the tobacco material. The slurry is then cast onto a surface and dried to form a sheet. The dried sheet can be shredded and used in various tobacco products, for example as cigarette filler.

[0005] In the papermaking process, tobacco waste is mechanically agitated in the presence of an aqueous solvent to digest and treat the tobacco into usable fiber. Water-soluble compounds present in the tobacco are then extracted into the aqueous solvent. The aqueous extract and the insoluble fiber portion are separated. Through a typical papermaking procedure, the separated fiber portion, sometimes called "pulp," undergoes further processing to form a base sheet. The aqueous extract is concentrated and then re-added to the base sheet. The base sheet is then dried to form paper.

[0006] Smoking tobacco is generally regarded as exposing the smoker to potentially harmful substances, which are generally believed to be produced in significant quantities through the burning of tobacco and / or the heat caused by the burning of tobacco, as well as through the constituents of burnt tobacco in the tobacco smoke itself.

[0007] Conventional combustible smoking articles, such as cigarettes, typically include a cylindrical tobacco rod that includes strips of tobacco surrounded by a wrapper, and typically also include a cylindrical filter that is axially aligned in abutting relationship with the rolled tobacco rod. The filter typically includes a filtration material circumscribed by a plug wrap. The rolled tobacco rod and the filter are held together by a rolled strip of tipping paper that circumscribes the entire length of the filter and adjacent portions of the rolled tobacco rod. Conventional cigarettes of this type are used by lighting the end opposite the filter to burn the tobacco rod. The smoker receives mainstream smoke from his or her mouth by drawing on the mouth or filter end of the cigarette. The combustion of organic materials, such as tobacco, is known to produce tar and other potentially harmful by-products. To avoid smoking tobacco, various smoking substitute systems (or "substitute smoking systems") have been proposed.

[0008] Such smoking substitution systems can form part of a nicotine replacement therapy aimed at people wishing to quit smoking and overcome their dependence on nicotine.

[0009] Smoking substitution systems include electronic systems that allow a user to simulate the act of smoking by producing an aerosol (also called "vapor") that is drawn (inhaled) through the mouth into the lungs and then exhaled. The inhaled aerosol typically has nicotine and / or flavorings without or with fewer odors and health risks associated with traditional smoking.

[0010] Generally, smoking substitution systems are intended to provide a substitute for the habitual behavior of smoking while providing users with an experience and satisfaction similar to that experienced with traditional smoking and combustible tobacco products. Some smoking substitution systems use smoking substitution articles, which are designed to resemble traditional cigarettes and are cylindrical in shape with a mouthpiece at one end.

[0011] The popularity and use of smoking substitution systems has grown rapidly over the past few years. Although originally marketed as aids to assist habitual smokers wishing to quit smoking tobacco, consumers increasingly view smoking substitution systems as a desirable lifestyle accessory.

[0012] There are several different categories of smoking proxy systems, each of which utilizes a different smoking proxy approach.

[0013] One approach for smoking substitution systems is the so-called "heat-not-burn" ("HNB") approach, in which tobacco (not "e-liquid") is heated or warmed to release vapor. The tobacco may be leaf tobacco or reconstituted tobacco. The vapor may contain nicotine and / or flavorings. In the HNB approach, the intention is that the tobacco is heated without being burned, i.e., the tobacco does not undergo combustion.

[0014] A typical HNB smoking substitution system may include a device and a consumable. The consumable may include tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be applied to the tobacco material by a heating element of the device, and airflow through the tobacco material causes moisture in the tobacco material to be released as vapor. The vapor may also be formed from a carrier in the tobacco material (which may include, for example, propylene glycol and / or vegetable glycerin), as well as volatile compounds released from the tobacco. The released vapor may be entrained in the airflow drawn through the tobacco.

[0015] As the vapor passes through the consumable (entrained in the airflow) from the inlet to the mouthpiece (outlet), it cools and condenses to form an aerosol for inhalation by the user. The aerosol typically contains volatile compounds.

[0016] In the HNB smoking replacement system, it is believed that heating, as opposed to burning, tobacco material results in fewer or lower amounts of more harmful compounds typically produced during smoking. As a result, the HNB approach can reduce odor and / or health risks that can result through tobacco burning, tobacco combustion, and pyrolytic degradation.

[0017] Improved designs of HNB consumables are needed to enhance the user experience and improve the functionality of HNB smoking substitution systems. Summary of the Invention [Problem to be solved by the invention]

[0018] The present disclosure has been devised in view of the above problems. [Means for solving the problem]

[0019] Most generally, the present disclosure relates to aerosol-forming articles, such as HNB consumables, that have increased concentrations of volatile compounds.

