Aerosol-generating materials including one or more foaming agents

Abstract

The present invention relates to an aerosol generating material, an aerosol generating composition including the aerosol generating material, a consumable including the aerosol generating composition, a non-combustion aerosol delivery system including the consumable, and a method of forming the aerosol generating material, the aerosol generating material including (i) one or more foaming agents, (ii) a filler, and (iii) an aerosol-forming material, wherein the aerosol generating material is a foam, and the aerosol generating material has a density of about 0.02 g / cm3 to about 0.7 g / cm3.

Description

[Technical field]

[0001] The present invention relates to an aerosol generating composition comprising a foaming aerosol generating material, a method of making a foaming aerosol generating material, a consumable for use in a non-combustion aerosol delivery system, a consumable for use in a combustion aerosol delivery system, the consumable comprising an aerosol generating composition, and a non-combustion and combustion aerosol delivery system.

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

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

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

[0005] In a first aspect, an aerosol-forming material is provided, the aerosol-forming material comprising: (i) one or more foaming agents; (ii) a filler; and (iii) an aerosol-forming material; the aerosol-forming material is a foam; The aerosol-generating material has a density of about 0.02 g / cm 3 ~about 0.7g / cm 3 has a density of

[0006] In one embodiment, the aerosol forming material further comprises a foam stabilizer.

[0007] In one embodiment, the aerosol forming material further comprises a foaming agent.

[0008] According to a further aspect of the present invention, there is provided a method of forming an aerosol-forming material, the method comprising the steps of: (a) (i) one or more foaming agents; (ii) a filler; (iii) an aerosol-forming material, and (iv) Solvent Providing a slurry comprising: (b) aerating the slurry; (c) forming a layer of aerated slurry; (d) drying the slurry to form an aerosol-generating material. Includes.

[0009] According to a further aspect of the present invention, there is provided a method of forming an aerosol-forming material, the method comprising the steps of: (a) (i) one or more foaming agents; (ii) a filler; (iii) a blowing agent, (iv) aerosol-forming materials, and (v) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) drying the slurry to form an aerosol-generating material. Includes.

[0010] According to a further aspect, there is provided an aerosol-forming material obtainable or obtained by the method described herein.

[0011] According to a further aspect, there is provided an aerosol-forming composition comprising the aerosol-forming material described herein.

[0012] According to a further aspect, there is provided a consumable for use in a combustion-based aerosol delivery system, the consumable comprising an aerosol generating composition as defined herein.

[0013] According to a further aspect, there is provided a consumable for use in a non-combustion aerosol delivery device, the consumable comprising an aerosol generating composition as described herein.

[0014] According to a further aspect of the present invention there is provided a non-combustion aerosol delivery system comprising a consumable as defined herein and a non-combustion aerosol delivery device comprising an aerosol generation device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0015] Features described in this specification in connection with one aspect of the invention are expressly disclosed in combination with each of the other aspects, insofar as they are combinable.

[0016] Further aspects of the invention described herein may provide for the use of an aerosol-generating material, a consumable, a combustion aerosol delivery system, or a non-combustion aerosol delivery system in generating an inhalable aerosol.

[0017] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which should be read in conjunction with the accompanying drawings, in which: [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a cross-sectional view of an example of a consumable item. [Diagram 2] FIG. 2 is a perspective view of the article of FIG. [Diagram 3] FIG. 2 is a cross-sectional elevation view of an example consumable. [Figure 4] FIG. 4 is a perspective view of the article of FIG. [Diagram 5] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 6] FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. Detailed Description

[0019] An aerosol-generating composition as described herein is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or in any other manner. The aerosol-generating composition may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. The aerosol-generating composition comprises an aerosol-generating material.

[0020] The aerosol-generating material may be an "amorphous solid." In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material may be non-fibrous or fibrous. The aerosol-generating material is a solid material that may retain some fluid therein, e.g., a liquid. In some embodiments, the retained fluid may be water (such as water absorbed from the aerosol-generating material's surroundings) or the retained fluid may be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0021] In some embodiments, the aerosol-generating composition may contain, for example, about 10%, 20%, 30%, 40%, 50%, 60%, or 70% by weight to about 90%, 95%, or 100% by weight of the aerosol-generating material.

[0022] In some embodiments, the aerosol forming composition comprises an aerosol forming material.

[0023] Aerosol-Generating Materials As described hereinabove, the present invention provides an aerosol-forming material, the aerosol-forming material comprising: (i) one or more foaming agents; (ii) a filler; and (iii) an aerosol-forming material; the aerosol-forming material is a foam; The aerosol-generating material has a density of about 0.02 g / cm 3 ~about 0.7g / cm 3 has a density of

[0024] The aerosol-generating material may improve the sensory (e.g. organoleptic) properties of the aerosol-generating material. In particular, the aerosol generated by the aerosol-generating material when heated, or the smoke generated when the article is smoked, may be particularly smooth. The aerosol-generating material may not exhibit undesirable organoleptic properties when heated or burned. Thus, the material exhibits a smooth, neutral aroma profile when smoked and does not emit a strong or unpleasant aroma. Without wishing to be bound by theory, it is hypothesized that this may be due to the aerosol-generating material having a dilution effect on the aerosol or smoke generated.

[0025] Foaming Agent The inventors have established that by including one or more foaming agents, air can be incorporated into the aerosol-generating material during the formation of the material. That is, by including one or more foaming agents, the aerosol-generating material can be provided in the form of a foam. This results in a decrease in the density of the material compared to when no foaming agent is present. The inventors have found that this decrease in density does not adversely affect the sensory experience of the user. Thus, the present invention provides an aerosol-generating material that has a decreased density while maintaining a good sensory experience. The fill value of the aerosol-generating material can also be decreased by including one or more foaming agents.

[0026] The aerosol-forming material may comprise from about 5%, 6%, 7%, 10%, 12%, or 15% to about 18%, 20%, 25%, 30%, or 35% by weight of one or more foaming agents (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 5-35%, 5-30%, 6-25%, 7-20%, or 12-18% by weight of one or more foaming agents (all calculated on a dry weight basis).

[0027] Frothing agents generally act to entrap bubbles when the foam is formed, for example, by entraining air into the slurry.

[0028] The one or more foaming agents may include hydroxypropyl methylcellulose (HPMC), guar gum, pectin, modified starch (e.g., hydroxylated starch), maltodextrin, and mixtures thereof. In some embodiments, the one or more foaming agents include, consist essentially of, or consist of HPMC.

[0029] Filler The aerosol-forming material may comprise from about 10%, 20%, 30%, 40%, 50%, or 60% to about 85%, 80%, or 75% by weight of the filler, all calculated on a dry weight basis. In exemplary embodiments, the aerosol-forming material may comprise from 10 to 85%, 50 to 80%, or 60 to 75% by weight of the filler, all calculated on a dry weight basis.

[0030] The filler may include one or more inorganic filler materials, such as calcium carbonate, chitosan, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives.

[0031] In some embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative, such as microcrystalline cellulose (MCC) and / or nanocrystalline cellulose.

[0032] Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in the aerosol-forming material may increase the tensile strength of the material, which may be particularly advantageous in instances where the aerosol-forming material is provided as a sheet, for example, when the sheet of aerosol-forming material surrounds a rod of aerosol-forming composition.

[0033] In some instances, the filler includes maltodextrin or microcrystalline cellulose (MCC).

[0034] As those skilled in the art will appreciate, crystalline cellulose can be formed by depolymerizing cellulose through a chemical process (e.g., using acid or enzymes). One method for forming crystalline cellulose includes acid hydrolysis of cellulose, using an acid such as HCl. The cellulose produced after this process is crystalline (i.e., no amorphous regions remain). Suitable methods and conditions for forming crystalline cellulose are well known in the art.

[0035] In some instances, the filler comprises, consists essentially of, or consists of wood pulp, calcium carbonate, and combinations thereof.

[0036] In some instances, the filler comprises, consists essentially of, or consists of wood pulp and calcium carbonate.

[0037] In some instances, the filler comprises, consists essentially of, or consists of wood pulp.

[0038] The aerosol-forming material may comprise from about 1%, 5%, 10%, 12%, or 13% to about 15%, 17%, or 20% by weight wood pulp (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 10-20%, 10-15%, or 13-14% by weight wood pulp (all calculated on a dry weight basis).

[0039] The aerosol-forming material may comprise from about 10%, 20%, 30%, 35%, 40%, or 45% to about 55%, 60%, 65%, or 70% by weight calcium carbonate (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 30-70%, 35-65%, or 45-65% calcium carbonate (all calculated on a dry weight basis).

[0040] Aerosol-forming materials The aerosol-forming material comprises from about 1%, 5%, 10%, 12%, or 13% to about 18%, 20%, 25%, 30%, 35%, 45%, 55%, 65%, 75%, or 80% by weight of the aerosol-forming material (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises from 1 to 80%, 1 to 50%, 5 to 35%, 10 to 25%, 12 to 20%, or 13 to 18% by weight of the aerosol-forming material (all calculated on a dry weight basis).

