Substrates Comprising Aerosol-Forming Material Surrounded by a Support and Uses Thereof - Patent application

Abstract

The present invention relates to a substrate comprising an aerosol-generating material surrounded by a support, the aerosol-generating material comprising a dry precursor material comprising an extract from a fragrance-containing and / or active-containing plant material and optionally an aerosol-forming material. The substrate may be used to generate an aerosol. For example, the substrate may be used in a combustion or non-combustion aerosol delivery system. The present invention also relates to an aerosol delivery system comprising the substrate, and a method of providing the substrate.

Description

[Technical field]

[0001] The present invention relates to a substrate comprising an aerosol-forming material surrounded by a support, a method for making the substrate and uses thereof. [Background technology]

[0002] Aerosol-generating materials for use in combustion or non-combustion aerosol delivery systems may contain a variety of different actives and / or flavorants. Factors such as the concentration of volatile active and / or flavoring ingredients in the aerosol-generating material and the stability of the aerosol-generating material affect the characteristics of the aerosol generated. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a substrate comprising an aerosol-generating material surrounded by a support, the aerosol-generating material comprising a dry precursor material comprising an extract from a fragrance-containing and / or active-containing plant material.

[0004] In some embodiments, the substrate comprises sheets and the aerosol-forming material is sandwiched between one or more of the sheets.

[0005] In some embodiments, the sheet comprises one or more selected from the group consisting of paper, card, cardboard, cardboard, recycled materials, plastic materials, ceramic materials, activated carbon, glass, sintered materials, composite materials, plant-derived materials, fabrics or fleeces, fibrous tow, metals, and metal alloys.

[0006] In some embodiments, the substrate has a rolled configuration.

[0007] In some embodiments, the aerosol-forming material is distributed within the support.

[0008] In some embodiments, the support is a porous material having the aerosol-generating material distributed within the pores. In some embodiments, the support is a fibrous material. In some embodiments, the fibrous material is selected from the group consisting of fibrous tow, nonwoven sheet, porous paper, and fabric or fleece.

[0009] In some embodiments, the substrate comprises an aggregate material. In some embodiments, the substrate is an extruded mixture of the substrate and an aerosol-forming material. In some embodiments, the substrate comprises a tobacco material.

[0010] In some embodiments, the support comprises a heating material.

[0011] In some embodiments, the substrate does not include a binder applied to adhere the aerosol-forming material to the support.

[0012] In some embodiments, a binder is included to adhere the aerosol-forming material to a support in an amount of about 0.1% to about 5% by weight, based on the total weight of the aerosol-forming material, hi some embodiments, the binder is selected from the group consisting of thermoreversible gelling agents, starches, polysaccharides, pectins, cellulose, cellulose derivatives, and alginates.

[0013] In some embodiments, the aerosol generating material further comprises an aerosol forming material.

[0014] In some embodiments, the precursor material comprises from about 10 to about 95% by weight extract derived from flavor- or active-containing plant material.

[0015] In some embodiments, the precursor material comprises from about 1 to about 36% by weight of the aerosol-forming material.

[0016] In some embodiments, the precursor material comprises from 0 to about 40% by weight of excipients.

[0017] In some embodiments, the aerosol-forming material comprises from about 45% to about 99% by weight of a dry extract derived from flavor- or active-containing plant material.

[0018] In some embodiments, the aerosol-forming material comprises from about 1 to about 34% by weight of the aerosol-forming material.

[0019] In some embodiments, the aerosol-forming material comprises from 0 to about 25% by weight of an excipient.

[0020] In some embodiments, the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

[0021] In some embodiments, the extract from the flavor-containing or active-containing plant material is an aqueous extract.

[0022] In some embodiments, the extract from flavor-containing or active-containing plant material is an aqueous tobacco extract.

[0023] In some embodiments, the aerosol-forming material has a moisture content of about 5% or less (calculated on a wet weight basis).

[0024] In some embodiments, the substrate includes a moisture impermeable coating that surrounds the aerosol-forming material.

[0025] In some embodiments, the substrate comprises an adsorbent material.

[0026] In some embodiments, the substrate is for use in an aerosol delivery system.

[0027] According to a second aspect of the present invention there is provided an article comprising an aerosol-forming material surrounded by a support, the aerosol-forming material comprising a dry precursor material comprising an extract from perfume-containing and / or active-containing plant material.

[0028] In some embodiments, the article comprises a substrate according to the first aspect.

[0029] In some embodiments, the article includes a means for preventing or reducing absorption of moisture by the dry aerosol-forming material.

[0030] In some embodiments, the means is provided separately from the aerosol-forming material and / or substrate.

[0031] In some embodiments, the means comprises a moisture impermeable coating or a film or wrapper that includes an adsorbent or desiccant material.

[0032] According to a third aspect of the present invention there is provided a non-combustion aerosol delivery system comprising a substrate according to the first aspect.

[0033] According to a fourth aspect of the present invention there is provided a method for providing a substrate comprising drying a precursor material comprising an extract from perfume-containing and / or active-containing plant material and an aerosol-forming material to form an aerosol-forming material, and entrapping the aerosol-forming material in a support.

[0034] In some embodiments, the aerosol-generating material is sandwiched between two layers of support material.

[0035] In some embodiments, the aerosol-generating material is sandwiched between two layers of support material and rolled.

[0036] In some embodiments, the aerosol-generating material is sandwiched between two layers of support material and rolled into the form of a hollow cylinder.

[0037] In some embodiments, a binder is added to one or more of the aerosol-forming material and the support before the aerosol-forming material is sandwiched between layers of support material.

[0038] In some embodiments, the aerosol-generating material is distributed within a fibrous support material.

[0039] In some embodiments, the method includes extruding a mixture of the aerosol-forming material and the support material.

[0040] In some embodiments, the precursor material is dried by spray drying or freeze drying.

[0041] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0042] [Figure 1] 1 is a schematic diagram of a substrate as described herein. [Diagram 2] FIG. 2 is a schematic diagram of another substrate described herein. [Diagram 3] 1 is a side cross-sectional view of a first embodiment of a consumable including a substrate as described herein. [Figure 4] FIG. 4 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable composition shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] An aerosol-forming material is a material that is capable of generating an aerosol when, for example, heated, irradiated, or in any other way energized.

[0044] Conventional aerosol generating materials, including tobacco materials or tobacco extracts, can be used in combustion and non-combustion aerosol generating devices, including hybrid devices and tobacco heating products, to provide users with an aerosol with authentic tobacco taste and texture. One problem encountered with such materials is that the content of flavors, other volatile compound(s) and nicotine decreases with storage of the aerosol generating material, especially toward the end of the material's life. This is because the more volatile components, including nicotine and many flavors and aromas, are easily released from the material. Furthermore, when the moisture content of the aerosol generating material increases due to moisture absorption, the release of substances such as nicotine and flavors is adversely affected. Aerosol generating materials produced using conventional methods and procedures generally need to be used within 1-3 days of production. Thus, there is a need to improve the shelf life of aerosol generating materials.

[0045] A further problem associated with conventional aerosol-forming materials that include tobacco materials or tobacco extracts is that the concentrations of desired components, such as nicotine and flavors, are relatively low. This limits the concentration of these desired components in the generated aerosol. Furthermore, this means that a relatively large amount of the aerosol-forming material is required, and therefore a large amount of energy is required to heat the aerosol-forming material to release the desired components.

[0046] The present invention relates to compositions comprising dried or dehydrated aerosol-forming materials formed from extracts from fragrance-containing and / or active-containing plant materials. In some embodiments, the extracts are liquid solutions or suspensions and may be dried or dehydrated using processes such as spray drying or freeze drying. The dried or dehydrated aerosol-forming materials may be formed from precursor materials comprising extracts from fragrance-containing and / or active-containing plant materials and aerosol-forming materials.

[0047] Aerosol-forming materials that include dried extracts from fragrance-containing and / or active-containing plant materials contain high concentrations of fragrances and / or actives, with little or no material contributing to the aerosol generated from the dry aerosol-forming material. Thus, small amounts of aerosol-forming material are sufficient to generate an aerosol with the desired active and fragrance content. Furthermore, the aerosol may be generated with a relatively low level of energy input.