[0020] According to a first aspect, the present invention provides an aerosol-forming article (e.g. an HNB consumable) comprising an aerosol-forming substrate having a coating of flavourant attached thereto, the aerosol-forming substrate being a slurry-type reconstituted plant material, and the flavourant content is up to 20% by weight of the aerosol-forming substrate.

[0021] References to "slurry-type" correspond to reconstituted plant material made by slurry casting, as opposed to a papermaking process.

[0022] By using an aerosol-forming substrate (which itself contains volatile compounds) with a coating of flavoring attached, the number / concentration of volatile compounds can be increased to provide the user with a vapor / aerosol containing a higher concentration of volatile compounds. This can provide the user with an enhanced recreational and / or medicinal effect when inhaled. In particular, the user experiences an enhanced flavor. The coating also adds flavoring to the aerosol-forming substrate uniformly, thus providing the user with a more consistent experience.

[0023] Optional features are described below, which may be applied alone or in any combination with any aspect.

[0024] The aerosol-forming article is preferably a heat-not-burn (HNB) consumable product.

[0025] The aerosol-forming substrate is capable of being heated to release at least one volatile compound capable of forming an aerosol. The aerosol-forming substrate may be located at the upstream end of the article / consumable.

[0026] As used herein, the terms "upstream" and "downstream" are intended to refer to the direction of vapor / aerosol flow, i.e., the downstream end of the article / consumable is the mouth end or outlet where the aerosol exits the article / consumable for inhalation by the user. The upstream end of the article / consumable is the end opposite the downstream end.

[0027] To generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound, which is intended to be vaporized / aerosolized and can provide a recreational and / or medicinal effect to the user when inhaled. Suitable chemically and / or physiologically active volatile compounds include the group consisting of nicotine, cocaine, caffeine, opiates and opioids, cathines and cathinones, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A, together with any combinations, functional equivalents, and / or synthetic substitutes of the above.

[0028] In some embodiments, the flavorant is a non-tobacco flavorant. Since the present invention is primarily intended to provide a smoking substitute consumable, the use of non-tobacco flavors is advantageous in providing the user with a non-traditional flavor that is not normally experienced, thus providing a changed and enhanced user experience.

[0029] Amaranthus dubius Arctostaphylos uva-ursi (Bearberry) Argemone mexicana Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii. Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Opium Lettuce), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort)、 Leonurus sibiricus (Honeyweed)、 Lobelia cardinalis、 Lobelia inflata (Indian-tobacco)、 Lobelia syphilitica、 Nepeta cataria (Catnip) Nicotiana species (Tobacco) Nymphaea alba (White Lily) Nymphaea caerulea (Blue Lily) Opium poppy Passiflora incamata (Passionflower) Pedicularis densiflora (Indian Warrior) Pedicularis greenlandica (Elephant ́s Head) Salvia divinorum Salvia dorrii (Tobacco Sage) Salvia species (Sage)At least one plant material selected from the list including Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combination, functional equivalent and / or synthetic alternative of the above.

[0030] Preferably, the plant material is tobacco. Any type of tobacco may be used, including, but not limited to, flue-cured, burley, Maryland, dark air-cured, oriental, dark fire-cured, perique, and rustica. This also includes blends of the aforementioned tobaccos.

[0031] Any suitable part of the tobacco plant may be used, including the leaves, stems, roots, bark, seeds, and flowers.

[0032] Tobacco can include one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, cut tobacco, extruded tobacco, cut rag tobacco, and / or reconstituted tobacco (e.g., slurry recon or paper recon).

[0033] The aerosol-forming substrate may comprise a collecting sheet of homogeneous slurry recon tobacco, or a collecting strip / strip formed from such a sheet.

[0034] In some embodiments, the sheet used to form the aerosol-forming substrate has a thickness of 100 g / m 2 or more, for example 120g / m 2 More than 110g / m 2 The sheet has a basis weight of at least 100 g.

[0035] The sheet is 300g / m 2 Below, for example, 250 g / m 2 or less than 200g / m 2 It may have the following basis weights:

[0036] Sheets are 120~190g / m 2 The sheet may have a basis weight of 100 g.

[0037] In some embodiments, the sheet used to form the aerosol-forming substrate has a density of 1100 mg / cm 3 Less than 1000 mg / cm 3 less than 900 mg / cm 3 has a density of less than .

[0038] In some embodiments, the sheet used to form the aerosol-forming substrate has a viscosity of 0.09 mg / mm 2 Less than 0.085 mg / mm 2 Less than 0.08 mg / mm 2 less than 0.075 mg / mm 2 has a mass / surface area of ​​less than

[0039] In some embodiments, the aerosol-forming substrate may have a thickness of less than about 1 mm, preferably less than about 0.5 mm, preferably about 0.1-0.3 mm, such as about 0.2 mm.

