Aerosol generating material

Abstract

To provide non-combustible aerosol provision systems and consumables comprising an aerosol generating material, as well as methods for preparing the aerosol generating material.SOLUTION: The invention relates to an aerosol generating material comprising cut tobacco material and cut plant material, the cut plant material having an average particle size of at least about 0.25 mm.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an aerosol-forming material comprising tobacco material and particles of plant material.

[0002] Aerosol-generating materials for use in combustion or non-combustion aerosol delivery systems may contain a variety of different actives and / or flavorings, with the user selecting the aerosol-generating material to provide the desired user experience.

[0003] The inclusion of clove material in traditional combustible cigarettes is known in the art and is commonly known as kretek. Factory-made kretek cigarettes have several features that can affect the sensory characteristics of the generated aerosol. These include a sweetened tip that can amplify and balance the flavor, and the casing and flavorings add a unique sweet and spicy flavor. The tobacco contains shredded "Rajangan" tobacco, which also gives these products their distinctive flavor. Kretek cigarettes can contain various types of tobacco; for example, "dark Rajangan" tobacco has a complex flavor compared to "bright Rajangan" tobacco, which is known for its lighter flavor. The chopped cloves found in these cigarettes contribute spicy, aromatic, numbing, and crisp flavors. These smoking articles may contain additional flavor ingredients. Overview

[0004] According to a first aspect of the invention described herein, there is provided an aerosol-forming material comprising cut tobacco material and shredded plant material, wherein the shredded plant material has an average particle size of at least about 0.25 mm.

[0005] In some embodiments, the shredded plant material has an average particle size of about 0.3 mm to about 0.5 mm.

[0006] In some embodiments, the shredded plant material comprises cloves.

[0007] In some embodiments, the cut tobacco material comprises reconstituted tobacco.

[0008] In some embodiments, the aerosol-forming material comprises about 25% to about 40% chopped plant material by weight, based on the weight of the aerosol-forming material.

[0009] In some embodiments, the density of the aerosol-forming material is from about 0.25 to about 0.45 g / cm 3 , optionally about 0.3 to about 0.4 g / cm 3 is.

[0010] In some embodiments, the cut tobacco material has a cut size of 20 to 25 CPI (cuts per inch), or about 7.9 to about 9.8 cuts per cm.

[0011] In some embodiments, the aerosol-forming material has a water content of about 8 to about 9%.

[0012] In some embodiments, the chopped plant material is not fixed within the aerosol-generating material.

[0013] In some embodiments, the shredded plant material is not incorporated into the tobacco material.

[0014] In some embodiments, the aerosol-forming material does not include a binder to bind the cut tobacco material and the shredded plant material together.

[0015] According to a second aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising an aerosol-forming material according to the first embodiment.

[0016] In some embodiments, the system is an aerosol-generating material heating system that includes an aerosol-generating material that is heated to volatilize constituents, and optionally includes a filter or filter element.

[0017] In some embodiments, the system is a hybrid system comprising an aerosol-generating material that is heated to volatilize constituents and a liquid that is heated to form a vapor, and optionally includes a filter or filter element.

[0018] In some embodiments, the aerosol-forming material is heated by steam.

[0019] In some embodiments, the liquid is a non-nicotine-containing liquid.

[0020] In some embodiments, the system includes a means for heating a liquid to form a vapor, but does not include a separate means for heating an aerosol-forming material.

[0021] According to a third aspect of the present invention, there is provided a consumable product comprising an aerosol-forming material according to the first aspect.

[0022] In some embodiments, the consumable product includes a cartridge or pod containing the aerosol-forming material.

[0023] In some embodiments, the consumable product comprises a rod or stick comprising an aerosol-forming material.

[0024] According to a fourth aspect of the present invention, there is provided a method of preparing an aerosol-forming material according to the first aspect, the method comprising combining cut tobacco material and cut plant material.

[0025] In some embodiments, the consumable comprises cut tobacco material and cut plant material, which are combined by a simple blend.