[0041] The aerosol forming material may include one or more of glycerol, propylene glycol, 1,3-propanediol, 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 phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some examples, the aerosol forming material includes, consists essentially of, or consists of glycerol.

[0042] Foam Stabilizer The aerosol-forming material may also include a foam stabilizer that can reduce or even prevent foam collapse after the foam is formed, in other words, the foam stabilizer can reduce the tendency of the liquid that forms the foam bubbles to have a reduced surface tension.

[0043] The aerosol-forming material may comprise from about 1%, 1.5%, or 2% to about 6%, 8%, or 10% by weight of the foam stabilizer (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 1-10%, 1.5-9%, or 2-6% by weight of the foam stabilizer (all calculated on a dry weight basis).

[0044] The foam stabilizer may comprise one or more surfactants. In some embodiments, the one or more surfactants are each nonionic, anionic, or amphoteric. In some examples, the foam stabilizer comprises sodium lauryl sulfate (SLS), Tween 60 (polyethylene glycol sorbitan monostearate), Tween 80 (polysorbate 80), Amphosol CA, Span 60 (sorbitan monostearate), Span 80 (sorbitan monooleate), lecithin, or mixtures thereof.

[0045] The inventors have found that the use of a foam stabilizer can aid in the formation of the foamed material of the present invention. In particular, the foam stabilizer can stabilize the foam formed in the slurry and therefore help prevent the foam from collapsing when the slurry dries. Thus, the use of a foam stabilizer can assist in the formation of the aerosol-forming material of the present invention.

[0046] However, the inventors have surprisingly found that when certain foaming agents are used (e.g., HPMC), foam stabilizers are not necessary and stable foams can be formed without the use of foam stabilizers. However, even when not required, foam stabilizers may still be used.

[0047] Foaming Agent The aerosol-forming material may include a blowing agent. The aerosol-forming material may include from about 1%, 2%, or 4% to about 7%, 8%, or 10% by weight of the blowing agent (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material includes from 1 to 10%, 2 to 8%, or 4 to 7% by weight of the blowing agent (all calculated on a dry weight basis).

[0048] The effervescent agent may include calcium carbonate, sodium carbonate, sodium bicarbonate, citric acid, tartaric acid, lactic acid, acetic acid, aluminum sulfate, or mixtures thereof. Calcium carbonate may be used as a filler and an effervescent agent. When calcium carbonate is so used, it may be present in any amount, such as the amounts disclosed above for fillers.

[0049] The inventors have found that the use of a foaming agent eliminates the need to mix the slurry at high speeds to aerate the slurry, which is particularly useful when a continuous process is used to form the aerosol-generating material.

[0050] fragrance The aerosol-forming material may comprise from about 0.1%, 0.5%, 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% to about 45%, 50%, or 60% by weight of flavoring (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises from 1%, 5%, 10%, 20%, 30%, or 35% to about 42%, 45%, or 47% by weight of flavoring. For example, the aerosol-forming material may comprise from 1 to 60%, 1 to 45%, 10 to 45%, 20 to 50%, 30 to 50%, 30 to 45%, or 35 to 45% by weight of flavoring.

[0051] As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sheesh Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the mint genus, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai tea citron, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose,They may contain saccharides such as acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid (such as an oil), a solid (such as a powder), or a gas.

[0052] In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components.

[0053] In some embodiments, the fragrance comprises eugenol.

[0054] In some embodiments, the flavoring comprises flavor components extracted from tobacco.

[0055] In some embodiments, the flavoring may include sensory agents aimed at achieving somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

[0056] In some embodiments, the aerosol-forming composition includes a flavoring, hi some embodiments, the flavoring is applied by spraying directly onto the composition once it is formed.

[0057] The aerosol-forming material may have any suitable water content, for example, from 1% to 15% by weight. Suitably, the water content of the aerosol-forming material may be from about 5%, 7%, or 9% to about 15%, 13%, or 11% by weight (wet weight basis) (WWB). The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0058] coloring agent The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can improve the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colorant to the aerosol-generating material, the aerosol-generating material can match the color of other components of the aerosol-generating composition or other components of the article comprising the aerosol-generating material.

[0059] Various colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (such as tobacco materials) in the aerosol-generating composition that includes the aerosol-generating material. In some embodiments, the addition of a colorant to the aerosol-generating material renders the aerosol-generating material visually indistinguishable from other components in the aerosol-generating composition.

[0060] The colorant may be incorporated during the formation of the aerosol-generating material (e.g., when forming a slurry with the materials that will form the aerosol-generating material), or the colorant may be applied to the aerosol-generating material after its formation (e.g., by spraying the colorant onto the aerosol-generating material).

[0061] active substance In some embodiments, the aerosol forming material further comprises an active agent. In some embodiments, the aerosol forming composition comprises an active agent.

[0062] As used herein, an active substance is a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active substance may be selected from, for example, functional foods, nootropics, psychoactive substances. The nootropics may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or other botanical substances.

[0063] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0064] In some embodiments, the active agent may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0065] In some embodiments, the active material may comprise or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, skins, etc. Alternatively, the material may comprise an active compound that is naturally present in the botanical material or is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo leaf extract, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and safflower. orchid, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv) and Apple mint (Mentha suaveolens).

[0066] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0067] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0068] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0069] For example, in some examples, the aerosol-forming composition further comprises tobacco material and / or nicotine. In some examples, the aerosol-forming composition may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some examples, the aerosol-forming composition may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active material. In some examples, the aerosol-forming composition may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming composition may comprise 1-70%, 10-50%, 15-40%, or 20-35% by weight of tobacco material. In some examples, the aerosol-forming composition may comprise from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the aerosol-forming composition may comprise 1-20%, 2-18%, or 3-12% by weight of nicotine.

[0070] In some examples, the aerosol-generating composition includes an active agent such as a tobacco extract. In some examples, the aerosol-generating composition may include 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the aerosol-generating composition may include about 5%, 10%, 15%, 20%, or 25% by weight to about 60%, 50%, 45%, 40%, 35%, or 30% by weight of tobacco extract (calculated on a dry weight basis). For example, the aerosol-generating composition may include 10-50%, 15-40%, or 20-35% by weight of tobacco extract. The tobacco extract may include nicotine in a concentration such that the aerosol-generating composition includes 1%, 1.5%, 2%, or 2.5% by weight to about 10%, 8%, 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some embodiments, the aerosol-forming composition may comprise 1-10%, 2.5-8%, or 2-6% nicotine by weight. In some instances, no nicotine other than that originating from the tobacco extract may be present in the aerosol-forming composition.

[0071] In some embodiments, the aerosol-generating composition does not include tobacco material but does include nicotine. In some such examples, the aerosol-generating composition may include from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the aerosol-generating composition may include from 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0072] The aerosol generating composition may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0073] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0074] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0075] The inclusion of an acid is particularly preferred in embodiments in which the aerosol generating composition includes nicotine. In such embodiments, the presence of an acid can stabilize species dissolved in the slurry from which the aerosol generating composition is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacture. The presence of an acid can also improve the flavor of the aerosol when nicotine is present. For example, the perceived harshness of nicotine can be reduced by the presence of an acid.

[0076] In some embodiments, the aerosol-forming material is substantially free of tobacco. By "substantially free," it is meant that the material contains less than 1% by weight of tobacco, such as less than 0.5% by weight. In some embodiments, the aerosol-forming material does not contain tobacco. In some embodiments, the aerosol-forming material does not contain tobacco fiber. In certain embodiments, the aerosol-forming material does not contain fibrous material.

[0077] In some embodiments, the aerosol forming composition does not include tobacco fiber, hi certain embodiments, the aerosol forming composition does not include fibrous material.

[0078] Aerosol-forming compositions One aspect provides an aerosol-forming composition comprising an aerosol-forming material as defined herein.

[0079] In some embodiments, the aerosol-forming composition further comprises a tobacco material. In these embodiments, the tobacco material does not form part of the aerosol-forming material, i.e., the tobacco material is present in the aerosol-forming composition separate from the aerosol-forming material.

[0080] As used herein, the term "tobacco material" refers to any material that contains tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract.

[0081] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. It may also be "fines" or dust of tobacco particles, expanded tobacco, stems, expanded stems, and other processed stem materials (such as rolled cut stems). The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may include tobacco fibers and may be formed by casting, a Fourdrinier-type approach with back-addition of tobacco extract, or extrusion.

[0082] In some embodiments, the amount of aerosol-forming material in the aerosol-forming composition is about 5 to about 30% by weight of the aerosol-forming composition on a dry weight basis. For example, in some embodiments, the aerosol-forming composition includes an amount of aerosol-forming material of about 10 to about 20% by weight, or about 13 to about 17% by weight. In some embodiments, the aerosol-forming composition includes an amount of aerosol-forming material of about 15% by weight. This amount includes any aerosol-forming material present in the aerosol-forming composition, for example, aerosol-forming material provided in the aerosol-forming material and any aerosol formers loaded into the tobacco material.