[0040] The aerosol-forming substrate may comprise at least 50% by weight of plant material, such as at least 60% by weight of plant material, for example about 65% by weight of plant material. The aerosol-forming substrate may comprise up to 80% by weight of plant material, for example up to 75 or 70% by weight of plant material.

[0041] The aerosol-forming substrate may include one or more additives selected from wetting agents, bulking agents, aqueous / non-aqueous solvents, and binders.

[0042] The humectant is provided as a source of vapor generation and the resulting vapor helps retain the volatile active compound and increases the visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butanediol, and vegetable glycerin (VG)) and their esters (e.g., glycerol monoacetate, diacetate, or triacetate). The humectant may be present in the aerosol-forming substrate in an amount of 1-50% by weight.

[0043] The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2% by weight, such as at least 5% by weight, such as at least 10% by weight, such as at least 20% by weight, such as at least 30% by weight, or such as at least 40% by weight.

[0044] The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40% by weight, such as at most 30% by weight, or such as at most 20% by weight.

[0045] Preferably, the humectant content is from 1 to 40% by weight of the aerosol-forming substrate, such as from 1 to 20% by weight.

[0046] Suitable binders are known in the art and can act to bind together the components forming the aerosol-forming substrate. Binders can include starch and / or cellulose binders such as methylcellulose, ethylcellulose, hydroxypropylcellulose, hydroxyethylcellulose, and carboxymethylcellulose, gums such as xanthan gum, guar gum, gum arabic, and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar, and pectin.

[0047] Preferably, the binder content is 5-20% by weight of the aerosol-forming substrate, for example about 6-8% by weight. The upper limit for the binder is preferably up to 15% by weight, such as up to 10% by weight. Preferably, the binder content is greater than 5% by weight.

[0048] Suitable fillers are known in the art and can act to enhance the aerosol-forming substrate. Fillers can include fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulosic fibers (e.g., wood fibers), jute fibers, and combinations thereof.

[0049] Preferably the filler content is from 5 to 10% by weight of the aerosol-forming substrate, for example about 6 to 9% by weight.

[0050] The aerosol-forming substrate may comprise an aqueous and / or non-aqueous solvent, hi some embodiments, the aerosol-forming substrate has a moisture content of 5-10% by weight, for example 6-9% by weight, such as 7-9% by weight.

[0051] The flavouring may be provided in solid or liquid form. The flavouring may include menthol, peppermint, spearmint, licorice, chocolate, fruit flavours (including, for example, citrus, cherry, etc.), vanilla, spices (e.g., ginger, cinnamon), coffee, eucalyptus, and tobacco flavours. The flavouring may be uniformly dispersed as a coating on the aerosol-forming substrate, or may be provided in separate locations and / or at different concentrations as a coating on the aerosol-forming substrate. Preferably, the flavouring is uniformly dispersed as a coating on the aerosol-forming substrate.

[0052] The flavorant is provided as a coating on the aerosol-forming article. Such a coating is provided on the aerosol-forming article by surface application of a liquid containing the flavorant, for example by brushing, spraying, or dipping into the liquid. The coating is preferably uniform across the surface of the aerosol-forming article.

[0053] In preferred embodiments, the coating is provided on a sheet of slurry-type reconstituted plant material from which the aerosol-forming article is formed. The coating may be provided on both major surfaces of the sheet, or alternatively, only on one major surface of the sheet. In preferred embodiments, the coating is provided on the sheet of slurry-type reconstituted plant material before the sheet is divided, for example by chopping or cutting, to form the aerosol-forming article. In some embodiments, the coating, when applied, is substantially continuous across the surface of the sheet or aerosol-forming article.

[0054] When the coating is applied to the surface of the aerosol-forming article, the flavoring agent may penetrate into the surface layer of the aerosol-forming article. Preferably, the flavoring agent is present only in the surface layer of the aerosol-forming article, i.e., not throughout the entire aerosol-forming article. These flavoring agents are known to be desired by users, but are also advantageous in providing a satisfying flavor "hit" to the user. In addition, a modified and enhanced flavor experience is achieved.

[0055] The deposited flavourant content of the aerosol-forming substrate may have a lower limit of at least 0.1% by weight of the aerosol-forming substrate, such as at least 0.5% by weight, such as at least 1% by weight, such as at least 2% by weight, such as at least 5% by weight, such as at least 10% by weight, such as at least 15% by weight.

[0056] The deposited flavourant content of the aerosol-forming substrate may have an upper limit of at most 20% by weight of the aerosol-forming substrate, such as at most 15% by weight, such as at most 10% by weight.