[0026] 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]

[0027] [Figure 1]1 is a flowchart illustrating the main steps of a process according to an embodiment of the present invention. [Figure 2] 1 is a schematic cross-sectional view of an article for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material. [Figure 3] FIG. 1 is a schematic diagram of a hybrid system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material. Detailed Description

[0028] The aerosol-forming materials described herein are used to generate aerosols with a distinctive flavor and quality that are inhaled by end users. One objective of the present invention is to provide end users with a distinctive experience using a non-combustion aerosol delivery system as a result of the inclusion of botanical material. The impact of the botanical material depends on the form in which it is included in the aerosol-forming material and how it affects the generated aerosol.

[0029] In embodiments in which the plant material is clove, the aerosol-forming material provides an aerosol produced by a non-combustion aerosol delivery system that more closely matches the consumption experience of a combustible kretek cigarette.

[0030] The present invention relates to an aerosol-forming material comprising shredded tobacco material and shredded plant material. The aerosol-forming material can be used in a non-combustion aerosol delivery system, for example, by incorporating it into a consumable product. The shredded plant material has an average particle size of at least about 250 μm, optionally up to about 500 μm, or from about 280 μm to about 450 μm.

[0031] Particles of these sizes have been found to provide different sensory characteristics to the generated aerosol than those provided by finer plant particles (e.g., what are sometimes called "dust"). For example, when the plant material is cloves, the sensory characteristics of the aerosol more closely resemble the characteristic flavors of cloves and kretek cigarettes.

[0032] The inclusion of shredded plant material with this larger particle size also means that it is easier to incorporate a higher proportion of plant material into the aerosol-forming material. For example, in some embodiments, the aerosol-forming material includes as much as about 35% plant material by weight. If the plant particles are very fine, the particles may need to be immobilized within the aerosol-forming material to prevent the plant material from being lost or moving relative to the shredded tobacco material, thereby preventing the materials from being uniformly or homogeneously mixed.

[0033] The presence of such a high proportion of fine plant particles can also increase the density of the aerosol-generating material within the non-combustion aerosol delivery system or consumable, making it more difficult for airflow, aerosol, or vapor to pass through it, or for all of the aerosol-generating material to be uniformly exposed to heat to generate an aerosol. Generally, the smaller the particle size, the greater the surface area and therefore the greater the flavor delivery. However, smaller particle sizes can present processing challenges and can make it more difficult to maintain the particles within the aerosol-generating material and / or consumable or non-combustion aerosol delivery system.

[0034] The present invention enjoys benefits from combining shredded plant material with shredded tobacco material, such as improved flavor of the aerosol produced by the aerosol-forming material. The size of the shredded plant material has several advantages, which are detailed herein.

[0035] An aerosol-generating material is a material that can generate an aerosol when activated, for example, by heating, irradiation, or in any other manner. The aerosol-generating material may include, for example, one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0036] The aerosol-forming material may include one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0037] 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.

[0038] In some embodiments, the aerosol-forming material is a simple mixture or blend of cut tobacco material and cut plant material.

[0039] plant material As used herein, chopped plant material may be cloves or other material obtained from a plant.

[0040] As referred to herein, shredded plant material may be obtained from any material obtained from a plant, including, but not limited to, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, pods, husks, etc. The material may be in the form of particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants or plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, and rose. Marie, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, angelica, black currant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, karvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens. suaveolens).

[0041] In some embodiments, the shredded plant material is cloves. The use of cloves as the shredded plant material provides the end user with a distinctive flavor and sensory experience. Cloves are known to have sensory effects, including, among others, aroma, spice, numbness, crispness, and throat-soothing characteristics. This improves the sensory characteristics of the inhaled medium, and can be achieved without changing the dimensions of the non-combustion aerosol delivery system.

[0042] The use of cloves in combustible cigarettes also has historical precedent in some regions, where they are known as "kretek" cigarettes. The present invention provides users with the experience of a kretek cigarette through a non-combustible aerosol-generating device. Thus, the use of cloves adds value to traditional tobacco-flavored non-combustible aerosol-generating devices. In some embodiments, the generated aerosol has a flavor reminiscent of kretek cigarettes, which is advantageous because this flavor is particularly popular with consumers in certain regions, such as Indonesia. Cloves contain several essential oils, such as eugenol, which is known to provide some of the distinctive flavor of clove and is believed to have analgesic effects in traditional Eastern medicine.