[0083] In some embodiments, the tobacco material comprises or consists of laminar tobacco (eg, cut rag tobacco), which provides desirable sensory characteristics.

[0084] In some embodiments, the tobacco material comprises reconstituted tobacco in an amount of less than about 50%, 30%, 10%, 5%, or 1% by weight of the dry weight of the tobacco material. In some embodiments, the tobacco material is substantially free of reconstituted tobacco.

[0085] The tobacco material may be present in any form, but is typically fine cut (e.g., chopped into small pieces). Fine cut tobacco material may be advantageously blended with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and aerosol-forming material throughout the aerosol-forming composition.

[0086] In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract. It is possible to use relatively large amounts of laminar tobacco in the aerosol-generating composition and still produce an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material. In certain examples, the tobacco material comprises shredded tobacco in an amount of at least about 50%, 60%, 70%, 80%, 85%, 90%, or 95% by weight of the tobacco material.

[0087] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0088] The tobacco material may typically be present in the aerosol forming composition in an amount of about 50-95%, or about 60-95%, or about 70-90%, or about 80-90% by weight of the aerosol forming composition.

[0089] In some embodiments, the aerosol-forming material is present in the aerosol-forming composition in an amount of about 5-40%, 5-30%, 5-25%, or 10-25%, or 10-20% by weight.

[0090] In some embodiments, the aerosol-forming composition consists or consists essentially of an aerosol-forming material and a tobacco material.

[0091] In some embodiments, the tobacco material itself comprises the aerosol-forming material. Typically, the tobacco material comprises fine-cut tobacco, and the aerosol-forming material is loaded onto the tobacco fragments. In an example, the tobacco material comprises the aerosol-forming material in an amount of about 1-10% by weight, such as about 3-6% by weight, of the tobacco material. The aerosol-forming materials defined above with respect to the aerosol-generating material are also suitable for use in the tobacco material.

[0092] The aerosol-generating material may be present in the aerosol-generating composition in any suitable form. In examples, the aerosol-generating material is present in sheet form. In examples, the aerosol-generating material is present as a shredded sheet (e.g., the aerosol-generating composition includes pieces of the aerosol-generating material). In examples, the aerosol-generating material is present as a shredded sheet and is blended with tobacco material that is fine cut and / or shredded, e.g., the aerosol-generating material and the tobacco material are in a similar form. Advantageously, providing both the aerosol-generating material and the tobacco material as pieces / fine cut portions allows for an aerosol-generating composition blend with a uniform distribution of the aerosol-generating material and the tobacco material throughout the aerosol-generating composition.

[0093] In examples, the aerosol-generating material has a surface density that is about 90-110% of the surface density of any tobacco material in the aerosol-generating composition. That is, the aerosol-generating material and the tobacco material have similar surface densities. Configuring the aerosol-generating material and the tobacco material to have similar surface densities allows for better blending of the aerosol-generating material and the tobacco material, typically when provided as shredded sheets. For example, aerosol-generating material in the form of shredded sheets and cut rag tobacco, having similar surface densities, can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition).

[0094] Fine cut tobacco (e.g., cut rag tobacco) has a cut width, typically expressed as CPI (cuts per inch), which refers to the width of the cut in the tobacco. In some instances where the tobacco material is fine cut (e.g., where the tobacco material includes cut rag tobacco) and the aerosol-generating material is a shredded sheet, the cut width of the aerosol-generating material is about 90-110% of the cut width of the cut rag tobacco. That is, the aerosol-generating material and the tobacco material have similar cut widths, or shred widths. Configuring the aerosol-generating material and the tobacco material to have similar cut widths allows for better blending of the aerosol-generating material and the tobacco material. For example, aerosol-generating material sheets and cut rag tobacco having similar cut widths can be blended to provide a more homogenous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition). The tobacco material may have a length of 1-4 cm.

[0095] support The aerosol-generating material may be present on or in a support to form a substrate. The support serves as a support on which the layer of aerosol-generating material is formed, facilitating manufacturing. The support may provide rigidity to the layer of aerosol-generating material, facilitating handling.

[0096] The support may be any suitable material that can be used to support the aerosol-generating material. In some examples, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or a combination thereof. In some examples, the support may include or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some examples, the support includes paper. In some examples, the support itself may be a laminated structure that includes layers of materials selected from the aforementioned list. In some examples, the support may also function as a flavor support. For example, the support may be impregnated with flavorants or tobacco extracts.

[0097] Suitably, the thickness of the support layer may range from about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm, or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, or 0.5 mm. The support may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

[0098] In some examples, the support may be magnetic. This feature may be used to secure the support to an assembly during use or to generate a particular aerosol-generating material shape. In some examples, the aerosol-generating substrate may include one or more magnets that may be used to secure the substrate to an induction heater during use.

[0099] In some instances, the support may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the support layer, thereby controlling the flow and ensuring that the aerosol or gas is delivered to the user. This may also be utilized to prevent the gas / aerosol from condensing or otherwise depositing during use, for example on the surface of a heater provided in the aerosol generation assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

[0100] In some instances, the surface of the support that abuts the aerosol-generating material may be porous. For example, in one instance, the support comprises paper. Porous supports such as paper are particularly suited to the present invention, where a porous (e.g., paper) layer abuts the aerosol-generating layer and forms a strong bond. The aerosol-generating material is formed by drying a gel, and, without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous support (e.g., paper) such that the support is partially bonded to the gel as the gel cures and forms crosslinks. This results in a strong bond between the gel and the support (and between the dried gel and the support).

[0101] In addition, surface roughness may contribute to the strength of the bond between the aerosol-generating material and the substrate. The roughness of the paper (at the surface in contact with the substrate) may preferably be in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specific pressure is forced between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

[0102] Conversely, the surface of the support that does not face the aerosol-generating material may be placed in contact with the heater, and the smoother surface may provide more efficient heat transfer. Thus, in some examples, the support is positioned to have a rougher surface that abuts the aerosol-generating material and a smoother surface that does not face the aerosol-generating material.

[0103] In one particular example, the support may be a paper-backed foil, where the paper layer abuts against the layer of aerosol-generating material, which abuts to provide the properties discussed in the previous paragraphs. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also act to transfer heat to the aerosol-generating material.

[0104] In another example, a foil layer of a paper-backed foil abuts the aerosol-generating material, the foil being substantially impermeable to prevent moisture provided in the aerosol-generating material from being absorbed by the paper, which could weaken the structural integrity of the paper.

[0105] In some cases, the support is formed from or includes a metal foil, such as aluminum foil. The metal support may allow for better transfer of thermal energy to the aerosol-generating material. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the support comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0106] In some examples, the support may have a thickness of from about 0.017 mm to about 2.0 mm, preferably from about 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

[0107] The aerosol-generating material may be made of a gel, which may further include a solvent present at 0.1 to 50% by weight. However, the inclusion of a solvent in which the fragrance can dissolve may reduce gel stability and cause the fragrance to leave the gel and crystallize. Thus, in some instances, the gel does not include a solvent in which the fragrance can dissolve.

[0108] The aerosol-generating material has a density of about 0.02 g / cm 3 , 0.06g / cm 3 , 0.1g / cm 3 , or 0.15 g / cm 3 ~about 0.25g / cm 3 , 0.4g / cm 3 , 0.6g / cm 3 , or 0.7 g / cm 3 In an exemplary embodiment, the aerosol-forming material may have a density of 0.02 to 0.7 g / cm. 3 , 0.02~0.6g / cm 3 , 0.02~0.5g / cm 3 0.02~0.4g / cm 3 , or 0.1 to 0.3 g / cm 3 has a density of

[0109] The aerosol generating material is approximately 380 cm 3 / More than 100g, about 400cm 3 / Over 100g or 420cm 3 It may have a loading value of more than 100 g. The fill value can be measured using a densimeter.

[0110] In one embodiment, the fill value is measured according to Method A below: Approximately 70-80 g of aerosol-generating material is weighed out. The weighed aerosol-generating material is then transferred to the container assembly of a densimeter and the bulk volume is measured. The fill value is then calculated according to Equation 1. Filling value = (bulk volume / weight) x 100 (Equation 1)

[0111] In some embodiments, an aerosol-forming material is provided, the aerosol-forming material comprising: (i) one or more foaming agents; (ii) a filler; and (iii) an aerosol-forming material; the aerosol-forming material is a foam; The aerosol-generating material has a density of about 0.02 g / cm 3 ~about 0.7g / cm 3 and having a density of The aerosol-generating material is approximately 380 g / cm 3 It has a filling value of over 100%.

[0112] The aerosol-forming material may have a Gurley porosity of about 100 sec / 100 mL or greater, 125 sec / 100 mL or greater, or 150 sec / 100 mL or greater.

[0113] Gurley porosity can be measured using a Gurley densometer.

[0114] In one embodiment, Gurley porosity is measured according to the following Method B: An aerosol-generating material is placed between the clamp plates of a Gurley densometer. The inner cylinder is then lowered and the time it takes for 100 cc of air to flow through the material is measured.