[0057] Preferably, the flavouring concentration is between 0.1 and 15% by weight. A flavouring concentration between 0.1 and 5% by weight of the aerosol-forming substrate is even more preferred.

[0058] Preferably, the flavouring agent is menthol.

[0059] More preferably, the flavoring agent is synthetically derived menthol. Advantageously, the origin of this menthol is not naturally derived. Usually, naturally derived menthol is provided in the form of mint or mint extract. As a result, the use of synthetic menthol excludes the presence of undesirable components present in mint or mint extract.

[0060] The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article / consumable resembles a conventional cigarette. The aerosol-forming substrate may have a diameter of 5 to 10 mm, such as 6 to 9 mm or 6 to 8 mm, for example about 7 mm. The aerosol-forming substrate may have an axial length of 10 to 15 mm, for example 11 to 14 mm, such as about 12 or 13 mm.

[0061] The aerosol-forming substrate may be circumscribed by a wrap layer, for example a paper wrap layer, which may overlie an inner foil layer or may comprise a paper / foil laminate (foil innermost).

[0062] The article / consumable may include at least one filter element. A terminal filter element may be located at the downstream / mouth end of the article / consumable. Multiple filter elements (e.g., terminal and upstream filter elements) may be located, and these filter elements may be adjacent to each other or spaced apart. Any upstream filter element may be at least partially (e.g., entirely) circumscribed by a (paper) wrap layer.

[0063] The filter element, or at least one of the filter elements (e.g., the terminal filter element and / or the upstream filter element) may be constructed from cellulose acetate tow. The filter element, or at least one of the filter elements (e.g., the terminal filter element and / or the upstream filter element) may be constructed from activated carbon. The filter element, or at least one of the filter elements (e.g., the terminal filter element and / or the upstream filter element) may be constructed from paper. The filter element, or at least one of the filter elements (e.g., the terminal filter element and / or the upstream filter element) may be constructed from plant material, e.g., extruded plant material. The or each filter element may be circumscribed by a plug wrap, e.g., a paper plug wrap.

[0064] The or each filter element may have a substantially cylindrical shape, the diameter of which substantially corresponds to the diameter of the aerosol-forming substrate (with or without its associated wrap layer). The or each filter element may have an axial length of less than 20 mm, such as 8 to 15 mm, for example 9 to 13 mm, for example 10 to 12 mm.

[0065] The, or at least one, filter element may be a solid filter element. The, or at least one, filter element may be a hollow filter element. The, or each, hollow filter may have an aperture of 1 to 5 mm, for example 2 to 4 mm, or 2 to 3 mm.

[0066] A terminal filter element (the downstream end of the article / consumable) can be joined to an upstream element to form the article / consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper can have an axial length greater than the axial length of the terminal filter element, such that the tipping paper completely circumscribing the terminal filter element and the wrap layer surrounding any adjacent upstream elements.

[0067] The filter element or at least one of the filter elements, e.g., the distal filter element, may include a capsule, e.g., a crushable capsule (crush ball), containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by a user to release the flavorant during smoking of the article / consumable. The capsule may be located axially at the center of the distal filter element.

[0068] In some embodiments, the article / consumable may include an aerosol cooling element adapted to cool the aerosol generated (by heat exchange) from the aerosol-forming substrate before it is inhaled by the user.

[0069] The aerosol-cooling element is located downstream from the aerosol-forming substrate. For example, the aerosol-cooling element may be between the aerosol-forming substrate and the upstream filter element, and / or between two filter elements. The aerosol-cooling element may be at least partially (e.g. completely) circumscribed by a (paper) wrap layer.

[0070] The aerosol cooling element may be formed from a plastic material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE), and polyethylene terephthalate (PET). The aerosol cooling element may be formed from a bonded / collecting sheet of material to form a high surface area structure with multiple longitudinal channels to maximize heat exchange and cooling of the aerosol.

[0071] The article / consumable may include a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the article / consumable. The spacer element may be provided between the aerosol-forming substrate and the upstream filter element and / or between two filter elements. The spacer element may include a tubular element, for example a paper tube. The spacer element may be at least partially (e.g. entirely) circumscribed by a (paper) wrap layer.

[0072] The spacer element may have an outer diameter of 5-10 mm, for example 6-9 mm or 6-8 mm, for example about 7 mm. The spacer element may have an axial length of 10-15 mm, for example 12-14 mm or 13-14 mm, for example about 14 mm.

[0073] In a second aspect, there is provided a smoking substitution system comprising an aerosol-forming article according to the first aspect and a device including a heating element.

[0074] The device may be an HNB device, ie a device adapted to heat an aerosol-forming substrate without combustion.