[0043] The clove material may be derived from whole cloves or portions of whole cloves, clove stalks, mother cloves, expanded cloves and / or spent cloves, as well as other clove derivatives or mixtures thereof known in the art.

[0044] In some embodiments, the plant material is chopped into particles. For example, the plant material may be chopped using any suitable process.

[0045] In some embodiments, the preparation of chopped plant (e.g., clove) particles comprises the following steps: 1) Conditioning the plant material with water, water vapor, and temperature to increase the moisture content to between 10% and about 30%. 2) Chopping the plant material, for example using a machine with a rotating knife, the rate at which the plant material is fed into the machine and the speed of the rotary chopping control the chop length. 3) The particle size of the chopped plant material can be determined by off-line testing (sieving).

[0046] In some embodiments, the plant particle size may range from about 0.2 to 0.5 mm, 0.25 to 0.4 mm, or 0.3 to 0.5 mm, or from about 0.25 to about 0.45 mm.

[0047] In some embodiments, the plant material is chopped to a size of 60-90 CPI (cuts per inch) or 23.6-35.4 cuts per cm, resulting in particles having an average size of about 0.42 to about 0.28 mm.

[0048] Particle size can be measured by various techniques, such as laser diffraction, microscopy, or preferentially by sieving. A common practice is to assign a "mesh value" to a cut material, which reflects the ability of more than 95% of the particles in a given particle population to pass through a screen of a given mesh value. In this context, the mesh value reflects the number of mesh holes per inch of the screen. This method selects particles of a desired size without the need to measure multiple particles to determine an average distribution. Furthermore, it can be used to measure the size of particles that do not have a regular spherical shape, which makes average measurements difficult.

[0049] The size of the chopped plant material particles is important and affects several characteristics of the blend, such as improved mixing of the blend components and flavor release / delivery. The particle size is selected to deliver the desired sensory effects, and the cloves are selected to provide a characteristic flavor. Without wishing to be bound by any particular theory, it is speculated that shredding the plant material to form chopped plant material particles enhances the release of flavor components, including volatile flavor and aroma compounds. The increased surface area of the tobacco particles is also believed to aid in volatilization, as described herein.

[0050] Particle size is important because it changes the surface area to volume ratio of particles.Without wanting to be bound by theory, it is proposed that larger particles with lower surface area to volume ratio are less exposed to air, which reduces the evaporation of the volatile compounds that contribute to the characteristic flavor of the aerosol produced.Larger particles are easier to handle, can be stored for a longer period of time, and release less volatile compounds before being intentionally heated by end-users.

[0051] The smaller particle size of the chopped plant material is associated with a lower particle size distribution and packing value, which allows the material to be more easily spread evenly throughout the aerosol-forming material, providing a consistent flavor to the end user across uses of the aerosol-forming material.

[0052] On the other hand, larger particle sizes of chopped plant material may be associated with different sensory experiences, and the particles must be large enough to allow volatiles to escape after heating without being too densely packed to prevent them from escaping.

[0053] Larger particles are easier to handle, remain substantially dry, and the cell structure is not substantially destroyed. Less sophisticated machinery can be used, which can be more economical to manufacture. Because less grinding is required, it is less energy intensive, saving energy and time in the manufacturing process.

[0054] Plant material particles of a desired size can be formed by crushing, chopping, chopping, or grinding the plant material. Suitable machinery for producing such plant particles includes, for example, shredders, cutters, or mills, such as hammer mills, roller mills, or other types of commercially available milling machinery. The size of the plant particles can be readily prepared from a variety of different types of plant material having the properties described herein, including cloves, and is selected to provide particles that provide a source of readily released volatile compounds.