[0115] In some embodiments, an aerosol-forming material is provided, the aerosol-forming material comprising: (i) one or more foaming agents; (ii) a filler; and (iii) an aerosol-forming material; the aerosol-forming material is a foam; The aerosol-generating material has a density of about 0.02 g / cm 3 ~about 0.7g / cm 3 and having a density of The aerosol-forming material has a Gurley porosity of about 100 seconds / 100 mL or greater.

[0116] consumables Aspects of the invention relate to articles (also referred to herein as consumables). Consumables are articles that are intended to be consumed in part or in whole during use by a user. Consumables may include or consist of an aerosol generating composition. Consumables may include one or more other elements, such as a filter or an aerosol modifying substance. Consumables may include a heating element that generates heat during use to cause aerosol generation from the aerosol generating composition. The heating element may comprise, for example, a combustible material or may comprise a susceptor that is heatable by the penetration of a fluctuating magnetic field.

[0117] The susceptor is a material that can be heated by the penetration of a fluctuating magnetic field, for example an alternating magnetic field. The heating material may be an electrically conductive material, in which case its penetration with a fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, in which case its penetration with a fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both electrically conductive and magnetic, in which case the heating material is heatable by both heating mechanisms.

[0118] Induction heating is a process in which an electrically conductive object is heated by the object's penetration into a fluctuating magnetic field. This process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a fluctuating current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another such that the resulting fluctuating magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to heat up. This process is called Joule, Ohmic, or resistive heating.

[0119] In some embodiments, the susceptor is in the form of a closed circuit. It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in stronger or improved Joule heating.

[0120] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by subjecting the object to a varying magnetic field. A magnetic material can be thought of as comprising many atomic-scale magnets or magnetic dipoles. When a magnetic field enters such a material, the magnetic dipoles align along the magnetic field. Thus, when a varying magnetic field, such as an alternating magnetic field produced by an electromagnet, enters a magnetic material, the orientation of the magnetic dipoles changes with the variation of the applied magnetic field. This reorientation of the magnetic dipoles causes the generation of heat in the magnetic material.

[0121] When an object is both electrically conductive and magnetic, immersing the object in a varying magnetic field can induce both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can intensify Joule heating.

[0122] In each of the above processes, when heat is generated within the object itself rather than by an external heat source via thermal conduction, a more rapid temperature rise and more uniform heat distribution in the object can be achieved, especially by selection of the appropriate object material and geometry, and appropriate varying magnetic field strength and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require physical contact between the source of the varying magnetic field and the object, allowing for greater design freedom and control over the heating profile and reducing costs.

[0123] The article of the present invention may be provided in any suitable shape. In some examples, the article is provided as a rod (e.g., substantially cylindrical). The article provided as a rod may include the aerosol-generating composition as a shredded sheet, optionally blended with cut tobacco. Alternatively, or in addition, the article provided as a rod may include the aerosol-generating composition as a sheet, for example, as a sheet surrounding a rod of aerosol-generating material (e.g., tobacco, or a combination of tobacco and aerosol-generating material, such as those described herein). In some embodiments, the article includes a layer portion of the aerosol-generating composition disposed on a carrier. In examples, the article may have at least one substantially flat surface.

[0124] The aerosol-forming material is a foam. In some instances, the aerosol-forming material is porous.

[0125] The aerosol-forming material may be continuous. For example, a foam may comprise or be a continuous sheet of material. The sheet may be cut into strips, e.g., about 20-30 cuts per inch, and used as a consumable or cigarette filter. The sheet may also be chopped into shredded sheet form and collected into strands or bundles for use as a consumable or cigarette. The sheet may be in the form of a wrapping paper, which may be gathered to form a gathered sheet.

[0126] In some embodiments, the aerosol-forming material is shredded and blended with another substrate. In one example, the aerosol-forming material is shredded and blended with another shredded aerosol-forming material. In some examples, the aerosol-forming material is shredded and blended with a tobacco material.

[0127] The thickness values ​​specified herein are average values ​​for the thickness in question. In some instances, the thickness may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0128] The "thickness" of an aerosol-generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first flat surface of the sheet and a second flat surface of the sheet opposite the first flat surface of the sheet. In some examples, the aerosol-generating composition may have a thickness of about 0.015 mm to about 10 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 5 mm, 3 mm, 2 mm, 1 mm, 0.5 mm, or 0.3 mm. The aerosol-generating material may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

[0129] In some examples, the aerosol-generating material (i.e., foam) may have a thickness of about 0.015 mm to about 10 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 5 mm, 3 mm, 2 mm, 1 mm, 0.5 mm, or 0.3 mm. The aerosol-generating material may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of the layers.

[0130] The delivery systems described herein can be implemented as combustion aerosol delivery systems or non-combustion aerosol delivery systems.

[0131] Combustion-type aerosol supply system Aspects of the present disclosure provide a combustion-type aerosol delivery system in which a component aerosol-generating material (or a component thereof) of the aerosol delivery system is combusted or burned during use to facilitate delivery of at least one substance to a user.

[0132] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0133] Non-combustion aerosol delivery device Aspects of the invention provide a non-combustion aerosol delivery system comprising an article according to the present disclosure, and a non-combustion aerosol delivery device comprising a heater configured to heat but not combust an aerosol product article. The non-combustion aerosol delivery system may also be referred to as an aerosol generation assembly. The non-combustion aerosol delivery device may also be referred to as an aerosol generation apparatus.

[0134] In some examples, the heater may heat the aerosol-generating material to a temperature of 350° C. or less, for example, 120° C. to 350° C., without burning the aerosol-generating material. In some examples, the heater may heat the aerosol-generating material to a temperature of 140° C. to 250° C., or 220° C. to 280° C., without burning the aerosol-generating material during use. In some examples, substantially the entire aerosol-generating material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater during use. In some examples, the material is disposed about 0.010 mm to 2.0 mm, preferably about 0.02 mm to 1.0 mm, preferably about 0.1 mm to 0.5 mm, from the heater. These minimum distances may reflect the thickness of the support supporting the aerosol-generating material in some examples. In some examples, the surface of the aerosol-generating material may be in direct contact with the heater.

[0135] The heater is configured to heat but not combust the aerosol product, and thus the aerosol generating composition. The heater may in some examples be a thin film electrical resistance heater. In other examples, the heater may comprise an inductive heater or other heater. The heater may be a combustible heat source or may be a chemical heat source that undergoes an exothermic reaction to generate heat when in use. The aerosol generating assembly may comprise multiple heaters. The heaters may be powered by a battery.

[0136] The aerosol product may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components so that they condense to form the aerosol. The cooling element may also act to move a hot portion of the non-combustion aerosol delivery device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0137] In some examples, the aerosol generating assembly may be a heat not burn device. That is, the aerosol generating assembly may include a solid tobacco-containing material (and no liquid aerosol-generating material). In some examples, the aerosol-generating material may include a tobacco material. A heat not burn device is disclosed in WO2015 / 062983A2, the entirety of which is incorporated herein by reference.

[0138] In some examples, the aerosol generating assembly may be an e-cigarette hybrid device. That is, the aerosol generating assembly may include a solid aerosol generating composition and a liquid aerosol generating material. In some examples, the aerosol generating material may include nicotine. In some examples, the aerosol generating material may include a tobacco material. In some examples, the aerosol generating material may include a tobacco material and a separate nicotine source. These separate aerosol generating compositions may be heated by separate heaters or may be heated by the same heater, and in some examples, the downstream aerosol generating material may be heated by the hot aerosol generated from the upstream aerosol generating composition. An e-cigarette hybrid device is disclosed in WO2016 / 135331A1, the entirety of which is incorporated herein by reference.

[0139] The aerosol product article (sometimes referred to herein as an article, cartridge, or consumable) may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some examples, the article may further comprise a filter and / or a cooling element (as described above). In some examples, the aerosol product article may be surrounded by a packaging material, such as paper.

[0140] The aerosol product article may further comprise vent holes. These may be provided in the sidewalls of the article. In some instances, the vent holes may be provided in the filter and / or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0141] The ventilation facilitates the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by a process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation) and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of newly formed droplets from the heated volatiles.

[0142] In some instances, the ratio of cold air to the sum of heated volatiles and cold air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0143] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0144] In some examples, the aerosol-generating composition may be included in the article / assembly in sheet form. In some examples, the aerosol-generating composition may be included as a flat sheet. In some examples, the aerosol-generating composition may be included as a flat sheet, as a pleated or gathered sheet, as a corrugated sheet, or as a rolled sheet (i.e., in the form of a tube). In some such examples, the aerosol-generating material of these embodiments may be included in the aerosol product article / assembly as a sheet, for example, as a sheet surrounding a rod of aerosol-generating material (such as tobacco). In other examples, the aerosol-generating composition may be formed as a sheet and then shredded and incorporated into the article. In some examples, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

[0145] In some examples, any of the first and second aerosol-generating materials described herein may be formed into sheets and then shredded and mixed together to form an aerosol-generating composition. The composition may then be incorporated into an article. In some examples, the shredded sheets may also be mixed with cut rag tobacco and incorporated into an article.

