Sheet coated with tobacco and consumables made therefrom

Abstract

The present disclosure provides an aerosol generating material in the form of a sheet. The aerosol generating material includes one or more binders and / or foaming agents, a filler, an aerosol forming agent material, and a tobacco material embedded in the sheet or adhered to the surface of the sheet. Further, a method of preparing the aerosol generating material is provided. The aerosol generating material can be configured to be used in an aerosol generating element for an aerosol delivery device. An aerosol delivery device including the aerosol generating element and the aerosol generating material is also provided. Such a device utilizes electrically generated heat or a combustible ignition source to heat the aerosol generating material and provide an inhalable substance in the form of an aerosol.

Description

Technical Field

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 353,160, filed Jun. 17, 2022, and U.S. Provisional Application No. 63 / 442,237, filed Jan. 31, 2023, each of which is hereby incorporated by reference in its entirety for all purposes.

[0002] The present disclosure relates to an aerosol-generating element containing an aerosol-generating material and a method of making the same. The present disclosure further relates to a consumable used within a combustible or non-combustible aerosol-providing system, a consumable containing an aerosol-generating element, and non-combustible and combustible aerosol-providing systems.

Background Art

[0003] Smoking articles such as cigarettes, cigars, and the like combust tobacco during use to create tobacco smoke. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a base material by heating without combustion. These may be referred to as non-combustible smoking articles, aerosol-generating assemblies, or non-combustible aerosol-providing systems. An example of such a product is a heating device that releases compounds by heating rather than combusting a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain tobacco material. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heated (non-combustion) devices, tobacco heating devices, or tobacco heating products (THPs). Various arrangements for volatilizing at least one component of a solid aerosolizable material are known.

[0004] As another example, there are hybrid devices of electronic cigarettes / tobacco heating products, which are also known as hybrid devices of electronic cigarette devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. These devices further contain a solid aerosolizable material (which may or may not contain tobacco material), and the components of this material are entrained in an inhalable vapor or aerosol to produce an inhalation medium.

[0005] Such certain tobacco heating products and hybrid devices of electronic cigarette devices have issues with inconsistent performance characteristics. For example, some articles have issues with inconsistent release of inhalable materials, improper feeding of the aerosol-forming material of the substrate, or insufficient sensory characteristics. Therefore, it may be desirable to provide a non-combustible smoking article that can provide the sensation of smoking a cigarette, a cigar, or a pipe without burning the substrate material and with advantageous performance characteristics. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0006] (SUMMARY OF THE INVENTION) The present disclosure relates to an aerosol generating element and an aerosol delivery device that utilize electrically generated heat or a combustible ignition source to heat an aerosol generating material to provide a substance inhalable in the form of an aerosol for human consumption.

[0007] An aerosol generating element in the form of a sheet has a preferred filling capacity that surpasses similar cast sheet technologies. However, previous attempts to impart tobacco characteristics by mixing milled tobacco into a foaming slurry to prepare a sheet containing tobacco had an adverse effect on the density of the foamed sheet. Surprisingly, it has been found according to the present disclosure that by top-feeding tobacco pieces onto the sheet, the desired tobacco characteristics are provided to the aerosol generating material while maintaining the desired filling capacity. Without being bound by theory, the addition of tobacco material onto / into the sheet may enhance the tobacco flavor by direct contact between the tobacco material and the aerosol forming agent material present in the foamed sheet, and thus may deliver better tobacco characteristics during the smoking operation. The disclosed aerosol forming material further has desirable properties, such as 1) immobilizing the tobacco material and preventing the fall of the tobacco material from the consumable containing the disclosed aerosol forming material even with a very low tobacco rod weight; 2) adding thickness from foaming to the sheet and depositing irregularly shaped tobacco pieces; 3) simplifying the design of the consumable by utilizing a single base material; 4) opportunities to adjust / optimize flavor and user satisfaction through the selection of tobacco types; and 5) opportunities to adjust / optimize physical parameters of the user's device such as pressure drop.

Means for Solving the Problems

[0008] Thus, in one aspect, the present disclosure provides an aerosol generating material in the form of a sheet having a surface and being either foamed or unfoamed, the aerosol generating material comprising (i) one or more binders and / or foaming agents; (ii) a filler; (iii) an aerosol forming agent material; and (iv) a tobacco material embedded in the sheet or adhered to the surface of the sheet is provided.

[0009] In some embodiments, the sheet is foamed, and the foamed sheet contains one or more foaming agents. In some embodiments, the aerosol generating material further contains about 1 to about 6 wt% of a foam stabilizer. In some embodiments, the foam stabilizer contains one or more surfactants or emulsifiers. In some embodiments, the foam stabilizer contains sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

[0010] In some embodiments, the aerosol generating material further contains a foaming agent. In some embodiments, the foaming agent contains calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminum sulfate, or a combination thereof.

[0011] In some embodiments, the aerosol generating material contains about 5 to about 35 wt% of a foaming agent. In some embodiments, the foaming agent contains hydroxypropyl methylcellulose (HPMC), gum, modified starch, maltodextrin, or a combination thereof. In some embodiments, the foaming agent contains HPMC.

[0012] In some embodiments, the sheet is not foamed, and the aerosol generating material contains one or more binders. In some embodiments, the one or more binders contain carboxymethyl cellulose, alginate, natural gum, or a combination thereof.

[0013] In some embodiments, the aerosol generating material contains about 10 to about 85 wt% of a filler. In some embodiments, the filler contains wood pulp, microcrystalline cellulose, or a combination thereof.

[0014] In some embodiments, the aerosol generating material contains about 20 to about 30 wt% of an aerosol forming agent material.

[0015] In some embodiments, the aerosol-forming agent material comprises glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or combinations thereof. In some embodiments, the aerosol-forming agent material is glycerol, propylene glycol, or a combination thereof.

[0016] In some embodiments, the sheet has a density in the range of about 0.02 g / cm 3 to about 0.7 g / cm 3 . In some embodiments, the aerosol-generating material has a fill value, determined by the formula: Fill value = (bulk volume / weight) × 100; (wherein the bulk volume is determined using a densitometer). greater than about 380 g / cm 3 . In some embodiments, the aerosol-generating material has a porosity of about 100 seconds / 100 ml or more, determined using a Gurley densitometer.

[0017] In some embodiments, the tobacco material embedded in or adhered to the surface of the sheet is granular or fibrous tobacco. In some embodiments, the tobacco material embedded in or adhered to the surface of the sheet has a width in the range of about 1 to about 2 mm and a length of up to about 3 mm. In some embodiments, the tobacco material embedded in or adhered to the surface of the sheet, the granular tobacco material, is powdered tobacco.

[0018] In some embodiments, the aerosol-generating material is in laminate form.

[0019] In some embodiments, the aerosol - generating material further comprises a top - coat of a film - forming agent that is disposed on the surface of the sheet, coats the tobacco material embedded in the sheet or adhered to the surface of the sheet. In some embodiments, the film - forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, monoglyceride, diglyceride, triethyl citrate, and combinations thereof. In some embodiments, the film - forming agent is hydroxypropyl methylcellulose. In some embodiments, the film - forming agent is a combination of hydroxypropyl cellulose, monoglyceride, diglyceride, and triethyl citrate.

[0020] In another aspect, there is provided an aerosol - generating element comprising the aerosol - generating material disclosed herein.

[0021] In some embodiments, the aerosol - generating element comprises from about 10% to about 100% by weight of the aerosol - generating material.

[0022] In some embodiments, the aerosol - generating material is in the form of a corrugated sheet. In some embodiments, the corrugated sheet is crimped and gathered into a cylindrical rod, and the aerosol - generating element further comprises a wrapping material surrounding the rod.

[0023] In some embodiments, the aerosol - generating material is in the form of a shredded sheet. In some embodiments, the shredded sheet is blended with additional tobacco material having different properties from the tobacco material embedded in or adhered to the surface of the sheet. In some embodiments, the additional tobacco material comprises reconstituted tobacco, tobacco laminar, fine - cut tobacco, cut - rag tobacco, or combinations thereof.

[0024] In yet another aspect, there is provided a consumable for use in a non - combustible aerosol - providing device and comprising the aerosol - generating element disclosed herein.

[0025] In yet another aspect, there is provided a non-flammable aerosol providing system including a consumable and a non-flammable aerosol providing device disclosed herein, wherein the non-flammable aerosol providing device includes an aerosol generating device configured to generate an aerosol from the consumable when the consumable is used with the non-flammable aerosol providing device.

[0026] In yet another aspect, there is provided a flammable aerosol providing system including a consumable and a flammable aerosol providing device disclosed herein.

[0027] In another aspect, there is provided a method of forming an aerosol generating material in the form of a sheet having a surface and having a tobacco material embedded in or adhered to the surface of the sheet, the method comprising: (a) (i) one or more binders and / or foaming agents; (ii) a filler; (iii) an aerosol forming agent material; and (iv) a solvent preparing a slurry comprising; (b) optionally, aerating the slurry to form an aerated slurry; (c) optionally, forming a layer of the aerated slurry; (d) optionally, depositing a tobacco material on the layer of the aerated slurry; and (e) drying the layer of the optionally aerated slurry having the tobacco material deposited on the surface to form an aerosol generating material. A method is provided that includes.

[0028] In some embodiments, the sheet is foamed.

[0029] In some embodiments, aerating the slurry includes mixing the slurry under high shear conditions. In some embodiments, preparing the slurry includes mixing the slurry under high shear conditions such that aeration occurs as part of step (a).

[0030] In some embodiments, aerating the slurry includes bubbling a gas through the slurry.

[0031] In some embodiments, aerating the slurry includes adding a foaming agent to the slurry and foaming the foaming agent, thereby introducing bubbles into the slurry.