[0055] According to some embodiments, the plant material is prepared along the following lines: First, the plant material is conditioned to adjust (increase) its moisture content, for example, to a range of about 32% to about 36%. This can be done by exposing the plant material to a temperature of about 60 to about 70°C and to water and water vapor. The plant material can then be subjected to a puffing step, for example, for 2 hours, to ensure that the water applied during the conditioning step is fully absorbed by the plant material. After puffing, the plant material can be ready to be chopped to a desired particle size. The chopped plant material can then be subjected to a drying step to adjust (reduce) its moisture content, for example, to a range of about 11% to about 12%. This can be done by exposing the plant material to a temperature of about 45 to about 55°C.

[0056] tobacco The tobacco material used to form the cut tobacco material can be any type of tobacco and any part of the tobacco plant, including tobacco blades, stems, stalks, veins, trash, and flakes, or a mixture of two or more thereof. Suitable tobacco materials include the following varieties: dark tobacco, light tobacco, Rajangan tobacco, Virginia or flue-cured tobacco, burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. Some of these tobacco varieties, such as Rajangan tobacco, may be processed differently, as known to those skilled in the art.

[0057] The tobacco may be expanded, such as dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, such as solid stem (SS); shredded dried stem (SDS); steam-treated stem (STS); or any combination thereof. The tobacco material may be fermented, dried, never-cured, toasted, or otherwise pre-processed.

[0058] In some embodiments, the tobacco material is in the form of reconstituted tobacco that has been processed and shredded to form cut rag tobacco.

[0059] In some embodiments, the tobacco material is in the form of tobacco particles.

[0060] In some embodiments, the tobacco material may be subjected to processing steps to improve its properties for inclusion in an aerosol-forming material. Exemplary steps are shown in the flow chart of FIG.

[0061] In some embodiments, the tobacco material is conditioned. For example, this may involve adjusting the moisture content of the starting tobacco material to 20-22%. In some embodiments, a casing may be added to the tobacco material, for example, at a ratio of 1.8-18% by weight.

[0062] The tobacco material may also be subjected to an expansion step in some embodiments.

[0063] After any such pre-treatment steps, the tobacco material is shredded. In some embodiments, the shred size is selected to ensure that the shredded tobacco material and shredded plant material have a particle size that produces a blend with the desired properties as discussed herein. In some embodiments, the tobacco material is shredded to a size of 20-25 CPI (cuts per inch) or about 7.9 to about 9.8 cuts per cm, resulting in strips having an average width of 1-1.5 mm.

[0064] In some embodiments, the cut tobacco is dried. For example, drying the tobacco may reduce the moisture content to about 7-8%.

[0065] In some embodiments, one or more flavorings may be added to the tobacco material. This may occur at any stage of tobacco processing. In some embodiments, the flavorings are added after the tobacco material has been shredded and after any additional drying steps.

[0066] In some embodiments, the flavoring agent is added to the tobacco material in an amount of about 1% to about 3% by weight, or about 1-2% by weight.

[0067] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used to produce a desired flavor, aroma, or other somatic sensation in products for adult consumers, as permitted by local regulations.They may be naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). , 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, nasturtium, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, Sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea, e.g. green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, tallow, black currant, valerian, pimento, mace, damiento , marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be simulated ingredients, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0068] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus fruit, and / or red berry flavoring ingredients. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring ingredients extracted from tobacco. In some embodiments, the flavoring includes flavoring ingredients extracted from cannabis.

[0069] In some embodiments, the flavoring agent may include sensates intended to achieve somatic sensations, typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the scent or taste nerves, and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucolyptol, WS-3.

[0070] In some embodiments, a flavoring is included to provide the aerosol generated by the aerosol-forming material with an aroma and flavor reminiscent of a kretek product. In some embodiments, a flavoring may be added to emphasize a particular scent or sensory effect associated with a kretek product. In some embodiments of the present invention, the flavoring is eugenol.

[0071] In some embodiments, flavorings are included to further encompass sweet and fruit and / or tropical flavorings.

[0072] Mixture of plant material and tobacco material The aerosol-forming material can be prepared by simply mixing one or more shredded plant materials and one or more shredded tobacco materials. Mixing can include blending the shredded materials, for example, using conventional mixing or blending techniques used to mix or blend shredded tobacco materials. Alternatively, the shredded plant material can be added on top of the shredded tobacco.