[0146] In some embodiments, the aerosol-generating material is formed as a foam or substrate. The aerosol-generating foam may be an open foam or a non-open foam, such as a construction of separate pieces of foam onto a substrate.

[0147] 1 and 2, there is shown a partially cut-away cross-sectional view and a perspective view of an example of an aerosol production article 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5-7, described below. In use, the article 101 can be removably inserted into the device at an insertion point 20 of the device 1 shown in Figure 5.

[0148] The example article 101 is in the form of a generally cylindrical rod including an aerosol-generating composition body 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition includes an aerosol-generating material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol-generating composition as described herein may be incorporated in both sheet form and chopped form.

[0149] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The aerosol generating composition body 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the aerosol generating composition body 103 between the aerosol generating composition body 103 and the filter segment 109 such that the cooling segment 107 is in an abutting relationship with the aerosol generating composition 103 and the filter segment 109. In another example, there may be a separation between the aerosol generating composition body 103 and the cooling segment 107 and between the aerosol generating composition body 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed toward proximal end 113 of article 101 and is adjacent filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0150] In one example, the rod of aerosol forming composition 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably has a length of 42 mm.

[0151] In one example, the overall length of the article 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0152] One axial end of the aerosol-generating composition body 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers one axial end of the aerosol-generating composition body 103.

[0153] The aerosol generating composition body 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the aerosol generating composition body 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0154] In one example, cooling segment 107 is an annular tube that is disposed around and defines a cavity within the cooling segment. The cavity provides a chamber through which heated volatile components generated from aerosol generating composition body 103 flow. Cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 101 during insertion into device 1. In one example, the wall thickness of cooling segment 107 is about 0.29 mm.

[0155] The cooling segment 107 provides a physical displacement between the aerosol generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol generating composition 103 when the aerosol generating composition 103 is heated by the device 1. If no physical displacement is provided between the filter segment 109 and the aerosol generating composition body 103 and the heating element of the device 1, the temperature-sensitive filter segment 109 may become damaged during use and may no longer effectively perform its required function.

[0156] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0157] The cooling segment 107 is made from paper, meaning that it is constructed from a material that does not generate compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 1 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness and straightness.

[0158] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 101 during insertion into device 1.

[0159] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatiles from the aerosol generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatiles without depleting the amount of the heated volatiles to an unsatisfactory level for the user.

[0160] In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be substantially centered within the filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, if a capsule is present, the capsule may contain a volatile component, such as a flavoring or an aerosol-forming material.

[0161] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to draw of the article 101. Thus, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the article 101. Additionally, the filter segment performs a filtration function in the article 101.

[0162] In one example, the filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0163] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the temperature of the contact of the user's lips with the surface of filter segment 109.

[0164] In one example, the filter segment 109 is between 6 mm and 10 mm in length, preferably 8 mm.

[0165] The mouth end segment 111 is an annular tube that is disposed around and defines a cavity within the mouth end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacture and insertion into the device 1. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0166] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outside diameter, roundness and straightness.

[0167] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0168] It should be appreciated that in one example, the oral end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 disposed within the tube to separate the oral end segment 111 and the cooling segment 107.

[0169] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0170] In the example of article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in article 301 to allow air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of article 301. The vent holes may be located in cooling segment 307 to aid in cooling article 301. In one example, ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

[0171] In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

[0172] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

[0173] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The location of the vent holes 317 is such that the vent holes 317 are not blocked by a user when the article 301 is in use.

[0174] By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 1 when the article 301 is fully inserted into the device 1, as seen in Figures 6 and 7. By locating the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 1 through the vent holes to help cool the article 301.

[0175] The length of the cooling segment 307 is such that when the article 301 is fully inserted into the device 1, the cooling segment 307 is partially inserted into the device 1. This length of the cooling segment 307 provides a first function of providing a physical gap between the heating device and the heat-sensitive filter device 309 of the device 1, and a second function of allowing the vent hole 317 to be located within the cooling segment while also being located outside the device 1 when the article 301 is fully inserted into the device 1. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located within the device 1. However, there is a portion of the cooling element 307 that extends outside the device 1. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 1.

[0176] 5-7 in more detail, an example of a device 1 is shown that is configured to heat an aerosol-generating composition to volatilize at least one component of said aerosol-generating composition, typically to form an inhalable aerosol. Device 1 is a heating device that releases compounds by heating, but not combusting, the aerosol-generating composition.

[0177] The first end 3 may be referred to herein as the oral or proximal end 3 of the device 1, and the second end 5 may be referred to herein as the distal end 5 of the device 1. The device 1 has an on / off button 7, allowing the entire device 1 to be started / stopped as desired by the user.

[0178] The device 1 includes a housing 9 for arranging and protecting various internal components of the device 1. In the illustrated example, the housing 9 includes a unitary sleeve 11 that surrounds the outer periphery of the device 1 and is capped with a top panel 17 that generally forms the "top" of the device 1 and a bottom panel 19 that generally forms the "bottom" of the device 1. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels, in addition to the top panel 17 and bottom panel 19.

[0179] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 1, or may be "permanently" secured to unitary sleeve 11, for example to prevent a user from accessing the interior of device 1. In one example, panels 17 and 19 are made of a plastic material (including glass-filled nylon formed by injection molding, etc.) and unitary sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

[0180] The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1, through which a user can insert and remove an article 101, 301 containing an aerosol-generating composition into and from the device 1 during use.

[0181] Housing 9 has disposed or secured therein heating device 23, control circuitry 25, and power source 27. In this example, heating device 23, control circuitry 25, and power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuitry 25 generally located between heating device 23 and power source 27, although other arrangements are possible.

[0182] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol generating composition within the article 101, 301, as discussed further below.

[0183] Power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and provides power when needed under the control of control circuitry 25 to heat the aerosol-forming composition within the article (to volatilize the aerosol-forming material without burning the aerosol-forming composition, as discussed above).

[0184] An advantage of placing the power source 27 laterally adjacent to the heating apparatus 23 is that a physically larger power source 25 can be used without excessively lengthening the overall device 1. Of course, a physically larger power source 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore can provide a longer battery life for the device 1.

[0185] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber into which the article 101, 301 containing the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride ceramics, as well as silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), resistive heating elements formed by resistive electrical windings, and the like.

[0186] In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the article 101, 301 is inserted into the device 1, substantially the entire body of the article 101, 301, which comprises the aerosol-forming composition 103, 303, is inserted into the heating device 23.

[0187] The, or each, heating element may be arranged so as to heat selected zones (areas) of the aerosol-forming material independently, for example sequentially (over time as described above) or together (simultaneously) as desired.

[0188] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heating device 23 to the exterior of the device 1. This generally reduces heat loss and therefore helps to keep the power requirements of the heating device 23 low. The insulation 31 also helps to keep the exterior of the device 1 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (including, for example, a suitable foam-type material) in addition to or instead of the double-walled sleeve.

[0189] The housing 9 may further include various internal support structures 37 for supporting all of the internal components as well as the heating device 23 .

[0190] The device 1 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 9, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along an outer surface of the chamber 35, each fin being disposed to circumscribe the outer surface of the chamber 35. When the article 101, 301 is inserted into the device 1 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the article 101, 301. The gap 36 circumscribes the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

[0191] The collar 33 includes a number of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage an article 101, 301 inserted within the device to help secure it within the device 1. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the articles 101, 301 form ventilation paths around the outer surfaces of the articles 101, 301. These ventilation paths allow hot steam escaping from the articles 101, 301 to exit the device 1, and allow cooling air to flow into the device 1 around the articles 101, 301 within the gap 36.

[0192] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 1, as shown in Figures 5-7. Referring specifically to Figure 6, in one example, the aerosol generating composition body 103, 303 (which is disposed at the distal end 115, 315 of the article 101, 301) is completely contained within the heating arrangement 23 of the device 1. The proximal end 113, 313 of the article 101, 301 extends from the device 1 and functions as a mouthpiece assembly for the user.

[0193] During operation, the heating device 23 heats the article 101 , 301 to volatilize at least one component of the aerosol-forming composition from the aerosol-forming composition body 103 , 303 .

[0194] The primary flow path for heated volatile components from the aerosol-generating composition body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating composition body is between 60° C. and 250° C., which may be above an acceptable inhalation temperature for a user. The heated volatile components cool as they travel through the cooling segment 107, 307, and some of the volatile components condense on the interior surface of the cooling segment 107, 307.

[0195] In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0196] Manufacturing method Another aspect of the present invention provides methods of making the aerosol-forming compositions described herein.

[0197] A method of forming an aerosol-generating material includes: (a) (i) one or more foaming agents; (ii) a filler; (iii) an aerosol-forming material, and (iv) Solvent Providing a slurry comprising: (b) aerating the slurry; (c) forming a layer of aerated slurry; (d) drying the slurry to form an aerosol-generating material. may include:

[0198] As mentioned above, the aerosol-forming material formed from this process is a foam.