[0075] The device may include a body for housing a heating element. The heating element may include an elongated, e.g., rod, tubular, or blade heating element. The heating element may protrude into or surround a cavity in the body for receiving the above-mentioned articles / consumables.

[0076] The device (e.g., main body) may further include a power source, e.g., a (rechargeable) battery, for supplying power to the heating element. The device may further include a control unit for controlling the supply of power to the heating element.

[0077] In a third aspect, there is provided a method of using a smoking substitution system according to the second aspect, comprising: Inserting an item / consumable into the device; Heating items / consumables using heating elements Includes.

[0078] In some embodiments, the method includes inserting the article / consumable into a cavity in the body and penetrating a heating element into the article / consumable as the article / consumable is inserted. For example, the heating element can penetrate an aerosol-forming substrate within the article / consumable.

[0079] In a fourth aspect, there is provided a method of producing an aerosol-forming substrate, the aerosol-forming substrate being a slurry-type reconstituted plant material, the method comprising combining comminuted plant material with an aqueous medium to form a slurry, casting the slurry onto a surface to form a sheet, and applying a flavourant to the sheet to provide a coating.

[0080] Advantageously, by applying the flavorant to the sheet as a coating, a more uniform application of the flavorant to the aerosol-forming substrate is achieved, as compared to providing the flavorant as a separate component or ingredient of the aerosol-forming substrate or article / consumable, or in a separate component or ingredient of the aerosol-forming substrate or article / consumable. This provides the user with an enhanced flavor and a more consistent flavor experience. Also, the application of the flavorant to the sheet may be performed in a secondary environment away from the main production line. Thus, contamination of the main line equipment with undesired flavorant is avoided. Therefore, in some embodiments, it is preferred to apply the flavorant after the sheet has been wound onto a bobbin, for example by unrolling the sheet from the bobbin before the flavorant is applied. Advantageously, such application of the flavorant may be performed after the transport of the sheet (e.g., winding onto a bobbin) to a location away from the casting location.

[0081] The plant material is preferably ground to a particle size of less than 120 microns. It is undesirable to have a particle size of more than 150 microns, as this is associated with the formation of defects and inhomogeneous areas in the sheet formed by casting the slurry. In particular, a particle size of 30 to 120 microns is preferred.

[0082] A binder may also be included in the slurry. The amount of binder used is selected to provide an amount of 5-20% by weight of binder in the sheet ultimately produced from the slurry, such as 5-15% by weight, such as 5-10% by weight. The ground tobacco may be combined with the binder prior to combining with the aqueous medium. Or alternatively, the binder may be combined with the aqueous medium prior to combining the ground tobacco with the aqueous medium.

[0083] The slurry may also contain fillers, humectants, preservatives, and / or flavors, which may be combined with the ground plant material prior to combining with the aqueous medium, or alternatively, may be added separately to the slurry.

[0084] The total solids content of the slurry is preferably 15%-30% of the total slurry weight. Within this preferred range, about 50-90% of the total solids content of the slurry should be plant material. Although the plant material content of the slurry is not essential, it is preferred that a minimum amount of aqueous medium be used to avoid leaching of plant material soluble matter into the aqueous medium.

[0085] The slurry is formed by mixing the various components of the slurry. This may be accomplished using a high energy mixer or a high shear mixer to homogenize the slurry. Optionally, the slurry may be heated during mixing.

[0086] Additionally, the slurry may be vibrated to aid in homogenization of the slurry, which may be accomplished by vibrating the tank or silo in which the slurry is contained.

[0087] After mixing, the slurry is cast onto a moving support surface, such as a dryer belt, to form a sheet. Casting the sheet may be accomplished by a roll coater system or laminator, or any other method suitable in the art. The moisture content of the sheet upon casting is preferably 60-80 percent of the total weight of the cast slurry. The cast sheet is then dried by exposure to elevated temperatures and / or reduced pressure to remove excess moisture content from the sheet. Suitable drying methods include steam dryers and / or heated air dryers. Alternatively, the sheet may be dried under ambient conditions.

[0088] Preferably, the flavourant is applied by spray coating.

[0089] Advantageously, by applying flavor to the cast sheet by spray coating, a more even application of flavor is achieved, providing a more homogenous product, and therefore a more consistent user experience.

[0090] Preferably, the flavouring is a non-tobacco flavouring. In particular, the flavouring is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavours, vanilla, spices, coffee, eucalyptus and tobacco flavourings, in particular the flavouring is synthetically derived menthol. The advantages of the flavouring are described above.

[0091] Preferably, the plant material is tobacco.