[0048] An additional advantage of the aerosol-forming materials used as solid substrates is that the low water content reduces the problems associated with "hot puffs" as known in the art.

[0049] In some embodiments, the dry aerosol forming material has a moisture content of 0 to about 10%, or 0 to about 5%, (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration. In some embodiments, the moisture content of the dry aerosol forming material is less than about 3% by weight, e.g., about 0 to about 3% by weight, or about 0.5 to about 2.5% by weight.

[0050] Karl Fischer titration is a classical method of chemical analysis to reliably determine the amount, even trace amounts, of water in a sample. The method can be easily performed using an automated Karl Fischer titrator. Similarly, the use of GC-TCD is also an established method to reliably determine the water content in a sample.

[0051] Unless otherwise stated, references to water content herein are references to water content as measured by Karl Fischer titration.

[0052] Dry aerosol-forming materials can be hygroscopic, so steps must be taken to ensure that the aerosol-forming material does not absorb moisture during processing, during incorporation into the final product, and during storage in that final product prior to use.

[0053] In the present disclosure, the aerosol-generating material is surrounded by a support or support material. The combination of the aerosol-generating material and the support is referred to herein as a substrate. The substrate may be used in an aerosol delivery system to generate an aerosol. The support carries and protects the aerosol-generating material and provides it in a manner suitable for use in the aerosol delivery system. This is a particularly advantageous method for providing the aerosol-generating material, which is highly concentrated and therefore requires very small amounts compared to conventional aerosol-generating materials.

[0054] Furthermore, because the aerosol-forming material is at least partially surrounded by the support, it is at least partially protected from moisture in the environment, meaning that absorption of moisture by the aerosol-forming material is limited and controlled.

[0055] Thus, a substrate is provided that includes a support surrounding an aerosol-forming material that includes a dry precursor material that includes an extract from a fragrance-containing and / or active-containing plant material.

[0056] In some embodiments, the hygroscopic aerosol-generating material has a water content of about 10% or less, or about 5% or less (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration. The water content of this aerosol-generating material is stable, meaning that the water content of the aerosol-generating material is within this range not only when the aerosol-generating material is first prepared, but also after incorporation into a substrate, transportation and storage. This stable water content is observed despite the fact that the hygroscopic aerosol-generating material rapidly absorbs moisture when exposed to the environment, even under "normal" humidity conditions. Indeed, when an aerosol-generating material is described as hygroscopic, this means that it rapidly absorbs water from the surrounding environment, significantly increasing its water content. For example, when the aerosol-generating material is exposed to the environment (e.g., storage in an open container, etc.), the water content rapidly increases to more than 20% or more than 25% (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0057] support As used herein, a support or support material surrounds the aerosol-generating material. This can be accomplished using a variety of different support materials and support configurations.

[0058] In some embodiments, the support comprises a sheet or is in the form of one or more sheets. To form the substrate, the aerosol-generating material is sandwiched between one or more of the sheets. For example, the support sheet can be folded and the aerosol-generating material is disposed between two or more layers of the folded sheet, such that the aerosol-generating material is sandwiched between layers of sheet material. In such a configuration, the aerosol-generating material may be present as a continuous or discontinuous layer, or as a portion or unit of the aerosol-generating material. Furthermore, a significant portion of the aerosol-generating material is shielded from the environment and from moisture by the layer of support material.

[0059] In another possible configuration, the support includes one or more rolled sheets, with the aerosol-generating material located between the layers of the sheet(s). Two such configurations are shown in Figures 1 and 2.

[0060] In Figure 1, two sheets of support material 2, 4 are provided between which is sandwiched a layer of aerosol-generating material 3. These three layers are then rolled to form a cylindrical substrate 1.

[0061] In FIG. 2, a single sheet of support material 2 is provided. This sheet 2 is rolled and a layer of aerosol-generating material 3 is sandwiched between adjacent layers to form a cylindrical substrate 1. In this embodiment, the aerosol-generating material may be at least partially held in place on the sheet as it is rolled. In some embodiments, the aerosol-generating material is tacky and therefore can adhere to the sheet without the need for the addition of a binder. In other embodiments, the aerosol-generating material is bonded to the sheet as a result of a precursor material being contacted with the sheet and dried. In still other embodiments, a binder is added to one or both of the aerosol-generating material and the support.

[0062] In another embodiment, the support is a pressed and / or collected sheet material, such as paper. The aerosol-generating material may be included in the form of particles, which may or may not be aggregated. In such an embodiment, even if the aerosol-generating material is provided in particulate form, it may not be necessary for the aerosol-generating material to be adhered or stuck to the support. Rather, in this configuration, the particles of the aerosol-generating material are held in place by friction, which may be assisted by the pressed and / or collected shape of the sheet material, which forms gaps and cavities in which the particles may be trapped and held. In some embodiments, particle capture is increased, and the pressed and / or collected sheet is formed into a rod, for example for incorporation into a consumable product.

[0063] The support sheets used in these embodiments may be flexible or rigid.

[0064] In some embodiments, the sheet material may be or may include one or more selected from the group consisting of paper, card, cardboard, cardboard, recycled materials, plastic or polymeric materials, ceramic materials, composite materials, plant-derived materials, fabrics or fleeces, metals, or metal alloys.

[0065] The sheet used as the support may be smooth, or may have a rough or porous surface. A rough or porous surface may be advantageous when the aerosol-forming material is not adhered to the sheet using a binder or provided as a layer attached to the surface of the sheet.

[0066] In some embodiments, the aerosol-forming material is distributed within the support.

[0067] In some embodiments, the support is a porous material and the aerosol-generating material is distributed within the pores. For example, the support may be a fibrous material. Such fibrous materials may be selected from the group consisting of fibrous tows, such as cellulose acetate tows, nonwoven sheets, such as airlaid materials, such as airlaid paper and other porous papers, and fabrics or fleeces.

[0068] For example, the support or a portion thereof may be formed from a rough or porous paper material, such as tipping paper, porous plug wrap, cigarette paper, or tea bag paper. The paper may be porous paper. When the aerosol-generating material is applied to the surface of such a support, the particles can penetrate into the pores of the porous paper, providing good adhesion between the solid surface of the particles and the paper. In some embodiments, the support surface comprises a paper material, the paper optionally having a weight of about 20 gsm to about 100 gsm.

[0069] In some embodiments, the substrate is or includes airlaid paper, which has a highly porous surface structure, and in some embodiments, the aerosol-forming material is applied to the surface of the airlaid paper, in other embodiments, the aerosol-forming material may be added during the manufacture of the airlaid paper, which manufacturing process is a dry process.

[0070] In some embodiments, the aerosol-generating material is in the form of particles distributed within the substrate. In other embodiments, the aerosol-generating material is in the form of a single mass located within the substrate. In some embodiments, the aerosol-generating material is in the form of a coating within the substrate.

[0071] In some embodiments, the aerosol-generating material is added to the porous support as the support material is formed or incorporated into the substrate. For example, if the support is a fibrous tow, the material may be collected and formed into a desired shape, such as a cylindrical plug. When the tow is collected, the aerosol-generating material may be added so that it becomes embedded in the support material of the substrate and is distributed throughout the support material.

[0072] In some embodiments, the aerosol-generating material is added to the porous support when the support material is manufactured. For example, if the support material is a nonwoven sheet such as paper, cloth, or recycled material (such as a sheet of reconstituted tobacco), the aerosol-generating material may be incorporated into the sheet as it is formed. This allows the aerosol-generating material to be embedded in the substrate support material and distributed throughout the support material.

[0073] In some embodiments, the support comprises an aggregate material, meaning that the aerosol-forming material can be dispersed or embedded within the aggregated support material.