[0073] In some embodiments, the shredded plant material is in a free-flowing solid form when mixed or blended with the shredded tobacco material.

[0074] In some embodiments, no binder is used when the tobacco and chopped plant material, such as cloves, are mixed.

[0075] Mixing may be carried out, for example, in a rotating cylinder mixer, and selection of appropriate process parameters includes cylinder length, cylinder inclination, and residence time. Generally, the longer the residence time, the more mixed the materials will be.

[0076] In some embodiments, the particles of the cut tobacco material and the shredded plant material are different sizes. In some embodiments, the particles of the cut tobacco material and the shredded plant material are the same size. The selection of size depends on several factors, such as the flavor and mouthfeel of the aerosol generated, the packing density of the aerosol-forming material, and other factors known to those skilled in the art.

[0077] The amount of shredded plant material included in the aerosol-forming material and the ratio of plant material to shredded tobacco material can vary in different embodiments. For example, in some embodiments, a higher proportion of clove material can provide a stronger clove flavor. This also applies to other plant materials and flavors. On the other hand, increasing the proportion of tobacco in the aerosol-forming material can increase the tobacco flavor and / or nicotine content in the generated aerosol. The ratio of ingredients can also affect the mouthfeel and texture of the aerosol.

[0078] The selection of the amount of plant material to include in the aerosol-forming material is based on sensory considerations. The goal is to impart the flavor and aroma of the plant material and to do so with an appropriate balance with the delivery of tobacco flavor and aroma. Another consideration may be that the delivery of flavor should be sustained throughout the use of the aerosol-forming material.

[0079] In some embodiments, including those in which the plant material is cloves, at least 15% by weight of the aerosol-forming material is plant material. As an upper limit, about 35% by weight of the aerosol-forming material may be plant material.

[0080] Varying the proportions of the components can also change the density of the aerosol-forming material and the amount that can be filled into a container or consumable of a given size. An additional factor to consider is the cost of the component materials. Blends can be formulated to provide a cost-effective product. The inclusion of a higher percentage of clove can aid in the mixing of the clove material with the tobacco material.

[0081] In some embodiments, the blend of cut tobacco material and shredded plant material comprises at least about 5% by weight or volume of shredded plant material, and may comprise about 25% to about 40% by weight or volume of shredded plant material. In some embodiments, the weight and / or volume of the clove component relative to the tobacco material component is about 25%. In some embodiments, the blend of cut tobacco material and shredded plant material comprises 5, 10, 15, 20, 25, 30, 35, 40, or 45% by weight or volume.

[0082] In some embodiments, the aerosol-forming material further comprises a diluent. The diluent may be in solid or liquid form. In some embodiments, the diluent is inert or substantially inert.

[0083] In some embodiments, the aerosol-forming material further comprises at least one aerosol-forming agent, which may be, for example, a polyol aerosol-forming agent or a non-polyol aerosol-forming agent, preferably a non-polyol aerosol-forming agent. This may be solid or liquid at room temperature, but is preferably liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, and esters such as diacetin, triacetin, triethyl citrate, or isopropyl myristate. Combinations of aerosol-forming agents in equal or different proportions may be used. Glycerol and propylene glycol may be particularly preferred.

[0084] In some embodiments, the aerosol-forming material includes one or more additional components, some of which may immobilize the shredded plant material and / or shredded tobacco material. The aerosol-forming material or tobacco material may also include one or more binder additives. The binder additives aid in the adhesion of the tobacco material particles to each other and to other components in the aerosol-forming material. Suitable binder additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose. The inclusion of a binder additive may have the advantage of making the aerosol-forming material easier to handle and process.

[0085] In some embodiments, the aerosol-forming material does not contain binders, plasticizers, or gelling agents. This reduces material costs and simplifies manufacturing. Furthermore, the inclusion of binders requires modification of some plant materials, such as cloves, by temperature or water / steam treatment, which can remove some of the oils that produce the desired sensory effect.