[0092] Since the present invention is primarily intended to provide a smoking consumable, the use of tobacco provides a slurry-type reconstituted plant material that has the inherent characteristics of tobacco, such as mouthfeel, flavor, and nicotine content.

[0093] Preferably, the method of the fourth aspect includes the step of drying the sheet, and the flavourant is applied to the sheet after drying.

[0094] Because many flavorants exhibit high volatility, it is advantageous to apply the flavoring after the sheet has been dried to avoid loss of flavorant due to evaporation when drying at elevated temperatures or reduced pressure.

[0095] Preferably, the method of the fourth aspect includes the step of winding the sheet onto a bobbin, and the flavourant is applied to the sheet after winding.

[0096] This advantageously facilitates efficient storage of the sheets and allows the flavoring to be applied in a secondary environment away from the main production line, thereby avoiding contamination of main line equipment with undesirable flavors.

[0097] Alternatively, the flavorant may be applied to the sheet before it is wound onto a bobbin.

[0098] Preferably, the method of the fourth aspect includes the step of making an HNB consumable from the sheet.

[0099] According to a fifth aspect, there is provided an aerosol-forming substrate for an HNB device produced by a process according to the fourth aspect.

[0100] Preferably, the aerosol-forming substrate according to the fifth aspect has a deposited flavourant content of between 0.1 and 20% by weight of the aerosol-forming substrate.

[0101] Those skilled in the art will recognize that, unless mutually exclusive, a feature or parameter described in connection with any one of the above embodiments may also be applied to any other embodiment. Further, unless mutually exclusive, any feature or parameter described herein may be applied to any embodiment and / or may be combined with any other feature or parameter described herein.

[0102] So that the present invention may be understood, and further aspects and features thereof may be realized, embodiments illustrating the principles of the invention will now be described in more detail, with reference to the accompanying drawings. [Brief description of the drawings]

[0103] [Figure 1] FIG. 1 illustrates a first embodiment of an HNB consumable. [Diagram 2] FIG. 1 illustrates a second embodiment of an HNB consumable. [Diagram 3] FIG. 13 illustrates a third embodiment of an HNB consumable. [Figure 4] FIG. 1 shows a first embodiment of a device forming an HNB system. [Diagram 5] FIG. 1 is an exemplary diagram of one embodiment of a manufacturing process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0104] As shown in FIG. 1, the HNB consumable 1 includes an aerosol-forming substrate 2 at the upstream end of the consumable 1 .

[0105] The aerosol-forming substrate 2 comprises reconstituted tobacco, the reconstituted tobacco comprising nicotine as a volatile compound and having up to 20% by weight of a flavourant coating applied thereto, the flavourant being selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavours, vanilla, spice, coffee, eucalyptus, and tobacco flavours.

[0106] The aerosol-forming substrate 2 comprises 65% by weight tobacco provided in the form of collected strips produced from a sheet of slurry-type reconstituted tobacco. The tobacco has 20% by weight of a humectant, such as propylene glycol (PG) or vegetable glycerin (VG), attached thereto and has a moisture content of 7-9% by weight. The aerosol-forming substrate further comprises a cellulose pulp filler and a guar gum binder.

[0107] The aerosol-forming substrate 2 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. The aerosol-forming substrate 2 has a diameter of about 7 mm and an axial length of about 12 mm.

[0108] The aerosol-forming substrate 2 is circumscribed by a paper wrap layer 3 .

[0109] The consumable 1 includes an upstream filter element 4 and a downstream (distal) filter element 5. The two filter elements 4, 5 are spaced apart by a paper tube spacer 6. Both filter elements 4, 5 are formed from cellulose acetate tow and are wrapped with respective paper plug layers (not shown).

[0110] Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 corresponds to the diameter of the aerosol-forming substrate 2. The diameter of the terminal filter element 5 is slightly larger, corresponding to the combined diameter of the aerosol-forming substrate 2 and the wrap layer 3. The upstream filter element is slightly shorter in axial length than the terminal filter element, having an axial length of 10 mm compared to 12 mm for the terminal filter element.

[0111] The paper tube spacer is longer than each of the two filter portions and has an axial length of about 14 mm.

[0112] Each filter element 4, 5 is a hollow filter element having a hollow bore extending longitudinally. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter, having a diameter of 3 mm compared to 2 mm for the terminal filter element.

[0113] The paper tube spacer 6 and the upstream filter portion 4 are circumscribed by the wrap layer 3 .

[0114] The terminal filter element 5 is joined to the upstream element to form the consumable by a circumscribing paper tipping layer 7. The tipping layer 7 surrounds the terminal filter portion and has an axial length of about 20 mm, thus overlapping a portion of the paper tube spacer 6.