[0074] In some embodiments, the aerosol-generating material is added to the aggregated support when the support material is manufactured. For example, the support material to be aggregated is mixed with the aerosol-generating material prior to the aggregation step. The aggregation step then incorporates the aerosol-generating material within the aggregated support. At least a portion of the aerosol-generating material is surrounded by the aggregated support material and is therefore protected from moisture in the surrounding environment.

[0075] In some embodiments, the mixture is agglomerated by extrusion.

[0076] In some embodiments, the aggregation process is dry, i.e., the components to be aggregated are dry and there is no addition of a liquid component. One such dry aggregation process is dry extrusion, where the components to be extruded are combined without any additional liquid components. In dry extrusion, the shear forces applied to the extruded composition may be sufficient to cause fusion or bonding to form a stable aggregate.

[0077] In other embodiments, liquid can be added to lubricate the agglomerating mixture. In some embodiments, water can be added as a processing aid. For example, the presence of water can help dissolve the components of the composition that are aggregates and / or can help binding or improve aggregation. In some embodiments, the liquid can include an aerosol-forming material. The aerosol-forming material can be one of the aerosol-forming materials discussed elsewhere herein. Another liquid that can be included to aid aggregation is a liquid extract from a fragrance-containing and / or active-containing plant material. These liquids can be used in addition to or instead of traditional liquid agglomeration aids.

[0078] In some embodiments, the aggregation process exposes the material to be aggregated to conditions that may dry the precursor material. One such aggregation process is extrusion, during which the mixture is exposed to heat and high shear forces that may have a drying effect. In such embodiments, the support material to be aggregated may be mixed with either the (already dried) aerosol-generating material, or the precursor material, or a combination of both. The subsequent aggregation step dries any precursor material present in the mixture to form the aerosol-generating material.

[0079] In some embodiments, the aggregated support material comprises tobacco material, for example tobacco material in particulate form.

[0080] The tobacco particles have a size small enough to ensure that multiple such particles can be agglomerated to form substrates having desired dimensions based on their intended use. Smaller granular particles have a greater surface area to volume ratio and therefore may exhibit enhanced release of tobacco constituents compared to larger sized particles.

[0081] Additionally, the size of the tobacco particles (and other particles in the composition being aggregated) affects the porosity and density of the aggregate structure and substrate formed therefrom. Thus, in some embodiments, the size of the tobacco particles can be selected to produce an aggregate structure having a desired porosity that affects the release of tobacco components from the tobacco support material and aerosol from the aerosol-generating material surrounded by the support.

[0082] The extrusion process used to form the aggregate structure may be sensitive to the size of the particles in the composition to be extruded. Thus, it may be desirable for the particles in the composition, including, for example, tobacco particles as the support material, to have an average particle size of about 0.5 mm or less, or to be extruded to have an average particle size of about 0.3 mm or less, as measured by sieving. In some embodiments, it may be desirable for the particles in the composition to have an average particle size of about 0.5 mm or less, or to be extruded to have an average particle size of about 0.3 mm or less, as measured by sieving. In some embodiments, the average particle size is in the range of about 0.1 to about 0.4 mm, or in the range of about 0.2 to about 0.3 mm. In some embodiments, at least about 90% of the particles in the composition to be extruded have a particle size in the range of 0.1 to 0.5 mm. In some embodiments, at least about 90% of the particles in the composition to be extruded have a particle size in the range of 0.1 to 0.5 mm. In some embodiments, none of the particles in the composition have a particle size greater than 1 mm.

[0083] The tobacco material used to form the particles of the support material may be any type of tobacco and any part of the tobacco plant, including tobacco blades, stems, stalks, ribs, crumbs and bits, or a mixture of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. The tobacco, such as dry ice expanded tobacco (DIET), may be expanded or processed by any other means. In some embodiments, the tobacco material may be a reconstituted tobacco material. The tobacco may be pre-treated or untreated, for example, solid stem (SS), shredded dried stem (SDS), steam treated stem (STS), or any combination thereof. The tobacco material may be fermented, cured, uncured, roasted, or otherwise pre-treated.

[0084] In some embodiments, the aggregated support may have an increased surface area by including particles of an inert filler material in the aggregated composition. Suitable inert fillers may be porous or non-porous.

[0085] In some embodiments, the composition to be aggregated does not include a binder or additive. In other embodiments, the composition to be aggregated includes a binder or additive. The binder additive may be selected to aid in the formation of the aggregate structure by helping to adhere the components in the composition to each other. Suitable binder additives include, for example, starch, polysaccharides, pectin, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates. Other suitable binders are discussed elsewhere herein.

[0086] In some embodiments, the support consists of or includes a heating material including one or more materials selected from the group consisting of conductive materials, magnetic materials, and magnetic conductive materials. In some embodiments, the heating material may include a metal or metal alloy. In some embodiments, the heating material may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, flat carbon steel, stainless steel, ferritic stainless steel, copper, and bronze.

[0087] In some embodiments, the heating material may be heated by induction heating, a process in which a conductive object is heated by penetrating a varying magnetic field into the conductive object. In some embodiments, the heating material may be heated by resistive heating. In such embodiments, the heating material is connected to a power source. Alternatively, the heating may be microwave heating or infrared heating.

[0088] In some embodiments, the heating material is a strip or ribbon embedded in the support. In some embodiments, the heating material is a rough surface or holes, for example in the form of a mesh or a perforated sheet. In some embodiments, the heating material is in particulate form.

[0089] In some embodiments, the heating material is in the form of a coating applied to one or more other components of the support.

[0090] An important consideration in the present invention is to balance the capture of the aerosol-generating material within the support material while still providing the aerosol-generating material in a form that can be volatilized during heating to generate the desired aerosol and / or vapor. This requires space for the aerosol-generating material, so the support needs to be sufficiently porous to provide this space. This porosity is also necessary to ensure that the aerosol and / or vapor generated by heating the aerosol-generating material can be released from the substrate. It is therefore important that the substrate has pores and channels that allow the generation and release of the aerosol and / or vapor. All of the support materials and support or substrate configurations described herein provide these.

[0091] In embodiments where the support is a sheet material, the surface roughness of the sheet contributes to the required porosity of the substrate.

[0092] Surface roughness is a component of surface texture and is generally quantified by the deviation of the direction of the normal vector of an actual surface from its ideal form. The profile roughness parameter is included in the BS EN ISO 4287:2000 British Standard, which is identical to the ISO 4287:1997 standard. One test of surface smoothness (or roughness) is the Bekk smoothness, measured by the air leak method, where the test surface is clamped between a flat glass plate and a circular metal head, and air is drawn across the surface of the test specimen under partial vacuum. The air flow rate is measured in ml / min between the paper, applicable standards are ISO 5627, Tappi T479 and DIN 53107.

[0093] In some embodiments, high "loft" materials may be particularly suitable for ensuring good aerosolization. Folding, creping, or embossing of the various sheet materials disclosed herein can provide these materials with additional loft that aids in the generation and release of aerosols from substrates formed using such support materials.

[0094] Dry aerosol-generating materials The aerosol-generating material comprises a dried extract from a flavor-containing and / or active-containing plant material. In some embodiments, the aerosol-generating material further comprises an aerosol-forming material.

[0095] In some embodiments, the aerosol-generating material is formed by drying a precursor material that includes an extract from a flavor-containing and / or active-containing plant material. The drying process is selected to preserve desired components of the precursor material, and thus the aerosol-generating material may include one or more actives and / or flavors.

[0096] In some embodiments, the precursor material further comprises one or more aerosol-forming materials. Additionally or alternatively, one or more aerosol-forming materials may be added to the dry precursor material to provide an aerosol-generating material having a desired aerosol-forming material content.

[0097] In some embodiments, the extract from the perfume-containing or active-containing plant material is an extract obtained by contacting the plant material with a suitable solvent, such as an aqueous solvent or an alcohol, such as ethanol, and the liquid portion containing the solvent and any dissolved plant components is then separated or partially separated from the remaining solid plant material to provide the extract contained in the precursor composition, which can then be dried.

[0098] Thus, the aerosol-forming material may include one or more active agents and / or flavorings, and optionally one or more aerosol-forming materials. The precursor material and / or dry aerosol-forming material may also, optionally, include one or more other functional materials.