[0032] In some embodiments, the aerosol generating material is top-coated with a film-forming agent, and the method places the film-forming agent on top of the slurry after (d) and optionally dries the placed film-forming agent to form a top-coated aerosol generating material; or places the film-forming agent on the aerosol generating material after (e) and optionally dries the placed film-forming agent to form a top-coated aerosol generating material further includes.

[0033] In some embodiments, the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, monoglyceride, diglyceride, triethyl citrate, and combinations thereof. In some embodiments, the film-forming agent is hydroxypropyl methylcellulose. In some embodiments, the film-forming agent is a combination of hydroxypropyl cellulose, monoglyceride, diglyceride, and triethyl citrate.

[0034] In some embodiments, the aerosol generating material is in laminate form, and the method After (d), optionally forming a second layer of the optionally aerated slurry on the layer of the optionally aerated slurry to form a laminated composite; and drying the laminated composite to form an aerosol-generating material in laminate form further comprising.

[0035] In some embodiments, the aerosol-generating material is in laminate form and the method after (e), forming a second layer of the optionally aerated slurry on the aerosol-generating material to form a laminated composite; and drying the laminated composite to form an aerosol-generating material in laminate form further comprising.

[0036] The present disclosure includes, but is not limited to, the following embodiments.

[0037] Embodiment 1: An aerosol-generating material in the form of a sheet having a surface, which may or may not be foamed, comprising (i) one or more binders, one or more foaming agents, or one or more binders and one or more foaming agents; (ii) a filler; (iii) an aerosol-forming agent material; and (iv) a tobacco material embedded in the sheet or adhered to the surface of the sheet an aerosol-generating material.

[0038] Embodiment 2: The aerosol-generating material of Embodiment 1, wherein the sheet is foamed and the foamed sheet comprises one or more foaming agents.

[0039] Embodiment 3: The aerosol-generating material of Embodiment 2, further comprising about 1 to about 6 wt% of a foam stabilizer.

[0040] Embodiment 4: The aerosol-generating material of Embodiment 3, wherein the foam stabilizer comprises one or more surfactants or emulsifiers.

[0041] Embodiment 5: The aerosol generating material of Embodiment 3, wherein the foam stabilizer comprises sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

[0042] Embodiment 6: The aerosol generating material according to any one of Embodiments 2 to 5, further comprising a foaming agent.

[0043] Embodiment 7: The aerosol generating material of Embodiment 6, wherein the foaming agent comprises calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminum sulfate, or a combination thereof.

[0044] Embodiment 8: The aerosol generating material according to any one of Embodiments 2 to 7, wherein the aerosol generating material comprises about 5% to about 35% by weight of a foam former.

[0045] Embodiment 9: The aerosol generating material according to any one of Embodiments 2 to 8, wherein the foam former comprises hydroxypropyl methylcellulose (HPMC), gum, modified starch, maltodextrin, or a combination thereof.

[0046] Embodiment 10: The aerosol generating material according to any one of Embodiments 2 to 9, wherein the foam former comprises HPMC.

[0047] Embodiment 11: The aerosol generating material of Embodiment 1, wherein the sheet is not foamed and the aerosol generating material comprises one or more binders.

[0048] Embodiment 12: The aerosol generating material according to any one of Embodiments 1 to 11, wherein the one or more binders comprise carboxymethyl cellulose, alginate, natural gum, or a combination thereof.

[0049] Embodiment 13: The aerosol generating material according to any one of Embodiments 1 to 12, wherein the aerosol generating material comprises about 10% to about 85% by weight of a filler.

[0050] Embodiment 14: The aerosol generating material according to any one of Embodiments 1 to 13, wherein the filler comprises wood pulp, microcrystalline cellulose, or a combination thereof.

[0051] Embodiment 15: The aerosol generating material according to any one of Embodiments 1 to 14, comprising about 20% to about 30% by weight of the aerosol forming agent material.

[0052] Embodiment 16: The aerosol generating material according to any one of Embodiments 1 to 15, wherein the aerosol forming agent material comprises glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination thereof.

[0053] Embodiment 17: The aerosol generating material according to any one of Embodiments 1 to 16, wherein the aerosol forming agent material is glycerol, propylene glycol, or a combination thereof.

[0054] Embodiment 18: The aerosol generating material according to any one of Embodiments 1 to 17, wherein the sheet has a density in the range of about 0.02 g / cm 3 to about 0.7 g / cm 3 .

[0055] Embodiment 19: The aerosol generating material according to any one of Embodiments 1 to 19, wherein the aerosol generating material has a filling value higher than about 380 g / cm Filling value = (bulk volume / weight) × 100 determined by 3 , and the bulk volume is determined using a densitometer.

[0056] Embodiment 20: An aerosol generating material according to any one of Embodiments 1 to 19, having a porosity of about 100 seconds / 100 mL or more, determined using a Gurley densitometer.

[0057] Embodiment 21: An aerosol generating material according to any one of Embodiments 1 to 20, wherein the tobacco material is granular or fibrous tobacco.

[0058] Embodiment 22: An aerosol generating material according to Embodiment 21, wherein the fibrous tobacco material has a width in the range of about 1 to about 2 mm and a length of at most about 3 mm.

[0059] Embodiment 23: An aerosol generating material according to Embodiment 21, wherein the granular tobacco material is powdered tobacco.

[0060] Embodiment 24: An aerosol generating material according to any one of Embodiments 1 to 23, wherein the aerosol generating material is in a laminated form.

[0061] Embodiment 25: An aerosol generating material according to any one of Embodiments 1 to 23, further comprising a top coat of a film-forming agent that covers the tobacco material disposed on the surface of the sheet, embedded in the sheet, or adhered to the surface of the sheet.

[0062] Embodiment 26: An aerosol generating material according to Embodiment 25, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, monoglyceride, diglyceride, triethyl citrate, and combinations thereof.

[0063] Embodiment 27: An aerosol generating element comprising an aerosol generating material according to any one of Embodiments 1 to 26.

[0064] Embodiment 28: An aerosol generating element according to Embodiment 27, comprising about 10 to about 100% by weight of the aerosol generating material.

[0065] Embodiment 29: The aerosol generating element according to Embodiment 27 or 28, wherein the aerosol generating material is in the form of a corrugated sheet.

[0066] Embodiment 30: The aerosol generating element according to Embodiment 27 or 28, wherein the aerosol generating material is in the form of a shredded sheet.

[0067] Embodiment 31: The aerosol generating element according to Embodiment 30, wherein the shredded sheet is blended with an additional tobacco material having different properties from the tobacco material embedded in or adhered to the surface of the sheet.

[0068] Embodiment 32: The aerosol generating element according to Embodiment 31, wherein the additional tobacco material includes reconstituted tobacco, tobacco lamina, fine cut tobacco, cut rag tobacco, or a combination thereof.

[0069] Embodiment 33: The aerosol generating element according to Embodiment 29, wherein the corrugated sheet is crimped and gathered into a cylindrical rod, and the aerosol generating element further includes a wrapping material surrounding the rod.

[0070] Embodiment 34: A consumable used in a non-combustible aerosol providing device and including any one of the aerosol generating elements according to Embodiments 27 to 33.

[0071] Embodiment 35: A non-combustible aerosol providing system including the consumable according to Embodiment 33 and a non-combustible aerosol providing device, wherein the non-combustible aerosol providing device includes an aerosol generating device arranged and configured to generate an aerosol from the consumable when the consumable is used together with the non-combustible aerosol providing device.

[0072] Embodiment 36: A combustible aerosol providing system including the consumable according to Embodiment 34 and a combustible aerosol providing device.

[0073] Embodiment 37: A method of forming an aerosol-generating material having a form of a sheet with a surface and having a tobacco material embedded in or adhered to the surface of the sheet, comprising: (a)(i) one or more binders, one or more foaming agents, or one or more binders and one or more foaming agents; (ii) a filler; (iii) an aerosol-forming agent material; and (iv) a solvent preparing a slurry comprising; (b) optionally, aerating the slurry to form an aerated slurry; (c) optionally forming a layer of the aerated slurry; (d) optionally depositing a tobacco material on the layer of the aerated slurry; and (e) drying the layer of the optionally aerated slurry having the tobacco material deposited on the surface to form an aerosol-generating material comprising a method.

[0074] Embodiment 38: The method of Embodiment 37, wherein the sheet foams.

[0075] Embodiment 39: The method of Embodiment 37 or 38, wherein aerating the slurry comprises mixing the slurry under high shear conditions.

[0076] Embodiment 40: The method according to any one of Embodiments 37 to 39, wherein preparing the slurry comprises mixing the slurry under high shear conditions such that aeration is carried out as part of step (a).

[0077] Embodiment 41: The method of Embodiment 37 or 38, wherein aerating the slurry comprises bubbling a gas through the slurry.

[0078] Embodiment 42: The method of Embodiment 37 or 38, wherein aerating the slurry comprises adding a foaming agent to the slurry and foaming the foaming agent to introduce bubbles into the slurry.

[0079] Embodiment 43: The aerosol generating material is top-coated with a film-forming agent, and the method is placing the film-forming agent on the slurry after (d) and optionally drying the placed film-forming agent to form a top-coated aerosol generating material; or placing the film-forming agent on the aerosol generating material after (e) and optionally drying the placed film-forming agent to form a top-coated aerosol generating material The method according to any one of Embodiments 37 to 42, further comprising

[0080] Embodiment 44: The method according to Embodiment 43, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, monoglyceride, diglyceride, triethyl citrate, and combinations thereof.