[0086] In some embodiments, the aerosol-forming material further comprises a preservative. Suitable preservatives are readily known to those skilled in the art and include, for example, those that are safe for use in products that generate inhalable aerosols. Examples of preservatives that may be used include propylene glycol, carvacrol, thymol, L-menthol, 1,8-cineole, phenoxyethanol, PhytoCide, sorbic acid and its salts, sodium hydroxymethylglycinate, ethylhexylglycerin, parabens, and vitamins such as vitamin E or vitamin C.

[0087] According to another aspect of the present invention, there is provided a non-combustion aerosol delivery system including an aerosol-forming material, which may comprise, consist essentially of, or consist of the aerosol-forming materials described herein.

[0088] As used herein, aerosol delivery systems include non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as a tobacco heating product, and hybrid systems for generating aerosols using a combination of aerosol-forming materials.

[0089] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-forming materials (or components thereof) of the aerosol delivery system are not combusted or incinerated to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0090] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vape device or an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not required.

[0091] 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.

[0092] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-forming materials, one or more of which may be heated. Each of the aerosol-forming materials may be, for example, in solid, liquid, or gel form and may be nicotine-free. 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.

[0093] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0094] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0095] In some embodiments, a non-combustion aerosol delivery system, e.g., a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be activated to deliver power in the form of heat to the aerosol-generating material or to a heat transfer material in proximity to the heat-generating power source.

[0096] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generating agent, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0097] In some embodiments, a consumable for use with a non-combustion type aerosol delivery device may comprise an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating agent, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0098] In some embodiments, the aerosol-forming material is included in the aerosol delivery system to volatilize the components of the aerosol-forming material by heating rather than by burning the material (i.e., tobacco heating products or so-called heat-not-burn products). In some of these products, the aerosol-forming material is heated to generate the aerosol.

[0099] 2 shows a cross-sectional view of one example of a tobacco heating product for heating aerosol-forming material. The device 11 has a heating chamber 14 containing aerosol-forming material that is heated and vaporized during use. In this embodiment, the aerosol-forming material is in the form of a single nicotine delivery composition 13. However, the aerosol-forming material may also be multiple particles of aerosol-forming material held within the heating chamber or provided in a cartridge.

[0100] The device 11 of FIG. 2 further includes an electronics / power chamber 16, which may include, for example, an electrical control circuit and / or a power source (not shown). The electrical control circuit may include a controller, such as a microprocessor component configured and arranged to control heating of the aerosol-generating material by a heating element (not shown). The electrical control circuit may receive a signal from a puff-activation sensor that is sensitive to changes in airflow pressure or velocity that occur during use, such as when a user initiates a draw on the device 11. The electrical control circuit may then operate to provide heating of the aerosol-generating material “on demand.” Various puff-activation sensor components are available, including, for example, thermistors, electromechanical devices, mechanical devices, optical devices, opto-mechanical devices, and microelectromechanical systems (MEMS)-based sensors. Alternatively, the device may include a manually operable switch for a user to initiate a puff.

[0101] Heat chamber 14 is housed within housing 12. For example, supports and / or insulating means (not shown) may be located between heating chamber 14 and housing 12 to help insulate housing 12 from heating chamber 14 so that housing 12 does not get hot, or at least so hot that it cannot be touched during use.

[0102] Housing 12 includes an inlet 15 through which air is drawn into the device. Housing 12 also includes an outlet 17 at a mouthpiece 18 of device 11. Air is drawn into device 11 through inlet 15 and travels through the device, picking up the active agent and other volatile constituents emitted by aerosol-forming material 13, and the resulting aerosol produced by device 11 exits device 11 through outlet 19 and is inhaled by the user.

[0103] According to some embodiments, the aerosol-generating material is included in a so-called hybrid system for heating the aerosol-generating material to volatilize at least one component of the aerosol-generating material. In some of these products, the aerosol-generating material is heated to generate the aerosol in addition to heating a liquid, such as a nicotine-containing or non-nicotine-containing liquid, which is heated by a heat source to form an aerosol or vapor. In some hybrid systems, the aerosol or vapor formed from the liquid is drawn onto or through the aerosol-generating material, entraining the active substance(s) and other volatile components. In other embodiments, the aerosol or vapor formed from the liquid is not drawn onto or through the aerosol-generating material.