[0099] The present invention takes advantage of aerosol-forming materials that are formulated to have a long shelf life and can therefore be easily transported and stored. Without wishing to be bound by any particular theory, it is hypothesized that the low moisture content of the dry aerosol-forming material reduces the evaporation of other solvents over time, reducing the decomposition of nicotine and / or other volatile compounds. The low moisture content also inhibits microbial growth.

[0100] Compositions including the dry aerosol-forming materials described herein are stable over a range of temperatures and humidities, providing long shelf lives and thus facilitating storage and transportation. In some embodiments, the compositions may be stored at temperatures ranging from 0 to 35° C. In some embodiments, the compositions may be stored at up to about 30%, or even 50% relative humidity prior to use.

[0101] Aerosol-generating materials also have the advantage of having a high concentration of the desired components, meaning that a relatively small amount of the aerosol-generating material is needed and less energy is needed to heat and release the desired components. Importantly, the aerosols generated from these materials also provide a reasonable intensity of authentic tobacco flavor.

[0102] A further advantage of the aerosol-forming materials is that they can be used as solid aerosol-generating substrates in hybrid systems or tobacco heating products (THPs), making the invention versatile enough for use in a variety of products without the need for further processing.

[0103] In some embodiments, the extract from flavorant- or active-containing plant material is an extract from tobacco material.

[0104] The tobacco extract or material may be from or may be any type of tobacco and any part of the tobacco plant, including tobacco blades, stems, stalks, ribs, crumbs and bits, or a mixture of two or more thereof. Suitable tobacco extracts or materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. Tobacco, such as dry ice expanded tobacco (DIET), may be expanded or processed by any other means. In some embodiments, the tobacco material may be a reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, for example, solid stem (SS), shredded dried stem (SDS), steam treated stem (STS), or any combination thereof. The tobacco material may be fermented, cured, uncured, roasted, or otherwise pre-processed. The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts / inch (about 5.9 cuts / cm, which corresponds to a cut width of about 1.7 mm). Cut rag tobacco can be formed from a mixture of tobacco material forms, such as a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco.

[0105] The precursor material that is dried to form the aerosol-forming material may comprise at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, or at least about 40% by weight tobacco solids (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 60%, up to about 55%, up to about 50%, up to about 45%, or up to about 40% by weight tobacco solids (calculated on a wet weight basis). In some embodiments, the precursor material comprises between about 20% and about 40% by weight tobacco solids (calculated on a wet weight basis).

[0106] In some embodiments, the precursor material comprises at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). Alternatively or additionally, the precursor material may comprise up to about 99% by weight, up to about 90% by weight, up to about 80% by weight, up to about 70% by weight, or up to about 60% by weight of an extract derived from tobacco or other flavor- or active-containing plant material (calculated on a wet weight basis). In some embodiments, the precursor material comprises about 50% by weight of a tobacco extract (calculated on a wet weight basis).

[0107] In some embodiments, the aerosol-forming material may comprise at least about 45%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% by weight of tobacco material or tobacco extract, or flavorant- or active-containing plant material extract (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise from about 60 to about 80% by weight of tobacco extract (calculated on a dry weight basis).

[0108] In some embodiments, the dry aerosol forming material may contain from about 2% to about 10% nicotine by weight (calculated on a dry weight basis), or from about 3% to about 6% nicotine by weight.

[0109] In some embodiments, the precursor material comprises about 50% v / v tobacco extract. When the precursor material comprises about 50% v / v tobacco extract, and the tobacco extract has a tobacco solids content of about 55 to about 60% v / v, the overall tobacco solids content of the precursor material is about 27.5 to about 30% v / v.

[0110] In some embodiments, the tobacco extract has a solids content of about 40% to about 65%, about 45% to about 65%, or about 40% to about 60% by weight (calculated on a wet weight basis). In some embodiments, the moisture content of the tobacco extract is about 35% to about 65%, or about 35% to about 55% by weight (calculated on a wet weight basis). In some embodiments, the nicotine content of the tobacco extract is about 1% to about 5% by weight (calculated on a wet weight basis).

[0111] In some embodiments, the dry aerosol-forming material may comprise at least about 45%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% tobacco solids by weight (calculated on a dry weight basis). Additionally or alternatively, the aerosol-forming material may comprise up to about 99%, up to about 98%, up to about 95%, up to about 90%, or up to about 80% by weight tobacco solids by weight. In some embodiments, the dry aerosol-forming material may comprise from about 60 to about 80% tobacco solids by weight (calculated on a dry weight basis).

[0112] In some embodiments, the tobacco extract is an aqueous tobacco extract. In some embodiments, the tobacco extract may be concentrated and then diluted before being added to the precursor material and dried. In other embodiments, the tobacco extract may not be concentrated and may be used directly to the precursor material.

[0113] The precursor material may be in the form of a slurry, suspension, gel, liquid or solid, but in some potentially preferred embodiments is in the form of a suspension or liquid, hi some embodiments, particles of solid material may be removed from the extract and / or precursor material by filtration and / or centrifugation.

[0114] In some embodiments, it may be desirable for any particles in the precursor composition to have an average particle size of about 3 mm or less, 1 mm or less, about 0.5 mm or less, or to have an average particle size of about 0.3 mm or less, as measured by sieving or by observing the size of the particles by SEM.

[0115] The water content of the precursor material can be at least about 20% by weight, at least about 30% by weight, at least about 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 70% by weight, at least about 80% by weight, or at least about 90% by weight on a wet weight basis. Alternatively or additionally, the water content of the precursor material can be up to about 95% by weight, up to about 90% by weight, up to about 85% by weight, up to about 80% by weight, up to about 75% by weight, up to about 70% by weight, up to about 65% by weight, up to about 60% by weight, up to about 55% by weight, or up to about 50% by weight on a wet weight basis. In some embodiments, the water content of the precursor material is about 40% to about 50% by weight (50% to 60% v / v%) on a wet weight basis. When the water content of the precursor material is low, the spray / freeze drying process is quicker because there is less water to remove.

[0116] In some embodiments, the dry aerosol-generating material and / or the precursor material includes one or more active agents, which may be obtained from an extract or may be added. In some embodiments, an extract from a flavored or active-containing plant material includes the active agents.

[0117] The active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0118] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0119] In some embodiments, the precursor material may include extracts from other plant source(s) along with or in place of tobacco extract.

[0120] As described herein, an extract may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Extracts may comprise or be derived from plants in the form of liquids, gases, solids, powders, dusts, crushed particles, granules, pellets, shreds, strips, sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, 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 americana, Mentha cv, Egyptian mint, Mentha piperita, Eau de cologne mint, Candy mint, Curly mint, Kentucky kernel mint, Horse mint, Pineapple mint, Pennyroyal mint, Green mentha, and Apple mint.

[0121] In some embodiments, the extract comprises or is derived from one or more plants selected from eucalyptus, star anise, cocoa, and hemp, or components, derivatives, or extracts thereof.

[0122] In some embodiments, the extract comprises or is derived from one or more plants selected from rooibos and fennel, or components, derivatives or extracts thereof.

[0123] In some embodiments, the aerosol-generating and / or precursor material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0124] The aerosol-generating material and / or precursor material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0125] The aerosol-generating material and / or precursor material may include cannabidiol (CBD).

[0126] The aerosol generating and / or precursor materials may include nicotine and cannabidiol (CBD).

[0127] The aerosol-generating and / or precursor materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0128] The aerosol-generating material further comprises an aerosol-forming material, which in some embodiments is included in the precursor material.

[0129] The aerosol-forming material may include one or more components capable of forming an aerosol. The aerosol-forming agent may be, for example, a polyol aerosol generating agent or a non-polyol aerosol generating agent. It may be a solid or liquid at room temperature, but is preferably a liquid at room temperature.

[0130] In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0131] In some embodiments, the aerosol forming agent comprises one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerin (VG), triacetin, sorbitol, and xylitol.