[0081] Embodiment 45: The aerosol generating material is in laminate form, and the method is forming a second layer of the optionally vented slurry on the optionally vented layer of slurry after (d) to form a laminated composite; and drying the laminated composite to form an aerosol generating material in laminate form The method according to any one of Embodiments 37 to 42, further comprising

[0082] Embodiment 46: The aerosol generating material is in laminate form, and the method is forming a second layer of the optionally vented slurry on the aerosol generating material after (e) to form a laminated composite, and drying the laminated composite to form an aerosol generating material in laminate form The method according to any one of Embodiments 37 to 42, further comprising

[0083] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description when read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the above-described embodiments, as well as any combination of two, three, four, or more features or elements described in the present disclosure, regardless of whether such features or elements are explicitly combined in a particular embodiment herein. The present disclosure is to be read as a whole such that any separable feature or element of the disclosed invention is intended to be combinable in any of its various aspects and embodiments, unless the context otherwise indicates.

[0084] Having thus generally described aspects of the present disclosure, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are merely illustrative and are not to be construed as limiting the present disclosure.

Brief Description of the Drawings

[0085]

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Mode for Carrying Out the Invention

[0086] Next, the present disclosure will be described more fully hereinafter with reference to its exemplary embodiments. These embodiments are described so that the present disclosure will be thorough and complete and will fully convey the scope of the present disclosure to those skilled in the art. In fact, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments described herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. When referring to "dry weight percent" or "dry weight basis", it refers to the weight based on the dry components (i.e., all components other than water). When referring to "wet weight", it refers to the weight of the mixture including water. Unless otherwise indicated, when referring to the "weight percent" of a material, it reflects the total wet weight of the material (i.e., including water).

[0087] As described below, the present disclosure generally relates to aerosol generating materials, components, and consumables, and methods of making them. Combustible and non-combustible aerosol delivery systems including aerosol generating materials, components, and consumables are further provided. The aerosol generating element includes an aerosol generating material. The aerosol generating materials, components, and consumables described herein are capable of generating an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol generating material may take the form of a sheet, for example, which may or may not contain nicotine.

[0088] Aerosol generating material As used herein, an aerosol generating material is provided. The aerosol generating material can enhance the sensory (e.g., organoleptic) properties of the aerosol generating element. In particular, the aerosol produced by the aerosol generating material when heated, or the smoke produced when the article is smoked, may be particularly smooth. The aerosol generating material may not exhibit undesirable organoleptic properties when heated or combusted. Thus, the material exhibits a smooth and neutral flavor profile when smoked and does not emit a very strong or unpleasant flavor. Without being bound by theory, this is theorized to be due to an aerosol generating material that has a diluting effect on the aerosol or smoke produced.

[0089] The aerosol generating material takes the form of a sheet having a surface and generally includes one or more sheet binders and / or forming agents, some of which may be foaming agents; fillers; aerosol forming agent materials; tobacco materials embedded in the sheet or adhered to the surface of the sheet. Each of the components of the aerosol generating material will now be further described below.

[0090] Binders and foaming agents The aerosol generating material disclosed herein includes one or more binders or foaming agents. In some embodiments, the aerosol generating material is in the form of a foaming sheet and includes one or more foaming agents. According to the present disclosure, it has been found that by including one or more foaming agents, air can be incorporated into the aerosol generating material during the formation of the material. That is, by including one or more foaming agents, the aerosol generating material can be provided in the form of foam. This results in a decrease in the density of the material compared to when no foaming agent is present. Surprisingly, according to the present disclosure, it has been found that this decrease in density does not adversely affect the user's sensory experience. Thus, the present disclosure provides an aerosol generating material having a reduced density while maintaining a good sensory experience. The filling value of the aerosol generating material can be reduced by including one or more foaming agents.

[0091] The aerosol generating material may include from about 5 wt%, 6 wt%, 7 wt%, 10 wt%, 12 wt% or 15 wt% to about 18 wt%, 20 wt%, 25 wt%, 30 wt% or 35 wt% (all calculated on a dry weight basis) of one or more forming agents. In some embodiments, the aerosol generating material includes from 5 to 35 wt%, 5 to 30 wt%, 6 to 25 wt%, 7 to 20 wt% or 12 to 18 wt% (all calculated on a dry weight basis) of one or more foaming agents. The forming agent generally acts to capture gas (e.g., air) bubbles, for example when bubbles are formed by aerating a slurry.

[0092] In some embodiments, the one or more foaming agents may include a gum, such as a natural gum. As used herein, natural gum refers to a naturally-derived polysaccharide material having binding properties and useful as a thickening or gelling agent. Representative natural gums typically derived from plants that are water-soluble to some extent include xanthan gum, guar gum, gum arabic, ghatti gum, tragacanth gum, karaya gum, locust bean gum, gellan gum, and combinations thereof. In some embodiments, the binder includes xanthan gum, guar gum, gum arabic, locust bean gum, tragacanth gum, or combinations thereof. In some embodiments, the one or more foaming agents include or are guar gum.

[0093] In some embodiments, the one or more foaming agents may include pectin, modified starch (e.g., hydroxylated starch), maltodextrin, or combinations thereof. In some embodiments, the foaming agent is modified starch. One particularly suitable modified starch emulsifier is available as TEXTRA, available from National Starch and Chemical Company, Bridgewater, NJ.

[0094] In some embodiments, the one or more foaming agents may include a cellulose ether (including carboxyalkyl ethers), which means a cellulose polymer in which the hydrogen of one or more hydroxyl groups in the cellulose structure is replaced by an alkyl, hydroxyalkyl or aryl group. Non-limiting examples of such cellulose derivatives include methylcellulose, hydroxypropylcellulose ("HPC"), hydroxypropylmethylcellulose ("HPMC"), hydroxyethylcellulose, and carboxymethylcellulose ("CMC"). Suitable cellulose ethers include hydroxypropylcellulose, such as Klucel H manufactured by Aqualon Co.; hydroxypropylmethylcellulose, such as Methocel K4MS manufactured by DuPont; hydroxyethylcellulose, such as Natrosol 250 MRCS manufactured by Aqualon Co.; methylcellulose, such as Methocel A4M, K4M, and E15 manufactured by DuPont; and sodium carboxymethylcellulose, such as CMC 7HF, CMC 7LF, and CMC 7H4F manufactured by Aqualon Co. In some embodiments, the one or more foaming agents are one or more cellulose ethers (e.g., a single cellulose ether or a combination of several cellulose ethers, such as a combination of two or three). In some embodiments, the one or more foaming agents are cellulose ethers selected from the group consisting of methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, and combinations thereof. In some embodiments, the one or more foaming agents include, consist essentially of, or consist of HPMC.

[0095] In some embodiments, the aerosol generating material in the form of a foaming sheet comprises a foam stabilizer. The foam stabilizer can reduce the collapse of the foam after formation and can also prevent the collapse of the foam. In some embodiments, the aerosol generating material comprises from about 1 wt%, 1.5 wt% or 2 wt% to about 6 wt%, 8 wt% or 10 wt% of the foam stabilizer (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises 1 to 10 wt%, 1.5 to 9 wt% or 2 to 6 wt% of the foam stabilizer (all calculated on a dry weight basis).

[0096] The foam stabilizer may comprise one or more surfactants. In some embodiments, each of the one or more surfactants is nonionic, anionic or amphoteric. In some embodiments, the foam stabilizer comprises sodium lauryl sulfate (SLS), Tween 60 (polyglycol sorbitan monostearate), Tween 80 (polysorbate 80), Amphosol CA, Span 60 (sorbitan monostearate), Span 80 (sorbitan monooleate), lecithin or a mixture thereof.

[0097] According to the present disclosure, it has been found that the use of a foam stabilizer can assist in the formation of the foaming material of the present disclosure. In particular, the foam stabilizer can stabilize the bubbles formed in the slurry and thus help prevent the bubbles from collapsing when the slurry is dried. Thus, the use of a foam stabilizer can assist in the formation of the aerosol generating material of the present disclosure.

[0098] Surprisingly, according to the present disclosure, when a particular foaming agent is used (e.g., HPMC), it has been found that a foam stabilizer is not required and stable foams can be formed without the use of a foam stabilizer. Thus, in some embodiments, the use of a foam stabilizer is optional.

[0099] In some embodiments, the aerosol generating material in the form of a foaming sheet further comprises a binder.

[0100] In some embodiments, the aerosol generating material takes the form of a non-foaming sheet, which sheet contains one or more non-foaming binders. Suitable binders include, but are not limited to, alginates, cellulose derivatives, starches, gums, dextrans, carrageenans, and the like.

[0101] In some embodiments, the one or more binders are alginates, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. Alginates, particularly high-viscosity alginates, may be used in combination with a controlled level of free calcium ions. In some embodiments, the aerosol generating material contains from about 0 to about 10% by weight of alginate, such as about 0%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% alginate.

[0102] In some embodiments, the one or more binders are one or more cellulose derivatives (e.g., a single cellulose derivative or a combination of several cellulose derivatives, such as a combination of two or three, etc.) or include such derivatives. In some embodiments, the aerosol generating material comprises from about 0 to about 5% by weight of one or more cellulose derivatives, such as about 0%, about 1%, about 2%, about 3%, about 4% or about 5% of one or more cellulose derivatives. In embodiments where the aerosol generating material comprises a plurality of cellulose derivatives, it is understood that the recited from about 0% to about 5% by weight of one or more cellulose derivatives reflects the total weight of the combination of cellulose derivatives. In some embodiments, the one or more cellulose derivatives are chemically modified cellulose derivatives. Suitable chemically modified cellulose derivatives include hydroxypropyl cellulose, such as Klucel H manufactured by Aqualon Co.; hydroxypropyl methylcellulose, such as Methocel K4MS manufactured by The Dow Chemical Co.; hydroxyethyl cellulose, such as Natrosol 250 MRCS manufactured by Aqualon Co.; microcrystalline cellulose, such as Avicel manufactured by FMC; methylcellulose, such as Methocel A4M manufactured by The Dow Chemical Co.; and sodium carboxymethylcellulose, such as CMC 7HF and CMC 7H4F manufactured by Hercules Inc. In some embodiments, the one or more binders are CMC.