[0115] Figure 2 shows a second embodiment of a consumable 1', which is the same as that shown in Figure 1, except that the terminal filter element 5 contains a crushable capsule 8 (crush ball) containing liquid menthol or cherry or vanilla flavouring. The capsule 8 is spherical and has a diameter of 3.5 mm. The capsule 8 is positioned in the axial centre of the terminal filter part 5.

[0116] FIG. 3 shows a third embodiment of consumable 1'', which is the same as the first embodiment except that the wrap layer 3 does not completely circumscribe the paper tube spacer 6, and therefore an annular gap 9 exists between the tip layer 7 and the paper tube spacer 6 downstream of the end of the wrap layer 3.

[0117] 4 shows a first embodiment inserted into an HNB device 10 that includes a rod-shaped heating element (not shown). The heating element protrudes into a cavity 11 in the body 12 of the device.

[0118] The consumable 1 is inserted into a cavity 11 in the body 12 of the device 10 such that the heating rod penetrates the aerosol-forming substrate 2. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 is achieved by supplying power to the heating element (e.g., by a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compounds (e.g., nicotine) within the tobacco and the aerosol former are released as vapor and are entrained in the airflow generated by inhalation by the user at the terminal filter portion 5.

[0119] As the vapor cools within the upstream filter element 4 and the paper tube spacer 6, it condenses and forms an aerosol containing the volatile compounds for inhalation by the user.

[0120] Figure 5 shows an exemplary diagram of one embodiment of the manufacturing process. Tobacco is ground to reduce particle size to less than 120 microns (101).

[0121] The ground tobacco 101 is then combined with guar gum binder, cellulose pulp filler, propylene glycol, and vegetable glycerin to form a mixture (102).

[0122] The mixture 102 is mixed with an aqueous medium to form a slurry (103). The mixing of the mixture 102 with the aqueous medium is performed in a high shear mixer. The tobacco content of the slurry is about 50-90% of the total solids content of the slurry, and the total solids content is 15-30% by weight of the slurry.

[0123] The resulting slurry is cast onto a dryer belt to form a sheet (104), which is dried using a steam dryer to remove excess moisture content from the sheet until it becomes free-standing (105).

[0124] The sheet is wound onto a bobbin for storage (106). The moisture content of the cast sheet when wound is about 7 to 15 percent of the dry weight of the tobacco sheet. Flavorants are then applied to the sheet using a spray coating to provide a flavorant coating on the sheet (107).

[0125] The sheet can then be made into, or is part of, an HNB consumable suitable for an HNB device (108). This is accomplished by cutting the sheet to the appropriate size. The sheet may be used as, or is part of, an HNB consumable for an HNB device (109). In particular, this is a slurry-type reconstituted tobacco product for use in an HNB device.

[0126] In an alternative embodiment, flavoring is applied to the dried sheet 105 prior to winding onto a bobbin 106 for storage.

[0127] The features disclosed in the above description, or the following claims, or the accompanying drawings, are appropriately expressed in their specific form or in terms of means for performing a disclosed function, or a method or process for obtaining a disclosed result, and may be utilized separately or in any combination of such features to realize the invention in its many and varied forms.

[0128] While the present invention has been described in conjunction with the exemplary embodiments set forth above, many equivalent modifications and variations will be apparent to those skilled in the art given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative rather than limiting. Various changes may be made to the described embodiments without departing from the scope of the invention.

[0129] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purpose of improving the understanding of the reader, and the inventors do not wish to be bound by any of these theoretical explanations.

[0130] All headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0131] Throughout this specification, including the claims which follow, unless the context requires otherwise, the words "have," "comprise," and "include," as well as variations such as "having," "comprises," "comprising," and "including," will be understood to imply the inclusion of a stated integer or step or group of integers or steps, but not to exclude any other integers or steps or group of integers or steps.

[0132] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. As used herein, ranges may be expressed as "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, by use of the prefix "about," when values ​​are expressed as approximations, it will be understood that the particular value forms another embodiment. The term "about" in connection with numerical values ​​is optional and means, for example, ±10%.

[0133] The words "preferred" and "preferably" are used herein to refer to embodiments of the invention that may provide certain benefits, under some circumstances. It is to be understood, however, that other embodiments may also be preferred, under the same or different circumstances. Thus, reference to one or more preferred embodiments does not mean or imply that other embodiments are not useful, nor is it intended to exclude other embodiments from the scope of the disclosure or the claims.

Claims

1. 1. An aerosol-forming substrate for an HNB device, said aerosol-forming substrate being a slurry-type reconstituted plant material having a coating of flavouring agent deposited thereon.

2. 2. The aerosol-forming substrate according to claim 1, wherein the deposited flavourant content is up to 20% by weight of the aerosol-forming substrate.