[0132] In some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. Glycerol provides a visible aerosol when the aerosol generating device is used. Aerosol generating devices that provide a visible aerosol are generally preferred by consumers because they allow them to visualize the product and what they are consuming. This makes glycerol a desirable choice for the aerosol-forming material. Propylene glycol has the advantage of being a better perfume carrier than glycerol.

[0133] Combinations of two or more aerosol forming agents may be used, in equal or differing proportions.

[0134] In some embodiments, the precursor material comprises at least about 1%, at least about 5%, at least about 10%, or at least about 20% by weight of aerosol-forming material (calculated on a wet weight basis). Additionally or alternatively, the precursor material may comprise up to about 40%, up to about 35%, up to about 30%, up to about 25%, up to about 20%, or up to about 10% by weight of aerosol-forming material (calculated on a wet weight basis).

[0135] In embodiments of the invention in which the aerosol-forming material is glycerol, the precursor material may contain up to 36% glycerol by weight. The inventors have demonstrated that dry weight content levels of aerosol-forming material of up to 36% by weight (calculated on a dry weight basis) are possible.

[0136] The amount of glycerol in the precursor material, and therefore in the dry aerosol material, is important because it is both an aerosol-forming material and a plasticizer. Too high a concentration of glycerol can be detrimental to the critical temperature of the product during the freeze-drying process, and can cause the product to collapse when the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide sufficient and pleasant aerosol to the consumer.

[0137] It is particularly surprising that precursor materials including glycerol and some other aerosol-forming materials can be freeze-dried because such materials are believed to have antifreeze properties. Nevertheless, the inventors have discovered that precursor materials including glycerol can be freeze-dried to form highly useful aerosol-generating materials.

[0138] In some embodiments, the dry aerosol-forming material may comprise at least about 1% by weight, at least about 5% by weight, at least about 10% by weight, at least about 20% by weight, at least about 30% by weight, or at least about 40% by weight of the aerosol-forming material (calculated on a dry weight basis).

[0139] In some embodiments, the dry aerosol-forming material may comprise from about 1 to about 34% by weight or from about 17 to about 34% by weight of the aerosol-forming material (calculated on a dry weight basis). In some embodiments where the aerosol-forming material is glycerol, the dry aerosol-forming material may comprise from about 13 to about 34% by weight of glycerol (calculated on a dry weight basis).

[0140] In embodiments in which burley tobacco is used, the aerosol-forming material may include about 17 to about 36% by weight glycerol. The amount of glycerol in the aerosol material is important as it is both an aerosol-forming material and a plasticizer. If the concentration of glycerol is too high, it may be detrimental to the critical temperature of the product during the freeze-drying process and may result in the collapse of the product if the critical temperature of the formulation is exceeded. On the other hand, sufficient glycerol should be included to provide a sufficient and pleasant aerosol to the consumer.

[0141] In some embodiments, the aerosol-generating material and / or the precursor material further comprises one or more excipients. In some embodiments, the excipients stabilize and preserve the precursor material, and the inventors have found that the inclusion of an excipient is particularly important for stability when the precursor material comprises glycerol as the aerosol-forming material. The excipients may also act as bulking or filler materials. In some embodiments, the inclusion of an excipient may also improve the handling properties of the dry aerosol-generating material and help the dry aerosol-generating material retain its granular morphology by helping to reduce moisture uptake and increase the resulting cohesiveness of the material. The presence of an excipient may also affect the rate of (freeze) drying.

[0142] Suitable excipients include mannitol, sucrose, trehalose, lactose, sorbitol, raffinose, maltose, dextrans such as dextran 10, dextran 70, dextran 90, maltodextrin, gelatin, agar, cyclodextrin, and polyethylene glycols such as PEG 2000-6000 and polyvinylpyrrolidone (PVP10).

[0143] In some embodiments, the aerosol-forming material and / or precursor material includes one or more excipients in an amount of 0 to about 40% by weight on a wet weight basis, hi some embodiments, the precursor material may include at least about 1%, at least about 10%, at least about 20%, at least about 30%, and / or up to about 40%, up to about 30%, up to about 20%, or up to about 10% by weight of excipients on a wet weight basis.

[0144] In some embodiments, the aerosol-forming material may comprise at least about 0.1%, at least about 10%, at least about 20%, or at least about 25% by weight of excipients (calculated on a dry weight basis). In some embodiments, the aerosol-forming material may comprise up to about 25%, up to about 20%, up to about 15%, or up to about 10% by weight of excipients (calculated on a dry weight basis).

[0145] In an exemplary embodiment, the aerosol-forming material includes, on a dry weight basis, about 36% glycerol, about 45% tobacco extract, and about 19% excipients.

[0146] In another exemplary embodiment, the aerosol-forming material comprises, on a dry weight basis, from about 17 to about 39% glycerol, from about 41 to about 76% tobacco extract, and from 0 to about 28% excipients.

[0147] In embodiments where the excipient is agar, the precursor material may comprise about 0%, about 5%, or about 10% by weight of agar. The inventors have found that when the precursor material comprises a lower concentration of the agar excipient, the agar makes the precursor material more viscous and the freeze-drying process is easier.

[0148] In some embodiments, the precursor material comprises about 50% by weight tobacco extract, 0 to about 36% by weight aerosol forming agent (e.g., 0 to about 15% v / v), and 0 to about 40% by weight excipients (e.g., about 37.5% v / v). The tobacco extract may comprise about 55% by weight tobacco solids, with the total tobacco solids content of the precursor material being about 27.5% by weight.

[0149] Some sample formulations of dry aerosol-forming materials formed from aqueous tobacco extracts are summarized in Table 1 below, with amounts provided on a dry weight basis. These are theoretical values ​​(before drying and inherent losses). Typically, about 80-89% of the glycerol is retained after drying. Glycerol may be used as the aerosol-forming material, but may be replaced or partially replaced with one or more other aerosol-forming materials, such as those disclosed herein. The excipient used may be dextran, e.g., dextran 70. Again, this may be replaced or partially replaced with alternative excipients, such as those disclosed herein.

[0150] [Table 1]

[0151] The nicotine content in the formulation depends on the type of tobacco used and the presence of other components, namely aerosol formers and excipients.

[0152] In some embodiments, the aerosol-forming material comprises one or more binders, hi some embodiments, the one or more binders are selected from the group consisting of thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, cellulose, cellulose derivatives such as carboxymethylcellulose, and alginates.

[0153] In some embodiments, the amount of binder used to adhere the aerosol-forming material to the substrate is about 1 to about 30% by weight, based on the weight of the aerosol-forming material. In some embodiments, the amount of binder used is up to about 20%, up to about 15%, up to about 10% by weight of the aerosol-forming material. Additionally or alternatively, the amount of binder, if used, may be at least about 1%, at least about 2%, at least about 5%, or at least about 8% by weight of the aerosol-forming material.

[0154] In some embodiments, the aerosol-generating and / or precursor materials include one or more flavor modifiers, flavors, or flavorings, which may be derived from extracts or may be added. As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in a product intended for adult consumers.They may be any naturally occurring flavoring material, botanical substance, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, 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, eggplant, betel quid, 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, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne , marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic, or natural origin, or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0155] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0156] In some embodiments, the fragrance may include a sensory elicitor, which is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce a heating, cooling, tingling, or 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, eucalyptol, WS-3.

[0157] In some embodiments, the aerosol-generating material and / or the precursor material include one or more other functional materials, which may include one or more of a pH adjuster, a colorant, a preservative, a filler, a stabilizer, and / or an antioxidant.

[0158] In some embodiments, the aerosol-forming material and / or the precursor material contains a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived raw materials. In some embodiments, the precursor material contains less than 60% filler by weight, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight on a wet weight basis.

[0159] When present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also include one or more organic filler materials such as wood pulp, hemp fiber, cellulose and cellulose derivatives.

[0160] In some embodiments, the dry aerosol-forming material is in the form of a gel. A gelling agent may be added to the aerosol-forming material, the precursor material, or may be optionally omitted. The gelling agent includes one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0161] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0162] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0163] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0164] The aerosol-generating material and / or the precursor material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid, and a triprotic acid. In some such embodiments, the acid may contain 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.