[0103] In some embodiments, one or more binders are starches. In some embodiments, the aerosol-generating material comprises from about 0 to about 30%, from about 0 to about 15%; or from about 20 to about 40% starch, by weight. In some embodiments, the aerosol-generating material comprises, for example, about 0%, about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35% or about 40% starch. Suitable starches include corn starch, rice starch and modified food starch. In some other embodiments, the binder is rice starch. In some embodiments, one or more binders are dextran. In some other embodiments, the binder may comprise cyclodextrin.

[0104] In some embodiments, one or more binders are gums. Suitable gums include xanthan gum, guar gum, gum arabic, locust bean gum, pullulan and tragacanth gum. In some embodiments, one or more binders are xanthan gum or pullulan. In some embodiments, one or more binders are carrageenan.

[0105] Filler The aerosol-generating material disclosed herein comprises a filler. The amount of filler can vary. In some embodiments, the aerosol-generating material comprises from about 10 wt%, 20 wt%, 30 wt%, 40 wt%, 50 wt% or 60 wt% to about 85 wt%, 80 wt% or 75 wt% filler (all calculated on a dry weight basis). In some embodiments, the aerosol-generating material comprises from about 10 to about 85 wt%, from about 50 to about 80 wt%, or from about 60 to about 75 wt% filler (all calculated on a dry weight basis). A plurality of fillers may be used. In such embodiments, it is understood that references to the weight percentages of the fillers are intended to reflect the total amount of the combination of fillers present in the substrate.

[0106] The filler may include materials such as non-tobacco botanical materials, cellulose materials, wood fibers or pulp, starch, sugars, sugar alcohols, inorganic substances, inert materials, and the like, as well as combinations thereof.

[0107] In some embodiments, the filler may include one or more inorganic filler materials such as calcium carbonate, chitosan, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic sorbents such as, for example, molecular sieves. In some embodiments, the filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In some embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives such as, for example, microcrystalline cellulose (MCC) and / or nanocrystalline cellulose. Without being bound by theory, it is believed that including a fibrous filler in the aerosol generating material of the present disclosure may increase the tensile strength of the material. This is particularly advantageous in embodiments where the aerosol generating material is provided as a sheet, such as when the aerosol generating material sheet surrounds the rod of the aerosol generating element.

[0108] In some embodiments, microcrystalline cellulose is used as a filler in the aerosol generating material. In addition to functioning as a filler, the microcrystalline cellulose material used herein can, in certain embodiments, act as a carrier for flavoring substances, for example. Microcrystalline cellulose has a number of uses as, for example, a texturizing agent, an anti-caking agent, a fat replacer, an emulsifier, a bulking agent and a swelling agent, as well as an excipient, a binder, a disintegrant, an absorbent, a filler, a diluent, a lubricant and an anti-adhesive agent for direct compression. In contrast to other cellulose materials obtained directly from pulp, microcrystalline cellulose is a purified pulp product. Pulp is a lignocellulosic fiber material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, waste paper or waste cloth, while microcrystalline cellulose is distinguished as a purified and partially depolymerized cellulose.

[0109] Cellulose is a naturally occurring polymer composed of glucose units connected by 1-4 beta-glycosidic bonds. The straight chains of cellulose are bundled together as microfibrils in the plant cell wall. Each microfibril defines a crystalline structure that is insoluble in water and resistant to reagents. However, the microfibrils contain amorphous regions with weaker internal bonds. The crystalline structure is isolated to produce microcrystalline cellulose. Microcrystalline cellulose can be produced simply from alpha-cellulose (also known as "chemical cellulose"), which is a highly purified insoluble, relatively high molecular weight cellulose from which sugars, pectin and other soluble materials have been removed. With respect to other types of cellulose, beta-cellulose is defined as a more degraded form of cellulose and has fewer crystalline regions. Further, gamma-cellulose is defined as short-chain hemicellulose. Thus, beta-cellulose and gamma-cellulose are typically removed from the inputs used to produce microcrystalline cellulose.

[0110] In the production of microcrystalline cellulose, alpha cellulose can first be shredded and then immersed in a warm bath of mineral acid to dissolve the amorphous regions of the microfibrils while leaving the microcrystalline structure intact. The microcrystalline structure can then be subjected to hydrolysis to break long polymer chains until the degree of polymerization decreases and levels off at a desired level. Chemicals and impurities can then be removed by washing with water followed by drying. The resulting microcrystalline cellulose can be embedded as a fine white crystalline powder in its raw form. Methods for forming microcrystalline cellulose from plant materials are described, for example, in U.S. Patent Nos. 9,339,058 to Byrd, Jr. et al. and 10,774,472 to Sebastian et al., which are hereby incorporated by reference in their entirety. MCC materials are commercially available from suppliers such as DuPont de Nemours, Inc., Asahi Kasei Corporation, Sigachi Industries Limited, Accent Microcell Pvt. Ltd., and DFE Pharma GmbH & Co. KG. Microcrystalline cellulose may be selected from the group consisting of AVICEL® grades PH-100, PH-102, PH-103, PH-105, PH-112, PH-113, PH-200, PH-300, PH-302, VIVACEL® grades 101, 102, 12, 20, and EMOCEL® grades 50M and 90M and the like, and mixtures thereof.

[0111] Microcrystalline cellulose is typically used in granular form, and the particle size can vary. In certain embodiments, the microcrystalline cellulose material takes a very fine granular form, such as particles having a D90 particle size of about 250 microns or less, such as about 170 microns or less or about 150 microns or less. As used herein, the term "D90 particle size" means that 90% of all the particles are smaller than a given size. The particle size can be measured, for example, by laser diffraction or using a particle size analyzer.

[0112] In certain embodiments, the microcrystalline cellulose material has a relatively low bulk density compared to other types of cellulose materials and is advantageous when a material with a larger packing value is desired. Exemplary ranges of bulk density for the microcrystalline cellulose materials used in the present disclosure are determined by measuring the volume of a known mass of the powder and are about 0.50 g / mL or less, such as about 0.26 to about 0.35 g / mL, or about 0.26 to about 0.5 g / mL.

[0113] In some embodiments, compared to other cellulose materials, microcrystalline cellulose can advantageously provide one or more of improved texture, anti-setting, and anti-sticking properties to an aerosol-generating material comprising the microcrystalline cellulose.

[0114] In some embodiments, the filler comprises additional cellulose materials, such as cellulose materials derived from flax, cotton linter, kenaf, hibiscus, hemp, tobacco, sisal, rice straw or African grass. Other suitable cellulose materials include, but are not limited to, cereal grains (e.g., corn, oats, barley, rye, buckwheat seeds and the like), sugar beet (e.g., FIBREX® brand filler available from International Fiber Corporation), bran fibers and mixtures thereof.

[0115] In some embodiments, the cellulose material is a cellulose pulp or regenerated cellulose comprising at least about 90% cellulose by weight, such as about 90%, about 95%, about 99%, or even 100% cellulose. "Regenerated cellulose" means natural cellulose that has been converted to a soluble or dissolved cellulose derivative and then regenerated, typically by forming fibers through polymer spinning or through film polymer casting, precipitation or extrusion.

[0116] In some embodiments, the cellulose material includes a nanocellulose material. As used herein, "nanocellulose material" refers to a cellulose material having at least one average particle size dimension in the range of about 1 nm to about 100 nm. By way of non-limiting example, suitable nanocellulose materials are fibrous materials prepared from any suitable cellulose-containing material such as grass (e.g., bamboo), cotton, tobacco, algae, and other plant-based materials, which may be materials in which the fibers are further refined such that nanofibrillated cellulose fibers are refined.

[0117] In some embodiments, the filler includes wood or wood-derived fibers (e.g., wood pulp). In some embodiments, the filler includes a combination of microcrystalline cellulose and wood pulp. In some embodiments, the filler is a combination of microcrystalline cellulose and wood pulp. In some embodiments, the filler includes wood pulp, consists essentially of wood pulp, or consists of wood pulp.

[0118] In some embodiments, the aerosol generating material includes from about 1 wt%, 5 wt%, 10 wt%, 12 wt% or 13 wt% to about 15 wt%, 17 wt% or 20 wt% of wood pulp (all calculated on a dry weight basis). In some embodiments, the aerosol generating material includes from about 10 to 20 wt%, 10 to 15 wt% or 13 to 14 wt% of wood pulp (all calculated on a dry weight basis).

[0119] In some embodiments, the filler includes a non-tobacco botanical material. As used herein, the term "botanical material" or "botanical" refers to any plant material or fungus-derived material, including plant material in its natural form and plant material derived from natural plant material, such as extracts or isolates from plant material or processed plant material (e.g., plant material subjected to heat treatment, fermentation, or other processing processes capable of changing the chemical nature of the material). For the purposes of the present disclosure, "botanical material" includes, without limitation, "herb material" which refers to seed-bearing plants that do not permanently generate woody tissue and whose medical or sensory properties are often evaluated (e.g., tea or herbal tea). References to botanical materials as "non-tobacco" are intended to exclude tobacco materials (i.e., do not include any Nicotiana species). The botanical materials used in the present disclosure may include, without limitation, any of the compounds and sources described herein, including mixtures thereof. This type of certain botanical material may also be referred to as a dietary supplement, nutraceutical, "phytochemical" or "functional food".