[0104] Figure 3 shows a cross-sectional view of one example of a hybrid product for heating an aerosol-forming material and a liquid. Device 21 has a housing 22 that houses a chamber 24 containing an aerosol-forming material 23 that is heated and vaporized during use. The aerosol-forming material may be held in the chamber or may be provided in a cartridge. Housing 22 also houses a liquid reservoir 25 that contains a liquid 26 that is heated to form a vapor.

[0105] Device 21 further includes electronics / power chamber 27, which may include, for example, electrical control circuitry and / or a power source (not shown). The electrical control circuitry may include a controller, e.g., a microprocessor arrangement, constructed and arranged to control the heating of aerosol-forming material and liquid 26 by one or more heating elements (not shown). The electrical control circuitry may enable device 21 to be puff-activated to provide heating of the aerosol-forming material "on demand." Alternatively, device 22 may include a manually operable switch for a user to initiate a puff.

[0106] Housing 22 also includes an inlet 28 through which air is drawn into the device. Housing 22 also includes an outlet 29 at a nozzle 30 of device 21. Air is drawn into device 21 through inlet 28 and travels through the device, picking up vapor formed by heating liquid 26 in liquid reservoir 25, as well as the active agent(s) and volatile components released by aerosol-forming material 23; the resulting aerosol produced by device 21 exits device 21 through outlet 29 and is inhaled by the user.

[0107] The hybrid device 21 shown schematically in Figure 3 represents just one possible configuration of such an apparatus. The relative positions of the liquid reservoir 25 and the aerosol-generating material chamber 24 can be varied, as can the path of the air flowing through the apparatus.

[0108] In one embodiment, the liquid reservoir is located upstream of the aerosol-generating material to be vaporized. Alternatively, the liquid reservoir may be located downstream of the aerosol-generating material to be vaporized. In a further configuration, two aerosol sources within the device may be positioned, for example, side-by-side.

[0109] In some embodiments, the vapor generated by heating the liquid in the liquid reservoir flows over or through an aerosol-generating material that includes or consists of one or more aerosol-generating materials. In some embodiments, the high temperature of the vapor causes the active substance and volatile components to be released. Alternatively, or additionally, the aerosol-generating material may be heated separately by a heating means.

[0110] In some embodiments, a hybrid device is provided in which vapor formed by heating a liquid heats the aerosol-forming material to volatilize at least one component of the aerosol-forming material. In some embodiments, the liquid is a nicotine-free liquid. In other embodiments, the liquid contains nicotine. When the aerosol-forming material is heated by the vapor to volatilize at least one component of the aerosol-forming material, in certain embodiments, the device does not include a separate means for heating the aerosol-forming material.

[0111] In other embodiments, the vapor generated by heating the liquid in the liquid reservoir does not flow over or through the aerosol-forming material, but rather the vapor and the aerosol generated by heating the aerosol-forming material simply mix after both are formed.

[0112] The tobacco heating products and hybrid products described herein may, in some embodiments, include aerosol-forming material in the form of a container or cartridge containing the aerosol-forming material. These containers or cartridges may be removable. They can replace both the chamber holding the aerosol-forming material and the aerosol-forming material within the device described above with reference to Figures 2 and 3 and in the alternative embodiments discussed.

[0113] consumables According to a third aspect of the present invention, there is provided a consumable for a non-combustion aerosol delivery system comprising an aerosol-forming material comprising combining shredded plant material and shredded tobacco material.

[0114] A consumable is an article that includes or consists of an aerosol-generating material, intended to be consumed, in part or in whole, by a user during use. A consumable may also include one or more other 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. A consumable may also include an aerosol-generating agent, such as a heating agent that releases heat during use to cause the aerosol-generating material to generate an aerosol. Heating agents may include, for example, combustible materials, materials heatable by electrical conduction, or susceptors. Consumables may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Consumables may also include one or more humectants, such as glycerin or propylene glycol.