[0199] The step (b) of aerating the slurry may comprise mixing the slurry under high shear conditions.

[0200] Step (c) of forming the layer of the slurry may include, for example, spraying, casting, or extruding the slurry. In some examples, the slurry layer is formed by electrostatically spraying the slurry. In some examples, the slurry layer is formed by casting the slurry.

[0201] In some instances, (c) and (d) may be performed at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (c) and (d) may be performed sequentially.

[0202] In some instances, the slurry is applied to a substrate, and a layer of the aerated slurry may be formed on the substrate.

[0203] The drying step (d) may, in some instances, remove from about 50%, 60%, 70%, 80%, or 90% to about 80%, 90%, or 95% of the water in the slurry (WWB).

[0204] The drying step (d) may in some instances reduce the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry may be cast to a thickness of 2 mm and the resulting dried aerosol-generating material may have a thickness of 0.2 mm.

[0205] During step (d), the slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0206] In some embodiments, a gas is bubbled through the slurry prior to step (d).

[0207] In some examples, the step (a) of providing a slurry includes mixing the slurry under high shear conditions, such that step (b) is part of step (a). In such embodiments, the method includes: (a) providing a slurry and mixing the slurry under high shear conditions to form an aerated slurry, the slurry comprising: (i) one or more foaming agents; (ii) a filler; (iii) an aerosol-forming material, and (iv) Solvent and (b) forming a layer of aerated slurry; (c) drying the slurry to form an aerosol-generating material. may include:

[0208] The step of aerating the slurry may occur after the layer of slurry is formed. In such an embodiment, the method comprises: (a) (i) one or more foaming agents; (ii) a filler; (iii) an aerosol-forming material, and (iv) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) aerating the slurry; (d) drying the slurry to form an aerosol-generating material. may include:

[0209] In such an example, the step of aerating the slurry may include bubbling a gas through the slurry.

[0210] The slurry itself may also form part of the present invention. In some instances, the slurry solvent may consist essentially of or consist of water. In some instances, the slurry may contain about 50%, 60%, 70%, 80%, or 90% solvent by weight (WWB).

[0211] In instances where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the aerosol-forming material. Thus, any discussion herein of the composition of solids is expressly disclosed in conjunction with the slurry aspects of the invention.

[0212] A method of forming an aerosol-generating material includes: (a) (i) one or more foaming agents; (ii) a filler; (iii) a blowing agent, (iv) aerosol-forming materials, and (v) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) drying the slurry to form an aerosol-generating material. may include:

[0213] Step (b) of forming the layer of the slurry may include, for example, spraying, casting, or extruding the slurry. In some examples, the slurry layer is formed by electrostatically spraying the slurry. In some examples, the slurry layer is formed by casting the slurry.

[0214] In some instances, (b) and (c) may occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (b) and (c) may occur sequentially.

[0215] In some instances, the slurry is applied to a substrate. A layer of the slurry may be formed on the substrate.

[0216] The drying step (c) may, in some instances, remove from about 50%, 60%, 70%, 80%, or 90% to about 80%, 90%, or 95% of the water in the slurry (WWB).

[0217] The drying step (c) may in some instances reduce the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry may be cast to a thickness of 2 mm and the resulting dry aerosol-generating material may have a thickness of 0.2 mm.

[0218] During step (c), the slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0219] In some embodiments, the slurry is further aerated prior to step (c), for example, in some embodiments, a gas is bubbled through the slurry prior to step (c).

[0220] The slurry itself may also form part of the present invention. In some instances, the slurry solvent may consist essentially of water or may consist of water. In some instances, the slurry may contain about 50%, 60%, 70%, 80%, or 90% solvent by weight (WWB).

[0221] In instances where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the aerosol-forming material. Thus, any discussion herein of the composition of solids is expressly disclosed in conjunction with the slurry aspects of the invention.

[0222] According to aspects of the invention, there is provided a method of generating an aerosol using a non-combustion aerosol delivery system as described herein. In some embodiments, the method includes heating the aerosol-generating material to a temperature of 350° C. or less. In some embodiments, the method includes heating the aerosol-generating material to a temperature of about 220° C. to about 280° C. In some embodiments, the method includes heating at least a portion of the aerosol-generating material to a temperature of about 220° C. to about 280° C. over a use session.

[0223] A "use session" as used herein refers to a single period of use of the non-combustion aerosol delivery system by a user. A use session begins when power is first applied to at least one heating unit present in the heating assembly. The device is ready for use after a period of time has elapsed since the start of the use session. A use session ends when power is not applied to any of the heating elements of the aerosol generating device. The end of a use session may coincide with the point at which the smoking article is depleted (the point at which the user considers the total particulate matter yield (mg) per puff to be unacceptably low). A session has a duration of multiple puffs. The session may have a duration of 7 minutes, or 6 minutes, or 5 minutes, or 4 minutes 30 seconds, or less than 4 minutes, or 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, or 3 to 4.5 minutes, or 3.5 to 4.5 minutes, or preferably 4 minutes. A session may be initiated by a user activating a button or switch on the device, initiating an increase in temperature of at least one heating element.