[0120] Non-limiting examples of non-tobacco botanical materials include, but are not limited to, acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, angelica, anise (e.g., star anise), annatto seeds, apple (Malus domestica), apricot oil, bacopa monniera, basil (Ocimum basilicum), beavermint, beetroot, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberry, boldo (Peumus boldus), borage, chervil, cacao, chufa root, camu (Myrcaria dubia), cannabis / hemp, caraway seed, catnip, katsuobushi, cayenne, cayenne pepper, chaga mushroom, chamomile, cherry, chervil, chocolate, cinnamon (Cinnamomum cassia), lemongrass (Cymbopogon citratus), clary sage, clove, coconut (Cocos nucifera), coffee, comfrey leaves and roots, coriander seed, cranberry, dandelion, echinacea, elderberry, elderflower, endive (Anethum graveolens), evening primrose, eucalyptus, fennel, feverfew, garlic, ginger (Zingiber officinale), ginkgo, ginseng, goji berry, goldenseal, grape seed, grapefruit, grapefruit rose (Citrus paradisi), graviola (Annona muricata), green tea, guava, hawthorn, hibiscus flower (Hibiscus sabdariffa)sabdariffa), honeybush, amachazul, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), lavender, lemon (Citrus limon), licorice, lilac, yamabushitake, maca (Lepidium meyenii), marjoram, milk thistle, mint (Mentha), oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quince, red clover, rooibos (red or green), rose hip (Rosa canina), rosemary, sage, St. John's wort, savory (Salvia officinalis), celery, soapwort, silybum marianum, slippery elm bark, sorghum bran hytannin, sorghum grain hytannin, spearmint (Mentha spicata), spirulina, smut bran, thyme, turmeric, uva ursi, valerian, vanilla, wild yam root, wintergreen, withania somnifera, yerba buena root, yellow dock, yerba mate and yerba santa are included.

[0121] In some embodiments, the filler comprises starch, including native and processed starches. Certain starch materials may be included in the substrate as binders or other functional additives. As used herein, "starch" may refer to pure starch, processed starch, or starch derivatives from any source. Starch is typically in granular form and is present in substantially all green plants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in the composition, as well as in the granular shape and size, in the composition. Often, starches from various sources have various chemical and physical characteristics. Particular starches can be selected for inclusion in the beads based on the ability of the starch material to impart particular functional properties to the beads. Starches from various sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, and corn) and root vegetables (e.g., potato and cassava). Other examples of starch sources include chestnut, arrowroot, aracacha, banana, barley, legumes (e.g., navy bean, lentil, mung bean, pea, chickpea), breadnut, buckwheat, canna, kudzu, yam bean, millet, oats, oca, taro, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, watermelon seed, and yam. Suitable starches include, but are not limited to, corn starch, rice starch, tapioca starch, and modified food starch. Certain starches are modified starches. Modified starches have undergone one or more structural modifications, often designed to alter their high thermal properties. Some starches are developed by genetic modification and are considered "modified" starches. Other starches are obtained and subsequently modified. For example, modified starches can be starches that have been subjected to chemical reactions such as esterification, etherification, oxidation, acid-catalyzed depolymerization (thinning) or oxidation in the presence of a base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), cross-linking, enzyme treatment, acetylation, hydroxypropylation and / or partial hydrolysis.Other starches are modified by heat treatment such as gelatinization, dextrinization and / or cold water swelling processes. Certain modified starches include monophosphate starch, distarch glycerol, diphosphate starch esterified with sodium trimetaphosphate, diphosphate starch phosphate, acetylated diphosphate starch, acetate starch esterified with acetic anhydride, acetate starch esterified with vinyl acetate, acetylated adipic acid distarch, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol and octenyl succinic anhydride starch sodium.

[0122] In some embodiments, the filler includes sugars. Suitable sugars include, but are not limited to, glucose, dextrose, fructose, maltose and lactose.

[0123] In some embodiments, the filler includes sugar alcohols. Suitable sugar alcohols include, but are not limited to, sorbitol, mannitol, isomalt, maltitol, erythritol and xylitol.

[0124] In some embodiments, the filler includes inorganic or inert materials such as, but not limited to, chitosan, carbon (graphite, diamond, fullerene, graphene), quartz, granite, diatomaceous earth, calcium carbonate, calcium phosphate, clay, crustaceans, and shells of other marine organisms or combinations thereof. In some embodiments, the substrate material may include various types of inorganic fibers (e.g., fiberglass, metal wire / screen, etc.) and / or (organic) synthetic polymers. In some embodiments, these "fibrous" materials may not be structured (e.g., randomly distributed like cellulose fibers in a tobacco casting sheet) or may be structured (e.g., wire mesh).

[0125] Aerosol forming agent material The aerosol generating material disclosed herein includes an aerosol forming agent material, which may also be referred to as a humectant. Suitable aerosol forming agent materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, and combinations thereof. In some embodiments, the aerosol forming agent material may include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, or any combination thereof. Each of the polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols is further described herein below.

[0126] The amount of aerosol forming agent material present in the aerosol generating material may vary. For example, in certain embodiments, a sufficient amount of aerosol forming agent material is used to result in the generation of a visible mainstream aerosol that in many respects resembles the appearance of tobacco smoke. The amount of aerosol forming agent material present may depend on factors such as the desired puff count per aerosol generating element. Generally, the aerosol generating material includes the aerosol forming agent material (e.g., one or more polyhydric alcohols, such as glycerol) in a relatively large weight percentage to enable the generation of an aerosol from the aerosol generating material when heated.

[0127] In some embodiments, the aerosol generating material includes the aerosol forming agent material in an amount of at least about 1 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, or at least about 60 wt% based on the total wet weight of the substrate. Exemplary ranges of the total aerosol forming agent material include from about 15% to about 60 wt%, such as from about 15% to about 55%, or from about 15% to about 25% based on the total wet weight of the aerosol generating material.

[0128] In some embodiments, the aerosol generating material comprises from about 1 wt%, 5 wt%, 10 wt%, 12 wt% or 13 wt% to about 18 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 45 wt%, 55 wt%, 65 wt%, 75 wt% or 80 wt% of the aerosol forming agent material (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises from about 1 to 80 wt%, 1 to 50 wt%, 5 to 35 wt%, 10 to 25 wt%, 12 to 20 wt% or 13 to 18 wt% of the aerosol forming agent material (all calculated on a dry weight basis).

[0129] In some embodiments, the aerosol forming agent material comprises one or more polyhydric alcohols. Examples of polyhydric alcohols include glycerol, propylene glycol and other glycols such as 1,3 - propanediol, diethylene glycol and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3 - propanediol, diethylene glycol, triethylene glycol, triacetin and combinations thereof.

[0130] In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. Glycerol and propylene glycol may be present in various ratios and either component may be the major component depending on the intended application. In some embodiments, glycerol and propylene glycol are present in a weight ratio of from about 3:1 to about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1, about 2:1, about 1:1, about 1:2 or about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0131] In some embodiments, the aerosol-forming agent material comprises one or more polysorbates. Examples of polysorbates include polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used or the combination of polysorbates used depends on the desired effect intended, as different polysorbates provide different attributes due to their molecular size. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller-sized polysorbate molecules creates less vapor but allows for deeper lung penetration. This may be desirable when the user does not want to create a large plume of "smoke" (i.e., vapor) in a public place. Conversely, larger polysorbate molecules can be used when a dense vapor that can convey the aromatic components of tobacco is desired. An additional benefit of using the polysorbate family of compounds is that polysorbates lower the heat of vaporization of the mixtures in which they are present.

[0132] In some embodiments, the aerosol-forming agent material comprises one or more sorbitan esters. Examples of sorbitan esters include sorbitan monolaurate, sorbitan monostearate (Span 60), sorbitan monooleate (Span 20), and sorbitan tristearate (Span 65).

[0133] In some embodiments, the aerosol-forming agent material comprises one or more fatty acids. The fatty acids may include short-chain, long-chain, saturated, unsaturated, straight-chain or branched-chain carboxylic acids. Fatty acids generally include C4-C 28 aliphatic carboxylic acids. Non-limiting examples of short-chain or long-chain fatty acids include butyric acid, propionic acid, valeric acid, oleic acid, linoleic acid, stearic acid, myristic acid, and palmitic acid.

[0134] In some embodiments, the aerosol-forming agent material comprises one or more fatty acid esters. Examples of fatty acid esters include alkyl esters, monoglycerides, diglycerides, and triglycerides. Examples of monoglycerides include monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tributyrate, and glycerol trihexanoate.

[0135] In some embodiments, the aerosol-forming agent material comprises one or more waxes. Examples of waxes include carnauba, beeswax, candelilla, which are known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

[0136] In some embodiments, the aerosol-forming agent material comprises one or more terpenes. As used herein, the term "terpene" refers to hydrocarbon compounds biosynthesized by plants from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, myrcene, geraniol, fenchol, and cembrene.

[0137] In some embodiments, the aerosol-forming agent material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols may act as flavor enhancers for certain flavor compounds, such as menthol and other volatiles, and generally improve the mouthfeel, tactile sensation, throat impact, and other sensory properties of the resulting aerosol.

[0138] In some embodiments, the aerosol-forming agent material comprises glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or any combination thereof. In some embodiments, the aerosol-forming agent material comprises glycerol, consists essentially of glycerol, or consists of glycerol.

[0139] Foaming agent In some embodiments, the aerosol-generating material comprises a foaming agent. According to the present disclosure, in some embodiments, it has been found that by using a foaming agent, the slurry does not require high-speed mixing to aerate the slurry. This is particularly useful when a continuous process is used to form the aerosol-generating material.

[0140] In some embodiments, the aerosol-generating material comprises from about 1 wt%, 2 wt% or 4 wt% to about 7 wt%, 8 wt% or 10 wt% of the foaming agent (all calculated on a dry weight basis). In some embodiments, the aerosol-generating material comprises from 1 to 10 wt%, 2 to 8 wt% or 4 to 7 wt% of the foaming agent (all calculated on a dry weight basis).

[0141] The foaming agent may contain calcium carbonate, sodium carbonate, sodium bicarbonate, citric acid, tartaric acid, lactic acid, acetic acid, aluminum sulfate, or a mixture thereof. To produce foaming, generally a carbonate or bicarbonate and an acid are combined, resulting in the release of gaseous carbon dioxide that serves to aerate the aerosol-generating material during its preparation. In some embodiments, the foaming agent contains calcium carbonate, sodium carbonate, sodium bicarbonate, or a combination thereof; and citric acid, tartaric acid, acetic acid, aluminum sulfate, or a combination thereof. Those skilled in the art will understand that after the reaction of the carbonate and acid components, the aerosol-generating material may contain little or no original foaming agent(s), and the foaming agent(s) has reacted to form and release carbon dioxide.