[0165] 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. In some embodiments, the acid is selected from one of lactic acid, benzoic acid, and levulinic acid.

[0166] 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.

[0167] The inclusion of an acid can be beneficial in embodiments in which the aerosol-generating material and / or precursor material includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-generating material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

[0168] In certain embodiments, the aerosol forming material comprises a gelling agent comprising a cellulosic and / or non-cellulosic gelling agent, an active agent, and an acid.

[0169] The dry aerosol-generating material may be in any solid form. For example, the aerosol-generating material may be in the form of particles, granules, or powder. The aerosol-generating material may be in monolithic form, tablet, agglomerate, or "cake" form. In some embodiments, the aerosol-generating material is formed by freeze-drying or spray-drying, and then processed as necessary by other suitable steps known to those skilled in the art to provide the dry material in the desired form, e.g., in the form of particles of the desired size(s).

[0170] In some embodiments, the aerosol-generating material is in the form of particles or granules. The granules can be of any size, cross-sectional shape, or mass. Aerosol-generating materials in the form of granules are advantageous due to their high surface area to volume ratio, which positively impacts the release of volatile substances from the material. This form also facilitates the incorporation of the material into an aerosol delivery system.

[0171] Smaller granule particles have a greater surface area to volume ratio and therefore may exhibit enhanced release of tobacco constituents compared to larger sized particles. They also have a greater tendency to adhere to surfaces, such as the rough surface of a substrate.

[0172] In some embodiments, the particles in the precursor composition have an average particle size of about 3 mm or less, 1 mm or less, 500 μm or less, about 200 μm or less, 100 μm or less, about 50 μm or less, 40 μm or less, about 30 μm or less, 20 μm or less, about 10 μm or less, about 5 μm or less, or desirably have an average particle size of about 1 μm or less, as measured by sieving.

[0173] In some embodiments, the average particle size is in the range of about 0.1 μm to about 1 mm, about 0.1 μm to about 500 μm, about 10 μm to about 200 μm, about 10 μm to about 100 μm, or about 10 μm to about 50 μm. In some embodiments, at least about 90% of the particles of the precursor composition have a particle size in the range of about 1 μm to about 1 mm, or about 10 to about 500 μm, or about 50 to about 200 μm. In some embodiments, at least about 90% of the tobacco particles of the precursor composition have a particle size in the range of about 1 μm to about 1 mm, or about 10 to about 500 μm, or about 50 to about 200 μm. In some embodiments, none of the particles in the precursor composition have a particle size greater than 1 mm, greater than 0.5 mm, greater than 0.2 mm, greater than 0.15 mm, or greater than about 0.1 mm. In some embodiments, the average particle size is less than 50 μm.

[0174] When preparing the dried precursor composition, the particle size of any solid material present can be reduced by grinding, shredding, cutting or crushing the tobacco material. Suitable machines for making such plant particles include, for example, shredders, cutters, or mills, such as hammer mills, roller mills or other types of commercially available milling machines. The size of the plant particles is selected to result in particles that can be readily prepared from a variety of different types of plant material having the characteristics described herein and that provide a source of readily releasable plant components.

[0175] Smaller size particles of the aerosol-generating material may be advantageous for aerosol generation. Without wishing to be bound by any particular theory, smaller particles may have a larger surface area to volume ratio, which may improve aerosol generation. In some embodiments, the dry aerosol-generating material readily forms particles having an average size of less than 1 mm. In some embodiments, the particles may be as small as 10 μm, or as small as 1 μm. The size of the particles may be determined by sieving or by observing the particles with a SEM.

[0176] In the context of the present invention, smaller particles of solid aerosol-generating material may be preferred. Particle adhesion between a particle and a surface or between particles involves a variety of different forces, including van der Waals forces, diffusion, mechanical interactions, and electrostatic attraction. At least some of these forces are generally stronger the greater the surface energy of the particle, which is related to the size of the particle. In essence, smaller particles tend to be more "sticky". Thus, in some embodiments, the particles of the aerosol-generating material have a particle size of 50 μm or less, 40 μm or less, 30 μm or less, 20 μm or less, or 10 μm or less. Such small particle sizes also mean that the rough surface of the support does not need to have large pores or irregularities to accommodate particles of such dimensions.

[0177] In some embodiments, the lyophilized precursor material can be ground into particles and sieved to remove particles that are deemed too small or too large for use as an aerosol generating material.

[0178] In some embodiments, the aerosol-generating material used in the present invention has a particle size distribution D10 of about 5 to about 25 μm (meaning that 10% of the particles in the test sample are smaller than the value), a particle size distribution D50 of about 30 to about 200 μm (meaning that 50% of the particles in the test sample are smaller than the value), and a particle size distribution D90 of about 500 to about 2500 μm (meaning that 90% of the particles in the test sample are smaller than the value). These values ​​are determined using a particle size analyzer, Microtrac CamSizer® X2. The percentages referred to herein are volume percentages.

[0179] In some embodiments, the lyophilized material used as an aerosol generating material according to the present invention has a particle size distribution, D10, of about 8 to about 15 μm, a particle size distribution, D50, of about 50 to about 150 μm, and a particle size distribution, D90, of about 900 to about 1700 μm.

[0180] In some embodiments, the D10 average is from about 10 to about 15 μm, the D50 average is from about 40 to about 140 μm, and the D90 average is from about 800 to about 1600 μm.

[0181] Spray drying and freeze drying The drying method used to dry the precursor material can be any suitable drying process, including freeze-drying or spray-drying processes. The drying process used must be compatible with the desired composition of the precursor material and the aerosol-forming material. Because it may be desirable for the aerosol-forming material to contain actives and / or flavorings from extracts in the precursor material, it is important to select a drying method that retains sufficient amounts of these components.

[0182] In a small scale example, the precursor material is freeze-dried using a freeze-drying microscope, for example a Lyostat freeze-drying microscope.

[0183] In the spray drying process, precursor material is atomized and dried rapidly using hot gas. The use of spray drying provides several advantages to the present invention, such as the dried particle size can be controlled and consistent, tobacco or flavor extracts or materials are heat sensitive but can still be spray dried at relatively high inlet temperatures, short residence times are required in the spray drying equipment, and loss of flavor / volatiles is minimal. This makes the process adaptable to reduce loss of volatile compounds and maintain the desired flavor of the aerosol-generating material.

[0184] Lyophilization, also known as cryodesication, is a process in which precursor materials are frozen, the temperature is reduced, and water is removed by sublimation under reduced pressure conditions. Without wishing to be bound by any particular theory, it is believed that the low processing temperature and rapid water loss by sublimation avoids changes in the structure, appearance and properties of the aerosol-forming material. This process preserves the structure of the precursor materials and reduces the loss and decomposition of volatile flavor compounds.

[0185] The dry aerosol-forming material has a lower water content than the precursor material. The water content of the aerosol-forming material may be up to about 0.5%, about 1%, about 2%, about 5%, about 10%, or about 20% by weight (calculated on a wet weight basis). The water content of the dry aerosol-forming material may be reduced by at least about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, about 98%, or about 100% by weight from the precursor material. In some embodiments, the dry aerosol-forming material has a water content of less than about 5%, less than about 4%, less than about 3%, less than about 2%, or less than about 1% by weight (calculated on a wet weight basis) as measured by gas chromatography-thermal conductivity detector (GC-TCD) or Karl Fischer titration.

[0186] In an exemplary embodiment of the invention, the precursor material comprises Burley tobacco extract and has a moisture content of 60% by weight. After the freeze-drying operation described herein, the dry aerosol-forming material has a moisture content of 3% by weight.

[0187] A lower moisture content of the dry aerosol-generating material is associated with shelf life and stability. However, a very low moisture content may be associated with a brittle structure and smaller particle size, as well as longer processing times. The material is also very hygroscopic. On the other hand, if the moisture content of the dry aerosol-generating material is too high, the desired stability improvement may not be achieved. The dry aerosol-generating material is also not easy to handle at higher moisture contents, and the material may become sticky.