[0224] Example Embodiments 1. An aerosol-forming material or slurry as defined in the Summary of the Disclosure. 2. The aerosol-forming material or slurry of embodiment 1, comprising about 5-35% by weight of a foaming agent. 3. The aerosol-forming material or slurry of embodiment 2, comprising about 5-25% by weight of a foaming agent. 4. The aerosol-forming material or slurry of embodiment 3, comprising about 5-20% by weight of a foaming agent. 5. The aerosol-forming material or slurry of embodiment 2, comprising about 10-35% by weight of a foaming agent. 6. The aerosol-forming material or slurry of embodiment 5, comprising about 10-25% by weight of a foaming agent. 7. The aerosol-forming material or slurry of embodiment 6, comprising about 10-20% by weight of a foaming agent. 8. The aerosol-forming material or slurry of any preceding embodiment, wherein the foaming agent comprises hydroxypropyl methylcellulose (HPMC), guar gum, pectin, modified starch (e.g., hydroxylated starch), maltodextrin, and mixtures thereof. 9. The aerosol-forming material or slurry of embodiment 8, wherein the foaming agent comprises (or is) HPMC. 10. The aerosol-forming material or slurry of any preceding embodiment, comprising about 10-80% by weight of a filler. 11. The aerosol-forming material or slurry of embodiment 10, comprising about 10 to 75% by weight of a filler. 12. The aerosol-forming material or slurry of embodiment 11, comprising about 10 to 70% by weight of a filler. 13. The aerosol-forming material or slurry of embodiment 10, comprising about 20-80% by weight of a filler. 14. The aerosol-forming material or slurry of embodiment 13, comprising about 20-75% by weight of a filler. 15. The aerosol-forming material or slurry of embodiment 14, comprising about 20-70% by weight of a filler. 16. The aerosol-forming material or slurry of embodiment 10, comprising about 30-80% by weight of a filler. 17. The aerosol-forming material or slurry of embodiment 16, comprising about 30-75% by weight of a filler. 18. The aerosol-forming material or slurry of embodiment 17, comprising about 30-70% by weight of a filler. 19. The aerosol-forming material or slurry of embodiment 10, comprising about 40-80% by weight of a filler. 20. The aerosol-forming material or slurry of embodiment 19, comprising about 40-75% by weight of a filler. 21. The aerosol-forming material or slurry of embodiment 20, comprising about 40-70% by weight of a filler. 22. The aerosol-forming material or slurry of embodiment 10, comprising about 50-80% by weight of a filler. 23. The aerosol-forming material or slurry of embodiment 22, comprising about 50-75% by weight of a filler. 24. The aerosol-forming material or slurry of embodiment 23, comprising about 50-70% by weight of a filler. 25. The aerosol-forming material or slurry of embodiment 10, comprising about 60-80% by weight of a filler. 26. The aerosol-forming material or slurry of embodiment 25, comprising about 60-75% by weight of a filler. 27. The aerosol-forming material or slurry of embodiment 26, comprising about 60-70% by weight of a filler. 28. The aerosol-forming material or slurry of any preceding embodiment, wherein the filler comprises inorganic filler materials, wood pulp, calcium carbonate, hemp fibers, cellulose, and cellulose derivatives. 28a. The aerosol-forming material or slurry of any preceding embodiment, wherein the filler is selected from wood pulp, calcium carbonate, and combinations thereof. 29. The aerosol-forming material or slurry of embodiment 28, wherein the filler comprises (or is) wood pulp. 30. The aerosol-forming material or slurry of any preceding embodiment comprising about 1-20% by weight wood pulp. 31. The aerosol-forming material or slurry of embodiment 30, comprising about 5-15% by weight of wood pulp. 32. The aerosol-forming material or slurry of embodiment 31, comprising about 13-14% by weight of wood pulp. 33. The aerosol-generating material or slurry of any preceding embodiment, comprising about 10-70% by weight calcium carbonate. 34. The aerosol-forming material or slurry of embodiment 33, comprising about 30-70% by weight of calcium carbonate. 35. The aerosol-forming material or slurry of embodiment 34, comprising about 45-65% by weight of calcium carbonate. 36. The aerosol-generating material or slurry of any preceding embodiment, comprising about 1-80% by weight of the aerosol-forming material. 37. The aerosol-generating material or slurry of embodiment 36, comprising about 1-50% by weight of the aerosol-forming material. 38. The aerosol-generating material or slurry of embodiment 37, comprising about 5-35% by weight of the aerosol-forming material. 39. The aerosol-generating material or slurry of embodiment 38, comprising about 10-25% by weight of the aerosol-forming material. 40. The aerosol-generating material or slurry of embodiment 39, comprising about 12-20% by weight of the aerosol-forming material. 41. The aerosol-generating material or slurry of embodiment 40, comprising about 13-18% by weight of the aerosol-forming material. 42. The aerosol generating material or slurry of any preceding embodiment, wherein the aerosol forming material comprises (or is) one or more of glycerol, propylene glycol, 1,3-propanediol, 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, laryl acetaee, lauric acid, myristic acid, and propylene carbonate. 43. The aerosol-generating material or slurry of embodiment 42, wherein the aerosol-forming material comprises (or is) one or more of erythritol, propylene glycol, glycerol, and triacetin. 44. The aerosol-generating material or slurry of embodiment 42, wherein the aerosol-forming material comprises (or is) glycerol, optionally in combination with propylene glycol. 45. The aerosol-forming material or slurry of any preceding embodiment, comprising about 1-10% by weight of a foam stabilizer. 46. ​​The aerosol-forming material or slurry of embodiment 45, comprising about 1 to 7% by weight of a foam stabilizer. 47. The aerosol-forming material or slurry of embodiment 46, comprising about 1 to 5% by weight of a foam stabilizer. 48. The aerosol-forming material or slurry of embodiment 45, comprising about 2 to 10% by weight of a foam stabilizer. 49. The aerosol-forming material or slurry of embodiment 48, comprising about 2-7% by weight of a foam stabilizer. 50. The aerosol-forming material or slurry of embodiment 49, comprising about 2-5% by weight of a foam stabilizer. 51. The aerosol-forming material or slurry of any preceding embodiment, wherein the foam stabilizer comprises (or is) a surfactant. 52. The aerosol-forming material or slurry of embodiment 51, wherein the foam stabilizer comprises (or is) sodium lauryl sulfate (SLS), Tween 60, Tween 80, Amphosol CA, Span 60 (sorbitan monostearate), Span 80 (sorbitan monooleate), lecithin, or a mixture thereof. 53. The aerosol-generating material or slurry of any preceding embodiment, comprising about 1-10% by weight of a blowing agent. 54. The aerosol-forming material or slurry of embodiment 53, comprising about 1 to 7% by weight of a blowing agent. 55. The aerosol-forming material or slurry of embodiment 54, comprising about 1 to 5% by weight of a blowing agent. 56. The aerosol-forming material or slurry of embodiment 53, comprising about 2 to 10% by weight of a blowing agent. 57. The aerosol-forming material or slurry of embodiment 56, comprising about 2-7% by weight of a blowing agent. 58. The aerosol-forming material or slurry of embodiment 57, comprising about 2 to 5% by weight of a blowing agent. 59. The aerosol-forming material or slurry of embodiment 53, comprising about 4 to 10% by weight of a blowing agent. 60. The aerosol-forming material or slurry of embodiment 59, comprising about 4 to 7% by weight of a blowing agent. 61. The aerosol-forming material or slurry of embodiment 60, comprising about 4-5% by weight of a blowing agent. 62. The aerosol-generating material or slurry of any preceding embodiment, wherein the effervescent agent comprises (or is) calcium carbonate, sodium carbonate, sodium bicarbonate, citric acid, tartaric acid, lactic acid, acetic acid, aluminum sulfate, or a mixture thereof. 63. The aerosol-forming material or slurry of any preceding embodiment, further comprising one or more other functional materials. 64. The aerosol-forming material or slurry of any preceding embodiment, which does not include fibrous material. 65. The aerosol-forming material or slurry of any of the preceding embodiments, which does not contain tobacco fiber. 66. The aerosol-generating material of any preceding embodiment, consisting of, or consisting essentially of, one or more of a foaming agent, a bulking agent, an aerosol-forming material, and water. 67. The aerosol-generating material of any of the preceding embodiments, consisting of, or consisting essentially of, one or more foaming agents, foam stabilizers, bulking agents, aerosol-forming materials, and water. 68. The aerosol-generating material of any of the preceding embodiments, consisting of, or consisting essentially of, one or more of a foaming agent, a filler, an aerosol-forming material, a blowing agent, and water. 69. The aerosol-generating material of any preceding claim, present on a substrate. 70. 0.02~0.7g / cm 3 4. The aerosol-generating material of any preceding claim, having a density of 71. 0.02~0.6g / cm 3 71. The aerosol-forming material of embodiment 70, having a density of 72. 0.02~0.4g / cm 3 72. The aerosol-forming material of embodiment 71, having a density of 73. 0.02~0.25g / cm 3 73. The aerosol-forming material of embodiment 72, having a density of 74. 0.06~0.7g / cm 3 71. The aerosol-forming material of embodiment 70, having a density of 75. 0.06~0.6g / cm 3 75. The aerosol-forming material of embodiment 74, having a density of 76. 0.06~0.4g / cm 3 76. The aerosol-forming material of embodiment 75, having a density of 77. 0.06~0.25g / cm 3 77. The aerosol-forming material of embodiment 76, having a density of 78. 0.1~0.7g / cm 3 71. The aerosol-forming material of embodiment 70, having a density of 79. 0.1~0.6g / cm 3 79. The aerosol-forming material of embodiment 78, having a density of 80. 0.1~0.4g / cm 3 80. The aerosol-forming material of embodiment 79, having a density of 81. 0.1~0.25g / cm 3 81. The aerosol-forming material of embodiment 80, having a density of 82.About 380cm 3 The aerosol generating material of any preceding embodiment having a fill value of greater than 1 / 100g. 83.About 400cmg 3 The aerosol-forming material of embodiment 82, having a fill value of greater than 1 / 100g. 84.About 420cmg 3 84. The aerosol-forming material of embodiment 83, having a fill value of greater than 1 / 100g. 85. The aerosol-generating material of any preceding embodiment, having a Gurley porosity of about 100 sec / 100 mL or greater. 86. The aerosol-generating material of embodiment 85, having a Gurley porosity of about 125 seconds / 100 mL or greater. 87. The aerosol-generating material of embodiment 86, having a Gurley porosity of about 150 sec / 100 mL or greater. 88. An aerosol-forming composition comprising an aerosol-forming material according to any preceding embodiment. 89. The aerosol forming composition of embodiment 88, further comprising one or more other functional materials. 90. The aerosol forming composition of embodiment 89, wherein the other functional materials include one or more pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants. 91. The aerosol forming composition of any of embodiments 88-90, comprising about 10-100% total weight (by weight) of aerosol forming materials. 92. The aerosol generating composition of any of embodiments 88-90, comprising about 20-100% total aerosol generating materials by weight (by WWB). 93. The aerosol generating composition of any of embodiments 88-90, comprising about 30-100% total weight (by weight) of aerosol generating materials. 94. The aerosol generating composition of any of embodiments 88-90, comprising about 40-100% total aerosol generating materials by weight (by WWB). 95. The aerosol generating composition of any of embodiments 88-90, comprising about 50-100% total aerosol generating materials by weight (by WWB). 96. The aerosol generating composition of any of embodiments 88-90, comprising about 60-100% total aerosol generating materials by weight (by WWB). 97. The aerosol forming composition of any of embodiments 88-90, comprising about 70-100% total aerosol forming materials by weight (by WWB). 98. The aerosol generating composition of any of embodiments 88-90, comprising about 50-95% total aerosol generating materials by weight (by WWB). 99. The aerosol generating composition of any of embodiments 88-90, comprising about 50-90% total aerosol generating material by weight (by WWB). 100. The aerosol-forming composition of any of embodiments 88-90, consisting of, or consisting essentially of, an aerosol-forming material. 100a. The aerosol forming composition of any of embodiments 88-100, further comprising a tobacco material. 100b. The aerosol forming composition of embodiment 100a, wherein the tobacco material is fine cut. 100c. The aerosol forming composition of any one of embodiments 100a-100b, wherein the tobacco material comprises laminar tobacco. 100d. The aerosol forming composition of any one of embodiments 100a-100c, wherein the tobacco material comprises cut rag tobacco. 100e. The aerosol-forming composition of any one of embodiments 100a-100d, wherein the aerosol-forming material is in the form of shredded sheets and blended with the tobacco material. 101. A consumable for use in a non-combustion aerosol delivery device, comprising the aerosol generating composition of any of embodiments 88-100e. 101a. A consumable for use in a combustion-type aerosol delivery device, the consumable comprising the aerosol generating composition of any of embodiments 88-100e. 102. A non-combustion aerosol delivery system comprising the consumable of embodiment 101 and a non-combustion aerosol delivery device. 102a. A combustion aerosol delivery system comprising the consumable of embodiment 101a and a combustion aerosol delivery device. 103. A consumable for use in the non-combustion aerosol delivery device of embodiment 101 or the non-combustion aerosol delivery system of embodiment 93, wherein the non-combustion aerosol delivery device is a non-combustion heated device. 104. A consumable for use in the non-combustion aerosol delivery device of embodiment 101 or the non-combustion aerosol delivery system of embodiment 102, wherein the non-combustion aerosol delivery device is an e-cigarette hybrid device. 105. A method of forming an aerosol-forming material as defined in any one of embodiments 1-87, comprising: (a) (i) one or more foaming agents; (ii) a filler; (iii) an aerosol-forming material, and (iv) Solvent Providing a slurry comprising: (b) aerating the slurry; (c) forming a layer of aerated slurry; (d) drying the slurry to form an aerosol-generating material. A method comprising: 105a. A method of forming an aerosol-forming material as defined in any one of embodiments 1-87, comprising: (a) (v) one or more foaming agents; (vi) fillers, (vii) aerosol-forming materials, and (viii) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) aerating the slurry; (d) drying the slurry to form an aerosol-generating material. A method comprising: 105b. The method of embodiment 105a, wherein step (c) comprises bubbling a gas through the slurry. 106. The method of embodiment 105, wherein step (b) comprises mixing the slurry under high shear conditions. 106a. The method of embodiment 105, wherein step (b) comprises bubbling a gas through the slurry. 107. The method of embodiment 105 or 106, wherein the step (a) of providing a slurry comprises mixing the slurry under high shear conditions, such that step (b) is part of step (a). 108. A method of forming an aerosol-forming material as defined in any one of embodiments 1-87, comprising: (a) (i) one or more foaming agents; (ii) a filler; (iii) a blowing agent, (iv) aerosol-forming materials, and (v) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) drying the slurry to form an aerosol-generating material. A method comprising: 108a. The method of embodiment 108, wherein in step (b), a gas is bubbled through the slurry prior to the drying step. 108. The method of any of embodiments 105-108, wherein the solvent comprises water. 109. The method of any of embodiments 105-107, wherein the solvent consists essentially of, or consists of, water. 110. The method of any of embodiments 105-107, wherein the slurry comprises about 50%, 60%, 70%, 80%, or 90% by weight of solvent (WWB). EXAMPLES