[0142] Water The moisture (e.g., water) content of the aerosol-generating material may vary. For example, in some embodiments, the aerosol-generating material contains from about 0% to about 30% water. In some embodiments, the aerosol-generating material is dried to remove at least a portion of the water present during preparation. In some embodiments, after drying, the aerosol-generating material contains from about 3% to about 21% water relative to the total weight of the substrate. In some embodiments, after drying, the aerosol-generating material contains from about 8% to about 10 or from about 12% to about 18% water relative to the total weight of the aerosol-generating material. In some embodiments, after drying, the aerosol-generating material contains from about 15% to about 21% water relative to the total weight of the aerosol-generating material. The amount of moisture in the aerosol-generating material is determined, for example, by Karl Fischer titration or gas chromatography / thermal conductivity detector (GC-TCD).

[0143] Tobacco material The aerosol generating material includes tobacco material. The tobacco material may be embedded in the sheet forming the aerosol generating material or may be adhered to the surface of the sheet forming the aerosol generating material. This "top loading" of the tobacco material into the cast foam sheet provides a three-dimensional network structure of the cast sheet and the tobacco material, adding depth and void volume to the sheet. The top-loaded tobacco material may be distributed uniformly or randomly on or in the sheet. For example, the tobacco material may be top-loaded in bands or other regular or irregular patterns on or in the sheet, or the deposit of this top-loaded tobacco may retain and / or improve the filling dose of the sheet while adding tobacco properties to the aerosol generating material. This is in contrast to aerosol generating materials prepared by directly mixing milled tobacco into the foaming slurry, which has been found to have an adverse effect on the filling capacity according to the present disclosure. Further, without being bound by theory, the addition of tobacco material onto / into the cast sheet may enhance the flavor by the leaf tobacco directly contacting the high-concentration aerosol forming agent in the cast sheet, so it is considered that better tobacco properties can be delivered during the smoking operation.

[0144] The tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, or tobacco stems. In some embodiments, the tobacco material includes "fine powder" or dust of tobacco particles, augmented tobacco, stems, augmented stems, and other processed stem materials, such as cut rolls of stems. In some embodiments, the tobacco material includes ground tobacco. In some embodiments, the tobacco material comprises or consists of laminar tobacco (such as cut rag tobacco). In some embodiments, the tobacco material is finely cut (e.g., cut into thin strips). In some embodiments, the tobacco material is granular or fibrous tobacco. In certain embodiments, the tobacco material is a fibrous tobacco material having a width in the range of about 1 to about 2 mm and a length of up to about 3 mm. Such tobacco material may be referred to as "short" and typically includes cut lamina. In other embodiments, the tobacco material is powdered tobacco.

[0145] Tobacco materials can vary in species, type, and form. Generally, tobacco materials are obtained from harvested plants of the Nicotiana species. Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N.attenuata), N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii. Various other representative types of plants from Nicotiana species are incorporated herein by reference in their respective entirety: Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); U.S. Patent No. 4,660,577 to Sensabaugh, Jr. et al.; No. 5,387,416 to White et al.; No. 7,025,066 to Lawson et al.; No. 7,798,153 to Lawrence, Jr.; and No. 8,186,360 to Marshall et al. Details of various types of tobacco, growing practices, and harvesting practices are described in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999), which is incorporated herein by reference.

[0146] Nicotiana species from which suitable tobacco materials can be obtained can be derived using genetic modification or breeding techniques (e.g., tobacco plants can be genetically engineered or bred to increase or decrease the production, characteristics, or attributes of components). See, for example, U.S. Patent Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; U.S. Patent Application Publication No. 2006 / 0236434 to Conkling et al.; and PCT WO2008 / 103935 to Nielsen et al. See also U.S. Patent Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

[0147] Nicotiana species can, in some embodiments, be selected with respect to the content of various compounds present therein. For example, plants can be selected based on their production of one or more compounds in relatively large amounts that are desirably isolated therefrom. In certain embodiments, plants of Nicotiana species (e.g., Galpao commun tobacco) grow particularly well due to the compounds on the surface of their abundant leaves. Tobacco plants can be grown in a greenhouse, a growth chamber, or outdoors in a field, or can be grown hydroponically.

[0148] Various parts or portions of plants of the Nicotiana species can be included in the aerosol - generating materials disclosed herein. For example, virtually all of the plant (e.g., the whole plant) can be harvested and used as is. Alternatively, various parts or pieces of the plant can be harvested or separated after harvest for further use. For example, flowers, leaves, stalks, stems, roots, seeds, and various combinations thereof can be isolated for further use or processing. In some embodiments, the tobacco material includes tobacco leaves (lamina). The aerosol - generating materials disclosed herein can include cured and aged tobacco that is a processed part or piece of tobacco and that is in essentially a natural lamina and / or stalk form. In certain embodiments, the tobacco material includes a solid tobacco material selected from the group consisting of lamina and stalk. The tobacco used in the aerosol - generating material is most preferably tobacco lamina, or a mixture of tobacco lamina and stalk, at least a portion of which has been treated with smoke. A portion of the tobacco may have a processed form, such as processed tobacco stalks (e.g., cut - rolled stalks, cut - rolled and bulged stalks, or cut - puffed stalks) or bulged tobacco (e.g., tobacco bulged with dry ice (DIET), puff - treated tobacco), etc. See, for example, U.S. Patent Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; 5,908,032 to Poindexter et al.; and 7,556,047 to Poindexter et al., which are incorporated herein by reference in their entirety for the tobacco bulging processes described therein. Further, the aerosol - generating materials may incorporate fermented tobacco. See also the types of tobacco processing techniques described in PCT WO2005 / 063060 to Atchley et al., which is incorporated herein by reference.

[0149] The methods for providing tobacco materials in the form of a fine powder or powder type may vary. Preferably, the plant parts or pieces are milled, ground, pulverized, or shredded into fine particle form using a device and technique for grinding, milling, or the like. The plant or its parts can be subjected to an external force or pressure (e.g., by pressurizing or subjecting to a rolling process). When implementing such processing conditions, the plant or its part can have a moisture content approximating its natural moisture content (e.g., the moisture content immediately after harvest), a moisture content achieved by adding moisture to the plant or its part, or a moisture content obtained from the drying of the plant or its part. For example, the powdered, shredded, pulverized, pulped, or milled pieces of the plant or its part can have a moisture content of less than about 25 weight percent, often less than about 20 weight percent, and frequently less than about 15 weight percent. Most preferably, the plant material is relatively dry in form during grinding or milling using a device such as a hammer mill, cutter head, air control mill, or the like. For example, the tobacco parts or pieces can be ground or milled when their moisture content is less than about 15 weight percent or less than about 5 weight percent.

[0150] In the preparation of aerosol generating materials, harvested Nicotiana plants are typically subjected to a curing process. The tobacco materials incorporated into the aerosol generating materials disclosed herein are generally those that have been properly cured and / or aged. Details of various types of curing processes for various types of tobacco are described in Tobacco Production, Chemistry and Technology, Davis et al. (eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are described in Nestor et al., Beitrage Tabakforsch.Int., 20, 467-475 (2003) and Peele U.S. Patent No. 6,895,974, which are incorporated herein by reference. Representative techniques and conditions for air-curing tobacco are described in Groves et al. U.S. Patent No. 7,650,892; Roton et al., Beitrage Tabakforsch.Int., 21, 305-320 (2005), and Staaf et al., Beitrage Tabakforsch.Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobacco can be subjected to alternative types of curing processes such as fire curing or sun curing.

[0151] In certain embodiments, tobacco materials that can be used include flue-cured or Virginia (e.g., K326), Burley, sun-cured (e.g., Indian Kurnool and Oriental tobacco such as Katerini, Prelip, Komotini, Xanthi, and Yambol tobacco), Maryland, Dark, dark-fired, dark air cured (e.g., Madole, Passanda, Cubano, Jatin and Bezuki tobacco), light air cured (e.g., North Wisconsin and Galpao tobacco), Indian air cured, Red Russian, and Rustica tobacco, as well as various other rare or special tobaccos, and various blends of any of the foregoing tobaccos.

[0152] The tobacco material may have a so-called "blended" form. For example, the tobacco material may include a mixture of portions or pieces of flue-cured, Burley (e.g., Malawi Burley tobacco) and Oriental tobacco (e.g., tobacco composed of or derived from tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a typical blend may incorporate from about 30 to about 70 parts of Burley tobacco (e.g., lamina, or lamina and stem) and from about 30 to about 70 parts of flue-cured tobacco (e.g., stem, lamina, or lamina and stem) on a dry weight basis. Other exemplary tobacco blends incorporate about 75 parts of flue-cured tobacco, about 15 parts of Burley tobacco, and about 10 parts of Oriental tobacco; or about 65 parts of flue-cured tobacco, about 25 parts of Burley tobacco, and about 10 parts of Oriental tobacco; or about 65 parts of flue-cured tobacco, about 10 parts of Burley tobacco, and about 25 parts of Oriental tobacco on a dry weight basis. Other exemplary tobacco blends incorporate from about 20 to about 30 parts of Oriental tobacco and from about 70 to about 80 parts of flue-cured tobacco on a dry weight basis.

[0153] The tobacco materials used in the present disclosure can be subjected to, for example, fermentation, bleaching, and the like. If desired, the tobacco materials can be irradiated, sterilized, or subjected to other controlled heat treatments. Such treatment processes are detailed in, for example, U.S. Patent No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, the tobacco materials can be treated with water and an additive capable of preventing the reaction of asparagine to form acrylamide upon heating of the tobacco materials (e.g., lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating divalent and trivalent cations, asparaginase, certain non-reducing sugars, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functional group, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof). See, for example, the types of treatment processes described in U.S. Patent Publications Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., which are all incorporated herein by reference. In certain embodiments, this type of treatment is useful when the initial tobacco materials are subjected to heating in the aforementioned processes.