[0188] The inventors have found that when a precursor material includes an excipient, the precursor material may be more suitable for drying by spray drying (compared to a precursor material that does not include an excipient). Without wishing to be bound by any particular theory, it is speculated that increasing the amount of excipient in the precursor material increases the glass transition temperature above 100° C., which affects the physical properties of the material making it more suitable for spray drying.

[0189] Use of the composition Substrates comprising aerosol-forming materials and supports can be used in combustion or non-combustion aerosol delivery systems, or in aerosol-free delivery systems.

[0190] The present invention also relates to a consumable or article that includes an aerosol-forming material surrounded by a support.

[0191] In some embodiments, the substrate is provided in a consumable product. Alternatively, the substrate may be used as a consumable product.

[0192] A consumable is an article that includes an aerosol-generating material, where some or all of the aerosol-generating material is intended to be consumed during use by a user, where the aerosol-generating material, or at least a portion of the aerosol-generating material, is provided as part of a substrate disclosed herein that includes an aerosol-generating material and a support.

[0193] The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. As discussed above, at least some of these components of the consumable may be components of the substrate described herein.

[0194] The consumable may be of any shape or size suitable for the aerosol generating device. In some embodiments, the consumable is rod-shaped. In other embodiments, it may take the form of a flat strip, a tube, a disk, or a flexible sleeve.

[0195] In some embodiments, the substrate comprising the aerosol-generating material and the support is provided in an aerosol-generating device, such as a tobacco heating product (THP) or a hybrid e-cigarette product. Suitably, the substrate can be directly heated without combustion to provide an inhalable aerosol. In some embodiments, heating the substrate first decomposes the coating, breaking the barrier formed around the aerosol-generating material. The aerosolized components of the aerosol-generating material, such as glycerol, nicotine, and / or tobacco flavorings, are then released.

[0196] In some embodiments, the substrate including the aerosol-forming material and support may be incorporated into a consumable product without any other carrier or other materials that need to be heated.

[0197] In other embodiments, the substrate comprises multiple layers, for example in the form of a laminate. For example, the substrate may comprise alternating layers of support material and aerosol-forming material. In some embodiments, further layers of different materials, such as further layers of different aerosol-forming materials, or layers comprising aerosol modifiers, such as fragrances, may be included.

[0198] In some embodiments, the consumable includes a moisture impermeable coating that surrounds the aerosol-forming material, but may be separate from the aerosol-forming material. For example, the moisture impermeable coating may surround the substrate (thereby surrounding the aerosol-forming material within the composition). In some embodiments, the moisture impermeable coating may be provided as a film or wrapper, and may optionally be deposited on a moisture permeable carrier.

[0199] In some embodiments, the consumable includes a sorbent or desiccant material. As mentioned above, the sorbent or desiccant material can be provided in the substrate. Alternatively, these components may be provided separately in the consumable, but in such a way that the sorbent still competes with the aerosol-generating material for moisture in the environment, thus reducing the amount of moisture absorbed by the aerosol-generating material. In some embodiments, the sorbent may be provided in or on a wrapper that surrounds the aerosol-generating material in the consumable. In other embodiments, the sorbent may be incorporated in a separate section of the consumable relative to the aerosol-generating material. This may have the advantage of reducing the exposure of the sorbent to the high temperatures to which the aerosol-generating material is heated during use. For example, the sorbent may be located in an adjacent section of the consumable that is not directly heated. This may be downstream or upstream of the aerosol-generating material. In some embodiments, the sorbent is included in one or more sections of the consumable that do not include the aerosol-generating material, such as a cooling element section or a filter section.

[0200] In yet another embodiment, the sorbent may be separated or removed from the aerosol-generating material and / or consumable prior to use. For example, the sorbent may be disposed within the packaging in which the consumable is held prior to use. In some embodiments, the packaging may be a wrapper, box, or other container. The sorbent may be incorporated into the packaging material or part thereof. Alternatively, the sorbent may be provided in a separate article, such as a sachet or sheet, that is placed with the consumable within the packaging.

[0201] Delivery System The delivery systems described herein can be combustion aerosol delivery systems, non-combustion aerosol delivery systems, or aerosol-free delivery systems.

[0202] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or hand-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; and An aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snus or moist snuff, where the at least one substance may or may not contain nicotine. Includes.

[0203] According to the present disclosure, a "combustion-based" aerosol delivery system is a system in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0204] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0205] In some embodiments, the present disclosure relates to components for use in combustion aerosol delivery systems, for example, aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads or beads, or papers such as plug wrap, tipping paper or cigarette paper.

[0206] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0207] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0208] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0209] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0210] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated and provided on a support. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0211] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0212] In some embodiments, the present disclosure relates to consumables that include a substrate that includes an aerosol-generating material and a support and is configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0213] In some embodiments, the non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to a substrate that includes the aerosol-generating material and the support or a heat transfer material in proximity to the heat generating power source.

[0214] In some embodiments, the non-combustion aerosol delivery system may include a receiving region, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0215] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include a substrate comprising an aerosol-generating material and a support, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0216] 3 is a side cross-sectional view of a consumable or article 10 for use in an aerosol delivery system. Article 10 comprises a mouthpiece segment 11 and an aerosol generation segment 12.

[0217] The aerosol-generating segment 12 is in the form of a cylindrical rod and includes a substrate 14. In one embodiment, the substrate includes an extruded rod formed by extruding a mixture of a support material, such as tobacco particles, and particles of an aerosol-generating material. In other embodiments, the substrate 14 is a substrate such as those shown in either of Figures 1 and 2. In general, the substrate 14 can be any of the substrates including aerosol-generating materials and supports discussed herein.

[0218] Although described above in the form of a rod, the aerosol-generation segment 12 may be provided in other forms.

[0219] The tipping segment 11 in the illustrated embodiment includes a body of material 15, such as a fibrous plug or filamentary tow. Disposed between the aerosol-generation segment 12 and the tipping segment 11 is a cooling section 13 that includes a hollow tube 16 formed from a suitable material, such as cellulose acetate, paper, or a heat absorbing material.

[0220] The consumable 10 further comprises a wrapper 17 , such as a paper wrapper, that circumscribes the mouthpiece segment 11 , the cooling section 13 , and the aerosol-generation segment 12 .

[0221] 4 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as a composition of a consumable product 110, as described herein. Generally, device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as article 10 shown in FIG. 3 or described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0222] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 in one end through which an item 110 can be inserted for heating by a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly where it can be heated by one or more components of the heater assembly.

[0223] The device 100 in this example includes a first end member 106 that includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Figure 4, the lid 108 is shown in an open configuration, but the lid 108 may be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "B."

[0224] Device 100 may also include user-operable controls 112, such as buttons or switches that, when pressed, operate device 100. For example, a user may turn device 100 on by operating switch 112.

[0225] The device 100 may also include an electrical component, such as a socket / port 114 that can accept a cable for charging a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0226] In some embodiments, the substance to be delivered may be a substrate aerosol-generating material as described herein, and optionally another aerosol-generating material that may or may not be heated. If desired, the substrate and other aerosol-generating materials may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0227] stability The present invention enjoys the advantage of a longer shelf life than other tobacco extracts.

[0228] The nicotine content of the precursor and aerosol-forming materials after the freeze-drying process is calculated, indicating the amount of nicotine retained after processing. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract is at least about 76% by weight on a dry weight basis. The nicotine recovery of the dried aerosol-forming material compared to the original tobacco extract may be at least about 60%, at least about 70%, at least about 75%, at least about 80%, or at least about 90% by weight on a dry weight basis.

[0229] The glycerol content of the precursor and dry aerosol generating material after the freeze-drying process is calculated to indicate the amount of glycerol retained after processing. The glycerol recovery of the dry aerosol generating material compared to the precursor material is at least about 85%. The glycerol recovery of the dry aerosol generating material compared to the precursor material can be at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90% or at least about 95% on a dry weight basis.