[0115] In some embodiments, the consumable is a cartridge or pod containing the aerosol-generating material. In other embodiments, the consumable may be in the form of a rod or stick containing the aerosol-generating material. For example, the rod or stick may be surrounded by a wrapper. The rod or stick may include one or more additional sections in addition to the one or more sections containing the aerosol-generating material. Such sections may include a filtering section, a cooling section, or a section containing other materials that generate the aerosol or modify the aerosol, for example, by adding flavors.

[0116] Method for preparing aerosol-forming materials According to a fourth aspect of the present invention, there is provided a method of preparing the aerosol-forming material described herein.

[0117] In a generalized example, preparation of an aerosol-forming material can include the following steps. The cut tobacco material may be prepared using a method that includes one or more of the following steps: tobacco material selection; conditioning and casing; expanding, cutting; drying; and aromatization. The shredded plant material may be prepared by a method comprising one or more of the following steps: selecting the plant material; conditioning; swelling, shredding; and drying.

[0118] The cut tobacco material and the cut plant material are then combined to form the aerosol-forming material. The combination may be mixed or blended. Optionally, the aerosol-forming material is incorporated into a consumable or non-combustion aerosol delivery system.

[0119] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not intended to be limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist essentially of, or consist 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 claimed herein but which may be claimed in the future. The delivery system described herein may be implemented as a non-combustion aerosol delivery system.

Claims

1. 1. An aerosol-forming material comprising: a shredded tobacco material and a shredded plant material, the shredded plant material having an average particle size of at least about 0.25 mm.

2. 10. The aerosol-forming material of claim 1, wherein the shredded plant material has an average particle size of about 0.3 mm to about 0.5 mm.

3. 3. The aerosol-forming material of claim 1 or 2, wherein the shredded plant material comprises cloves.

4. The aerosol-forming material of any one of claims 1 to 3, wherein the cut tobacco material comprises reconstituted tobacco.

5. 5. The aerosol-forming material of claim 1, comprising about 25% to about 40% by weight of shredded plant material, based on the weight of the aerosol-forming material.

6. The density of the aerosol-forming material is from about 0.25 to about 0.45 g / cm ３ , optionally from about 0.3 to about 0.4 g / cm ３ 6. The aerosol-forming material according to claim 1, wherein

7. 7. The aerosol-forming material of any one of claims 1 to 6, wherein the cut tobacco material has a cut size of 20 to 25 CPI (cuts per inch), or about 7.9 to about 9.8 cuts per cm.

8. 8. The aerosol-forming material of claim 1, having a water content of about 8 to about 9%.

9. The aerosol-forming material of any one of claims 1 to 8, wherein the chopped plant material is not fixed within the aerosol-forming material.

10. 10. The aerosol-forming material of claim 9, wherein the shredded plant material is not incorporated into a tobacco material.

11. 10. The aerosol-forming material of claim 9, wherein the aerosol-forming material does not include a binder to bind the cut tobacco material and the cut plant material together.

12. A non-combustion aerosol delivery system comprising the aerosol-forming material of any one of claims 1 to 11.

13. 13. The system of claim 12, which is an aerosol-generating material heating system comprising an aerosol-generating material that is heated to volatilize constituent substances, and optionally including a filter or filter element.

14. 13. The system of claim 12, which is a hybrid system comprising an aerosol-generating material that is heated to volatilize constituents and a liquid that is heated to form a vapor, and optionally includes a filter or filter element.

15. The system of claim 14 , wherein the aerosol-forming material is heated by the vapor.

16. 16. The system of claim 15, wherein the liquid is a non-nicotine-containing liquid.

17. 17. The system of claim 15 or 16, including means for heating the liquid to form a vapor, but not including separate means for heating the aerosol-forming material.

18. A consumable product comprising the aerosol-forming material of any one of claims 1 to 11.

19. 20. The consumable product of claim 18, comprising a cartridge or pod containing the aerosol-forming material.

20. 20. The consumable product of claim 18, comprising a rod or stick comprising the aerosol-forming material.

21. A method of preparing the aerosol-forming material of any one of claims 1 to 11, comprising combining cut tobacco material and cut plant material.

22. 22. The method of claim 21, wherein the cut tobacco material and the cut plant material are combined by simple blending.

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