[0154] In some embodiments, the type of tobacco material is initially selected to be visually brighter in color to some extent than other tobacco materials (e.g., whitened or bleached). The tobacco pulp can be whitened in certain embodiments according to any means known in the art. For example, bleached tobacco materials produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Exemplary oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorites, chlorates, perchlorates, hypochlorites, ozone, ammonia, potassium permanganate, and combinations thereof. Exemplary oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof.Processes for treating tobacco with bleaching agents are discussed in, for example, U.S. Patent No. 787,611 to Daniels, Jr.; No. 1,086,306 to Oelenheinz; No. 1,437,095 to Delling; No. 1,757,477 to Rosenhoch; No. 2,122,421 to Hawkinson; No. 2,148,147 to Baier; No. 2,170,107 to Baier; No. 2,274,649 to Baier; No. 2,770,239 to Prats et al.; No. 3,612,065 to Rosen; No. 3,851,653 to Rosen; No. 3,889,689 to Rosen; No. 3,943,940 to Minami; No. 3,943,945 to Rosen; No. 4,143,666 to Rainer; No. 4,194,514 to Campbell; Nos. 4,366,823, 4,366,824, and 4,388,933 to Rainer et al.; No. 4,641,667 to Schmekel et al.; No. 5,713,376 to Berger; No. 9,339,058 to Byrd Jr. et al.; No. 9,420,825 to Beeson et al.; and No. 9,950,858 to Byrd Jr. et al.; and U.S. Patent Application Publication Nos. 2012 / 0067361 to Bjorkholm et al.; 2016 / 0073686 to Crooks; 2017 / 0020183 to Bjorkholm; and 2017 / 0112183 to Bjorkholm, and PCT Publication No. WO1996 / 031255 to Giolvas, and WO2018 / 083114 to Bjorkholm, all of which are hereby incorporated by reference in their entirety.

[0155] In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness in the range of about 50% to about 90%, about 55% to about 75%, or about 60% to about 70%. ISO brightness can be measured in accordance with ISO 3688:1999 or ISO 2470-1:2016.

[0156] In some embodiments, the whitened tobacco material can be characterized by a lighter color (e.g., “whitened”) compared to the untreated tobacco material. White is often defined with reference to the chromaticity diagram of the International Commission on Illumination (CIE). The whitened tobacco material can be characterized as being closer to pure white in the chromaticity diagram than the untreated tobacco material in certain embodiments.

[0157] The tobacco material may be processed to remove at least a portion of the nicotine present. Suitable methods for extracting nicotine from the tobacco material are known in the art. In some embodiments, the tobacco material is substantially free of nicotine. “Substantially free of” means that only a very small amount is present in the tobacco material. For example, in certain embodiments, the tobacco material can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001% or even less than 0% by weight of nicotine, calculated as the free base and relative to the total weight of the tobacco material.

[0158] Active ingredient In some embodiments, the aerosol - generating material comprises one or more active ingredients. As used herein, "active ingredient" refers to one or more substances belonging to any of the following categories: API (active pharmaceutical ingredient), food additives, natural medicines, and naturally occurring substances that can exert an effect on humans. Exemplary active ingredients include components that are known to affect one or more biological functions in the body, such as those that have pharmacological activity or other direct effects in the diagnosis, cure, alleviation, treatment, or prevention of diseases, or that affect the structure or any function of the human body (e.g., those that provide a stimulating effect on the central nervous system, an energizing effect, an antipyretic or analgesic effect, or other useful effects on the body). In some embodiments, the active ingredient may be of the type commonly referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods". These types of additives include substances (e.g., botanical materials) that are typically available from natural sources and that provide one or more beneficial biological effects (e.g., health promotion, disease prevention, or other medicinal effects) but are not separated or regulated as drugs, as defined in the art.

[0159] Non - limiting examples of active ingredients include synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, inorganic compounds, and nucleic acid sequences that have therapeutic, prophylactic, or diagnostic activity and fall into the categories. Non - limiting examples of active ingredients include botanical components, stimulants (e.g., caffeine and guarana), amino acids (e.g., taurine, theanine, phenylalanine, tyrosine, and tryptophan), and / or pharmaceutical, nutritional, and medicinal components (e.g., vitamins such as B6, B12, and C, and / or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)), antioxidants, and nicotine components that fall into the categories. The specific selection of the active ingredient will vary depending on the desired flavor, texture, and desired properties of the particular product.

[0160] The specific percentage of the active ingredient present will vary depending on the desired properties of the particular product. Typically, the active ingredient or combination thereof is present at a total concentration of at least about 0.001% by weight of the aerosol generating material, for example in the range of about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present at a concentration of about 0.1% w / w to about 10% by weight, for example about 0.5% w / w to about 10%, about 1% to about 10%, about 1% to about 5% by weight, etc., based on the total weight of the aerosol generating material. In some embodiments, the active ingredient or combination of active ingredients is from about 0.001%, about 0.01%, about 0.1% or about 1% to a maximum of about 20% by weight, for example about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19% or about 20% by weight, based on the total weight of the aerosol generating material. Further suitable ranges for specific active ingredients are provided hereinbelow.

[0161] In some embodiments, the active ingredient comprises one or more non - tobacco botanicals. As used herein, the terms "botanical ingredient" or "botanical" refer to any plant material or fungus - derived material, including plant material in its natural form (e.g., leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, shells and the like), and plant material derived from natural plants, such as extracts or isolates from plant material, or processed plant material (e.g., plant material subjected to heat treatment, fermentation, or other processing processes capable of changing the chemical nature of the material).

[0162] For the purposes of the present disclosure, "botanical material" includes, but is not limited to, "herbal material" (e.g., tea or herbal tea) that gives rise to no persistent woody tissue and is often valued for its medical or sensory properties. The material may take the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, stripes, sheets or the like. References to botanical material as "non-tobacco" shall exclude tobacco materials (i.e., any Nicotiana species). The botanical material used in the aerosol generating material of the present invention may include, but is not limited to, any of the compounds and sources described herein, including their mixtures. This type of certain botanical material is sometimes referred to as a nutritional supplement, nutraceutical, "phytochemical" or "functional food".

[0163] Non-limiting examples of botanical materials, many of which are related to antioxidant properties, include, but are not limited to, acai berry, alfalfa, allspice, anise seed, annatto seed, apricot oil, ashwagandha, Bacopa monniera, baobab, basil, bay, beavermint, beetroot, bergamot, black pepper, black tea, blueberry, borage seed oil, borage, cocoa, calamus root, cardamom, cassis, catnip, katsuobushi, cayenne pepper, Centella asiatica, chaga mushroom, chervil, chamomile, cherry blossom, chervil, chlorophyll, dark chocolate, cilantro, cinnamon, citrus, clove, cocoa, coffee, comfrey leaf and root, black cohosh, cordyceps, coriander, cranberry, cumin, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata, echinacea, elderflower, eucalyptus, fennel, flos carthami, flax, Galphimia glauca, garlic, geranium, ginger, ginkgo, ginseng (e.g., Panax ginseng), goji berry, hydrastis, grape seed, green tea, grapefruit, Griffonia simplicifolia, guarana, gotu kola, hawthorn, hazel, hemp, hibiscus flower, honeybush, hops, jasmine, Japanese knotweed, juniper, Kaempferia parviflora (Thai ginseng), kava, laurel, lavender, lemon, lemon balm, lemongrass, licorice, maitake mushroom, lutein, maca, mace, marjoram, matcha, mulberry, Nardostachys chinensischinensis), marjoram, thistle, mint (menthol), myrtle, nutmeg, olive, oolong tea, orange, oregano, papaya, paprika, pennyroyal, peppermint, pimento, potato peel, primrose, quercetin, red clover, resveratrol, Rhizoma gastrodiae, Rhodiola, rooibos, rooibos (red or green), rose essential oil, rosehip, rosemary, saffron, sage, clary sage, sandalwood, celery, saw palmetto, Sceletium tortuosum, ginseng, silybum marianum, tatsoi, spearmint, licorice, spirulina, slippery elm bark, sorghum bran tannin, sorghum grain tannin, St. John's wort, star anise, sumac bran, tarragon, terpene, thyme, chizhans, turmeric, Turnera aphrodisiaca, aralia, valerian, vanilla, Viola odorata, white mulberry, wild yam root, wintergreen, Withania somnifera, yerba mate and yerba santa are included.

[0164] In some embodiments, the active ingredient comprises, consists of, or is derived from one or more botanicals or their constituents, derivatives or extracts. In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa, hemp, rooibos, fennel and combinations thereof. When present, the botanical active ingredient is typically in a concentration of about 0.01% w / w to about 10% by weight, such as about 0.01% w / w, about 0.05%, about 0.1% or about 0.5% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9% or about 10%, about 11%, about 12%, about 13%, about 14% or about 15% by weight, based on the total weight of the aerosol generating material.

[0165] In some embodiments, the active ingredient comprises a nicotine component. The "nicotine component" means any suitable form of nicotine (e.g., free base or salt) to effect systemic absorption of at least a portion of the nicotine present. The source of nicotine may vary and may be of natural origin or synthetic. Most preferably, nicotine occurs naturally and is obtained as an extract of Nicotiana species (e.g., tobacco). Nicotine can have the enantiomeric forms S-(-)-nicotine, R-(+)-nicotine, or a mixture of S(-)-nicotine and R-(+)-nicotine. Most preferably, nicotine is in the form of S-(-)-nicotine (e.g., substantially all in the form of S(-)-nicotine) or a racemic mixture consisting mainly or mostly of S-(-)-nicotine (e.g., a mixture consisting of about 95 parts by weight of S-(-)-nicotine and about 5 parts by weight of R-(+)-nicotine). Most preferably, nicotine is used in a substantially pure or essentially pure form. A very preferred nicotine used has a purity higher than about 95 percent by weight, more preferably higher than about 98 percent by weight, and most preferably higher than about 99 percent by weight.