[0230] Furthermore, when surrounded by a moisture impermeable coating, the content of volatile ingredients such as nicotine and flavorings, as well as the content of aerosol-forming materials in the aerosol-forming material, is maintained until the composition is heated to generate an aerosol, even in the absence of packaging or other protection from exposure to moisture.

[0231] Example 1 In a first test, the precursor material consisted essentially of an aqueous tobacco extract and glycerol. The aqueous tobacco extract was further diluted with glycerol to about 24% by weight (calculated on a dry weight basis). The aqueous burley tobacco extract had a tobacco solids content of about 40% by weight and a moisture content of about 60% by weight. The precursor material was dried by freeze drying.

[0232] Example 2 In further tests, the precursor material consisted essentially of aqueous tobacco extract, glycerol and dextran 70. The glycerol content was from about 0 to about 15% v / v, or up to about 36% by weight, calculated on a dry weight basis. The precursor material was dried by lyophilization.

[0233] Example 3 The freeze-dried aerosol-generating material of Example 1 or Example 2 is ground to obtain a loose powder having an average size of about 10 μm to about 50 μm. 50 mg of the powder is then applied to the surface of a substrate comprising a sheet of paper having a porous surface texture. The particles of the aerosol-generating material easily fit into the pores and form rods that are incorporated into the consumable. The rolled sheet holds the particles of the aerosol-generating material between layers of substrate material such that the aerosol-generating material is surrounded by the substrate. A significant proportion of the particles remain in place when the substrate is packaged and shipped.

[0234] Example 4 The freeze-dried aerosol-generating material of Example 1 or Example 2 is ground to obtain a loose powder having an average size of about 500 μm to about 1000 μm. Once the fibrous cellulose acetate tow is collected and formed into a cylindrical plug, powdered aerosol-generating material is added so as to be embedded in and distributed throughout the support material to form a matrix.

[0235] Example 5 The freeze-dried aerosol-generating material of Example 1 or Example 2 is ground to obtain a loose powder having an average size of about 10 μm to about 50 μm. 200 mg of the powder is then added during the manufacture of a sheet of airlaid paper such that the particles of the aerosol-generating material are embedded within the structure of the airlaid sheet. The airlaid paper sheet is then covered with an aluminum foil sheet, which acts as a susceptor. The two sheet payers are then rolled to form a rod containing the support material, the aerosol-generating material, and the heating material. The particles of the aerosol-generating material are surrounded by a first support (the airlaid paper) and a second support (the sheet of heating material), which protect and hold the aerosol-generating material in place.

[0236] Example 6 The freeze-dried aerosol-generating material of Example 1 or Example 2, particles of tobacco material, and particles of metal heating material are co-extruded to form a solid mass that is cut to a desired size and used in a consumable as an aerosol-generating substrate.

[0237] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A substrate comprising an aerosol-generating material surrounded by a support, wherein the aerosol-generating material comprises a dried precursor material containing an extract derived from a fragrance-containing and / or active-containing plant material.

2. The substrate according to claim 1, wherein the support comprises a sheet, and the aerosol generating material is sandwiched between one or more of the sheets.

3. The substrate according to claim 2, wherein the sheet comprises one or more selected from the group consisting of paper, cardboard, thick paper, recycled materials, plastic materials, ceramic materials, activated carbon, glass, sintered materials, composite materials, plant-derived materials, fabric or fleece, fibrous tow, metals, and metal alloys.

4. The substrate according to claim 2 or 3, wherein the substrate has a roll-like structure.

5. The substrate according to claim 1, wherein the aerosol generating material is distributed within the support.

6. The substrate according to claim 5, wherein the support is a porous material in which the aerosol-generating material is distributed within the pores.

7. The substrate according to claim 6, wherein the support is a fibrous material.

8. The substrate according to claim 7, wherein the fibrous material is selected from the group consisting of fibrous tow, nonwoven sheet, porous paper, and fabric or fleece.

9. The substrate according to claim 5, wherein the support comprises an aggregate material.

10. The substrate according to claim 9, wherein the substrate is an extruded mixture of the support and the aerosol generating material.

11. The substrate according to claim 9 or 10, wherein the support comprises tobacco material.

12. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the support comprises a heating material.

13. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the substrate does not contain a binder applied to adhere the aerosol generating material to the support.

14. The substrate according to any one of claims 1 to 3, 5 to 10, wherein a binder is included in an amount of about 0.1% to about 5% by weight, based on the total weight of the aerosol generating material, for bonding the aerosol generating material to the support.

15. The substrate according to claim 14, wherein the binder is selected from the group consisting of a thermoreversible gelling agent, starch, polysaccharides, pectin, cellulose, cellulose derivatives, and alginate.

16. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the aerosol generating material further comprises an aerosol forming material.

17. The base material according to any one of claims 1 to 3, 5 to 10, wherein the precursor material comprises an extract derived from a plant material containing fragrance or active ingredients in an amount of about 10 to about 95% by weight.

18. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the precursor material comprises about 1 to about 36% by weight of an aerosol-forming material.

19. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the precursor material comprises 0 to about 40% by weight of an excipient.

20. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the aerosol generating material comprises about 45 to about 99% by weight of a dried extract derived from the fragrance-containing or active plant material.

21. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the aerosol generating material comprises about 1 to about 34% by weight of an aerosol forming material.

22. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the aerosol generating material comprises 0 to about 25% by weight of an excipient.

23. The base material according to any one of claims 1 to 3, 5 to 10, wherein the plant material is selected from the group consisting of tobacco, eucalyptus, star anise, cocoa, and hemp.

24. The base material according to any one of claims 1 to 3, 5 to 10, wherein the extract derived from the fragrance-containing or active plant material is an aqueous extract.

25. The base material according to any one of claims 1 to 3, 5 to 10, wherein the extract derived from the fragrance-containing or active plant material is an aqueous tobacco extract.

26. The substrate according to any one of claims 1 to 3, 5 to 10, wherein the aerosol generating material has a water content of about 5% or less (calculated on a wet weight basis).

27. A substrate according to any one of claims 1 to 3, 5 to 10, comprising an impermeable coating surrounding the aerosol generating material.

28. A substrate according to any one of claims 1 to 3, 5 to 10, comprising an adsorbent material.

29. A substrate according to any one of claims 1 to 3, 5 to 10, for use in an aerosol supply system.

30. An article comprising an aerosol-generating material surrounded by a support, wherein the aerosol-generating material comprises a dried precursor material containing an extract derived from a fragrance-containing and / or active-containing plant material.

31. The article according to claim 30, comprising the base material according to claim 1.

32. The article according to claim 30, comprising means for preventing or reducing the absorption of moisture by the dry aerosol-generating material.

33. The article according to claim 32, wherein the means is provided separately from the aerosol generating material and / or substrate.

34. The article according to claim 33, wherein the means includes a film or wrapper containing an impermeable coating or an adsorbent or desiccant material.

35. A non-combustible aerosol supply system comprising a substrate according to any one of claims 1 to 3 or 5 to 10, or an article according to any one of claims 30 to 34.

36. A precursor material containing an extract derived from a fragrance-containing and / or active plant material and an aerosol-forming material is dried to form an aerosol-generating material, The aerosol-generating material is trapped within the support, A method for providing a substrate, including the above.

37. The method according to claim 36, wherein the aerosol generating material is sandwiched between two layers of a support material.

38. The method according to claim 37, wherein the aerosol-generating material sandwiched between two layers of a support material is wound.

39. The method according to claim 38, wherein the aerosol generating material is sandwiched between two layers of a support material and wound into the form of a hollow cylinder.

40. The method according to any one of claims 37 to 39, wherein a binder is added to one or more of the aerosol-generating material and the support before the aerosol-generating material is sandwiched between layers of the support material.

41. The method according to claim 36, wherein the aerosol generating material is distributed within a fibrous support material.

42. The method according to claim 36, comprising extruding a mixture of the aerosol generating material and the support material.

43. The method according to any one of claims 36 to 39, 41, or 42, wherein the precursor material is dried by spray drying or freeze-drying.

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