[0225] Exemplary, non-limiting formulations of aerosol-generating materials are shown in Table 1.

[0226] [Table 1]

[0227] [Table 2]

[0228] [Table 3]

[0229] The aerosol-forming materials of the present invention provide a lightweight yet sensory substrate. The use of foaming agents (e.g., HPMC) allows for the incorporation of air into the thin film, reducing density (Table 3).

Claims

1. (i) one or more foaming agents; (ii) a filler; and (iii) an aerosol-forming material; and 1. An aerosol-forming material comprising a foam, Approximately 0.02g / cm ３ ~Approx. 0.7g / cm ３ The aerosol-generating material has a density of

2. 10. The aerosol forming material of claim 1, further comprising a foam stabilizer.

3. 3. The aerosol generation of claim 1 or 2, comprising a blowing agent.

4. The aerosol-forming material according to any one of claims 1 to 3, which is porous.

5. Approximately 0.02g / cm ３ ~Approx. 0.6g / cm ３ 5. The aerosol-forming material of claim 1, having a density of

6. Approximately 0.02g / cm ３ ~Approx. 0.5g / cm ３ 6. The aerosol-forming material of claim 1, having a density of

7. Approximately 0.02g / cm ３ ~ about 0.4 g / cm ３ 7. The aerosol-forming material of claim 1, having a density of

8. 8. The aerosol generating material of claim 1, wherein the foaming agent comprises hydroxypropyl methylcellulose (HPMC), guar gum, modified starch, such as hydroxylated starch, maltodextrin, or mixtures thereof.

9. The aerosol-forming material of any one of claims 1 to 8, wherein the foaming agent comprises HPMC.

10. The aerosol-forming material of any one of claims 1 to 9, wherein the filler comprises calcium carbonate, wood pulp, or a combination thereof.

11. The aerosol-forming material of any one of claims 1 to 10, wherein the filler comprises wood pulp or a combination of wood pulp and calcium carbonate.

12. 12. The aerosol-forming material of claim 1, comprising from about 5 to about 35% by weight of a foaming agent.

13. 13. The aerosol-forming material of claim 1, comprising from about 6 to about 25% by weight of a foaming agent.

14. 14. The aerosol-forming material of claim 1, comprising from about 10 to about 20% by weight of a foaming agent.

15. The aerosol-forming material of any one of claims 1 to 14, comprising from about 10 to about 85% by weight of a filler.

16. 16. The aerosol-forming material of claim 1, comprising from about 50 to about 80% by weight of a filler.

17. Approximately 380g / cm ３ 17. The aerosol-forming material of claim 1, having a filling value of greater than 0.

05.

18. 20. The aerosol-forming material of claim 17, wherein the value is measured according to Method A described herein.

19. 19. The aerosol-forming material of any one of claims 1 to 18, having a Gurley porosity of about 100 seconds / 100 mL or greater.

20. 20. The aerosol-forming material of claim 1, having a Gurley porosity of about 150 seconds / 100 mL or greater.

21. 21. The aerosol-generating material of claim 19 or 20, wherein the Gurley porosity is measured according to Method B described herein.

22. The aerosol forming material of claim 2 , wherein the foam stabilizer comprises one or more surfactants.

23. 23. The aerosol forming material of any one of claims 1 to 22, comprising about 1 to about 5% by weight of a foam stabilizer.

24. 24. The aerosol forming material of claim 22 or 23, wherein the foam stabilizer comprises sodium lauryl sulfate (SLS), Tween 60, Tween 80, Amphosol CA, Span 60 (sorbitan monostearate), Span 80 (sorbitan monooleate), lecithin, or a mixture thereof.

25. 4. The aerosol generating material of claim 3, wherein the effervescent agent comprises calcium carbonate, sodium carbonate, sodium bicarbonate, citric acid, tartaric acid, acetic acid, aluminum sulfate, or a mixture thereof.

26. The aerosol-forming material of any one of claims 1 to 25, which is substantially free of tobacco.

27. An aerosol forming composition comprising an aerosol forming material according to any one of claims 1 to 26.

28. 30. The aerosol-forming composition of claim 27, wherein the aerosol-forming material comprises tobacco.

29. 27. The aerosol forming composition of claim 25 or 26, comprising about 10 to 100% by weight (by WWB) of the aerosol forming material.

30. 30. The aerosol forming composition of claim 27 or 29, further comprising a tobacco material.

31. 31. The aerosol forming composition of claim 30, wherein the tobacco material is fine cut.

32. 32. The aerosol forming composition of claim 30 or 31, wherein the tobacco material comprises laminar tobacco.

33. 33. The aerosol forming composition of any one of claims 30-32, wherein the tobacco material comprises cut rag tobacco.

34. The aerosol forming composition of any one of claims 30 to 33, wherein the aerosol forming material is in the form of shredded sheets and is blended with the tobacco material.

35. 35. A consumable for use in a non-combustion aerosol delivery device, comprising the aerosol forming composition of any one of claims 27 to 34.

36. A consumable for use in a combustion-type aerosol delivery device, comprising the aerosol forming composition of any one of claims 27 to 34.

37. 36. A non-combustion aerosol delivery system comprising the consumable of claim 35 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

38. 37. A combustion aerosol delivery system comprising the consumable of claim 36 and a combustion aerosol delivery device.

39. 1. A method of forming an aerosol-generating material, comprising: (a) (i) one or more foaming agents; (ii) a filler, (iii) an aerosol-forming material, and (iv) Solvent Providing a slurry comprising: (b) aerating the slurry; (c) forming a layer of the aerated slurry; (d) drying the slurry to form the aerosol-forming material. A method comprising:

40. 40. The method of claim 39, wherein step (b) comprises mixing the slurry under high shear conditions.

41. 41. The method of claim 39 or 40, wherein the step (a) of providing the slurry comprises mixing the slurry under high shear conditions, such that step (b) is part of step (a).

42. 40. The method of claim 39, wherein step (b) comprises bubbling a gas through the slurry.

43. 1. A method of forming an aerosol-generating material, comprising: (a) (i) one or more foaming agents; (ii) a filler, (iii) a blowing agent, (iv) an aerosol-forming material, and (v) Solvent Providing a slurry comprising: (b) forming a layer of the slurry; (c) drying the slurry to form an aerosol-forming material. A method comprising:

44. A method according to any one of claims 39 to 43, wherein a gas is bubbled through the slurry prior to the drying step.

45. The method of any one of claims 39 to 44, wherein the solvent is water.

Images