3. 3. The aerosol-forming substrate according to claim 1 or 2, wherein the plant material is a material that emits volatile compounds different from the flavouring agent.

4. 3. The aerosol-forming substrate of claim 1, further comprising a humectant in an amount of from 1 to 50% by weight.

5. 3. The aerosol-forming substrate according to claim 1 or 2, wherein the flavourant is a non-tobacco flavourant.

6. 6. The aerosol-forming article of claim 5, wherein the flavoring agent is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavors, vanilla, spices, coffee, and eucalyptus.

7. 7. The aerosol-forming article of claim 6, wherein the flavoring agent is synthetically derived menthol.

8. 3. The aerosol-forming substrate according to claim 1 or 2, wherein the flavourant is a tobacco flavourant.

9. 3. The aerosol-forming substrate according to claim 1 or 2, wherein the plant material is tobacco.

10. 3. The aerosol-forming substrate according to claim 1 or 2, wherein the flavouring agent is uniformly dispersed on the surface of the plant material.

11. 11. The aerosol-forming substrate of claim 10, wherein the flavouring agent does not permeate throughout the plant material.

12. An aerosol-forming article comprising the aerosol-forming substrate according to claim 1 or 2.

13. The aerosol-forming article of claim 12, wherein the aerosol-forming article is a heat-without-burn (HNB) consumable product.

14. 14. The aerosol-forming article of claim 13, wherein the aerosol-forming substrate comprises a collecting sheet of homogenous slurry recon tobacco or a collecting strip formed from said sheet.

15. The basis weight of the sheet is 100 g / m ２ Above, 110g / m ２ or more, or 120 g / m ２ The aerosol-forming article according to claim 14 .

16. The basis weight of the sheet is 300 g / m ２ Below, 250g / m ２ or less than 200 g / m ２ 15. The aerosol-forming article of claim 14, wherein:

17. The density of the sheet is 1100 mg / cm ３ Less than 1000 mg / cm ３ Less than or equal to 900 mg / cm ３ The aerosol-forming article of claim 14, wherein the aerosol-forming article is less than 100 μm.

18. The aerosol-forming article of claim 14 , wherein the coating is provided on both major surfaces of the sheet.

19. The aerosol-forming article of claim 12; A device including a heating element; Including, the system.

20. 20. A method of using the system of claim 19, comprising the steps of: Inserting the aerosol-forming article into the device; and heating the aerosol-forming article using the heating element; and A method comprising:

21. 3. A method for producing an aerosol-forming substrate according to claim 1 or 2, wherein the aerosol-forming substrate is a slurry-type reconstituted plant material, the method comprising the steps of: combining the ground plant material with an aqueous medium to form a slurry; casting the slurry onto a surface to form a sheet; applying a flavoring agent to said sheet to provide a coating; A method comprising:

22. 22. The method of claim 21, wherein the flavoring is applied by spray coating.

23. 23. The method of claim 21 or 22, wherein the flavorant is a non-tobacco flavorant.

24. 24. The method of claim 23, wherein the flavoring agent is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavors, vanilla, spices, coffee, and eucalyptus.

25. 25. The method of claim 24, wherein the flavoring agent is synthetically derived menthol.

26. 23. The method of claim 21 or 22, wherein the flavourant is a tobacco flavourant.

27. 23. The method of claim 21 or 22, comprising the step of drying the sheet, and wherein the flavouring agent is applied to the sheet after drying.

28. 30. The method of claim 27, further comprising the step of transporting the sheet to a secondary environment after drying the sheet, wherein applying the flavorant to the sheet is performed in the secondary environment.

29. 23. The method of claim 21 or 22, comprising winding the sheet onto a bobbin.

30. 30. The method of claim 29, wherein the flavoring is applied to the sheet after it is wound onto the bobbin.

31. 30. The method of claim 29, wherein the flavoring is applied to the sheet before it is wound onto the bobbin.

32. 23. The method of claim 21 or 22, wherein the flavoring is provided on both major surfaces of the sheet.

33. 23. The method of claim 21 or 22, wherein the plant material is tobacco.

34. 23. The method of claim 21 or 22, comprising dividing the sheet by shredding or cutting.

35. 34. The method of claim 33, wherein the step of applying a flavoring to the sheet is performed after the step of dividing the sheet by shredding or cutting.

36. 23. The method of claim 21 or 22, wherein the comminuted plant material is comminuted to a particle size of less than 120 microns.

37. 23. The method of claim 21 or 22, wherein the total solids content of the slurry is between 15% and 30% by total slurry weight, and 50-90% of the total solids content of the slurry is the comminuted plant material.

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