[0166] Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, nicotine is in its free base form. Nicotine may be tobacco-derived (e.g., tobacco extract) or non-tobacco-derived (e.g., obtained synthetically or by other means). In various embodiments, the aerosol-generating material may comprise a nicotine component. In various embodiments, the aerosol-generating material may not comprise a nicotine component. In some embodiments, the aerosol-generating material may comprise a non-tobacco-derived nicotine component.

[0167] Typically, when present, the nicotine component (calculated as the free base) is at a concentration of at least about 0.001% by weight of the aerosol - generating material, for example in the range of about 0.001% to about 10%. In some embodiments, the nicotine component is present at a concentration of about 0.1% w / w to about 10% by weight, for example about 0.1% w / w, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8% or about 0.9% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9% or about 10% by weight, calculated as the free base and relative to the total weight of the aerosol - generating material. In some embodiments, the nicotine component is present at a concentration of about 0.1% w / w to about 3% by weight, for example about 0.1% w / w to about 2.5%, about 0.1% to about 2.0%, about 0.1% to about 1.5% or about 0.1% to about 1% by weight, calculated as the free base and relative to the total weight of the aerosol - generating material. These ranges can also apply to other active ingredients described herein.

[0168] In some embodiments, the aerosol - generating material of the present disclosure can be characterized as being completely or substantially free of nicotine component. "Substantially free of nicotine component" means that, for example, in botanical materials or milled tobacco materials without nicotine, the nicotine component is not intentionally added beyond trace amounts that may be naturally present. For example, a particular embodiment can be characterized as having less than 0.001% by weight of nicotine calculated as the free base, or having less than 0.0001% or even 0% nicotine.

[0169] In some embodiments, the active ingredient includes a tobacco extract. In certain cases, the aerosol-generating material may contain 5 to 60% by weight (calculated on a dry weight basis) of the tobacco extract. In certain cases, the aerosol-generating material may contain from about 5% by weight, 10% by weight, 15% by weight, 20% by weight or 25% by weight to about 60% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight or 30% by weight (calculated on a dry weight basis) of the tobacco extract. For example, the aerosol-generating material may contain 10 to 50% by weight, 15 to 40% by weight or 20 to 35% by weight of the tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol-generating material contains 1% by weight, 1.5% by weight, 2% by weight or 2.5% by weight to about 10% by weight, 8% by weight, 6% by weight, 5% by weight, 4.5% by weight or 4% by weight (calculated on a dry weight basis) of nicotine. In some embodiments, the aerosol-generating element may contain 1 to 10% by weight, 2.5 to 8% by weight or 2 to 6% by weight of nicotine. In certain cases, there may be no nicotine in the aerosol-generating element other than that obtained from the tobacco extract.

[0170] In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse natural or synthetic compounds that act on intracellular cannabinoid receptors (e.g., CB1 and CB2) and alter neurotransmitters in the brain. Cannabinoids are cyclic molecules that exhibit certain properties such as the ability to readily cross the blood-brain barrier. Cannabinoids may occur naturally from plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or may be artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, which may be divided into subclasses including cannabigerol, cannabinchrome, cannabidiol, tetrahydrocannabinol, cannabinol and cannabinodiol, and other cannabinoids such as cannabigerol (CBG), cannabinchrome (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabinocyclol (CBL), cannabivaline (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabinchromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA) and tetrahydrocannabivarinic acid (THCV A).

[0171] In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabinchromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabidiorol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabinchromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA), tetrahydrocannabivarinic acid (THCV A) and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. In some embodiments, the cannabinoid (e.g., CBD) is added to the aerosol generating material in the form of an isolate. The isolate is an extract from a plant such as cannabis, and the active material in question (in this case, a cannabinoid such as CBD) is present in a high degree of purity, for example higher than 95%, higher than 96%, higher than 97%, higher than 98%, or about 99% purity. In some embodiments, the cannabinoid is an isolate of CBD of high purity, and the amount of any other cannabinoid in the substrate is about 1 wt% or less of the substrate, for example about 0.5 wt% or less of the substrate, for example about 0.1 wt% or less of the substrate, for example about 0.01 wt% or less of the substrate. The options for cannabinoids that may be present in the disclosed substrates and their specific percentages will vary depending on the desired properties of the aerosol generating material.

[0172] In some embodiments, cannabinoids (such as CBD) are present in the aerosol - generating material at a concentration of at least about 0.001% by weight, for example, in a concentration range of about 0.001% to about 2% by weight of the aerosol - generating material. In some embodiments, cannabinoids (such as CBD) are present in the aerosol - generating material at a concentration of about 0.1% to about 1.5% by weight based on the total weight of the aerosol - generating material. In some embodiments, cannabinoids (such as CBD) are present at a concentration of about 0.4% to about 1.5% by weight based on the total weight of the aerosol - generating material.

[0173] Alternatively or in addition to cannabinoids, the active ingredient may include cannabinimetics, which are a class of compounds derived from plants other than cannabis that exert biological effects on the endocannabinoid system similar to cannabinoids. Examples include yagonin, alpha - amyrin or beta - amyrin (which are also classified as terpenes), cyanidin, curcumin (turmeric), catechin, quercetin, salvianolic acid A, N - acyl ethanolamine, and N - alkylamide lipids. Such compounds can be used in the same amounts and ratios as described herein for cannabinoids.

[0174] In some embodiments, the active ingredient includes nicotine and cannabidiol (CBD). In some embodiments, the active ingredient includes nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol). In some embodiments, the active ingredient includes nicotine, caffeine, taurine, theine, vitamins such as vitamin B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof.

[0175] Active ingredients suitable for use in the present disclosure can also be classified as terpenes, many of which are associated with biological effects such as a sedative effect. Terpenes have the general formula (C5H8) nIt is understood to have and contain monoterpenes, sesquiterpenes and diterpenes. The terpene can have an acyclic, monocyclic or bicyclic structure. Some terpenes exhibit an anthrage effect when used in combination with cannabinoids or cannabinimetics. Examples include beta-caryophyllene, linalool, limonene, beta-citronellol, linalyl acetate, pinene (alpha or beta), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, and germacrene, which can be used alone or in combination.

[0176] In some embodiments, the terpene is a terpene derivable from a phytocannabinoid-producing plant, such as a plant from a strain of the Cannabis sativa species, such as hemp. Suitable terpenes in this regard include so-called "C10" terpenes, such as terpenes containing 10 carbon atoms, and so-called "C15" terpenes, such as terpenes containing 15 carbon atoms. In some embodiments, the active ingredient contains a plurality of terpenes. For example, the active ingredient may contain 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene and mixtures thereof. The terpene and / or cannabinoid may be present in the aerosol generating material as an active ingredient, as an aerosol forming agent material or as a flavoring component. The amounts of terpenes and / or cannabinoids present may vary accordingly based on their intended purpose.

[0177] The active ingredient may be a component of the aerosol forming agent material, or may be impregnated in or otherwise separately incorporated into the aerosol generating material. For example, the impregnation may be carried out during the preparation of the aerosol generating material, after the formation of the aerosol generating material, or both.

[0178] acid In some embodiments, the aerosol generating material comprises an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may 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.

[0179] 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.

[0180] In some embodiments, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0181] In certain embodiments, the aerosol generating material comprises nicotine and further comprises an acid. In such embodiments, the presence of the acid may stabilize nicotine species dissolved in the slurry from which the aerosol generating element is formed. The presence of the acid may reduce or substantially prevent the evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacture. The presence of the acid may also improve the flavor of the aerosol when nicotine is present. For example, the perceived unpleasantness of nicotine can be reduced by the presence of the acid.

[0182] flavoring substance In some embodiments, the aerosol generating material comprises a flavoring substance. As used herein, the reference to "flavoring substance" refers to a compound or component that can be aerosolized and delivered to the user and that provides a sensory experience with respect to taste and / or aroma. They may take any suitable form, such as a liquid like an oil, a solid like a powder, or a gaseous form. The flavoring substance may be natural or synthetic, and the flavor characteristics imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionery, floral, fruity, or spicy.Some examples of flavor substances include, but are not limited to, aloe vera, aniseed, apple, Asian spice, Bacopa monniera, basil, bay leaf, shiso, bergamot, berry, kinnow, blueberry, bourbon, camphor, cannabis, caraway, cardamom, dwarf lilyturf tuber, cassia bark, cassia, blackcurrant, celery, chamomile, cherry, cherry blossom, chive, pak choi, cinnamon, citrus fruits, clementine, clove, cocoa, coffee, cognac, coriander, cranberry, cucumber, cumin, turmeric, damiana, dragon fruit, durian, elderflower, eucalyptus, eugenol, fennel, fenugreek, flax, geranium, gin, ginger, Ginkgo biloba, grape, guayusa, hazel, hemp, hibiscus, honeybush, honey essence, hydrangea, Indian spice, jasmine, Japanese star anise, kaffir lime, lavender, laurel, lemon, lemongrass, lemon balm, lemon oil, lemon peel, licorice, lime, limonene, mace, Japanese white bark magnolia leaf, mango, maple, marjoram, matcha, mate, menthol, mint, ginger lily, mulberry fruit, snapdragon, nutmeg, olive, orange blossom, orange oil, orange peel, oregano, papaya, paprika, peach, peppermint, pepper, pineapple, rhubarb, rooibos, rosemary, rose hip, rose oil, rum, saffron, sage, sandalwood, Scotch, shisha, spearmint, strawberry, tarragon, tea such as green tea or black tea, tequila, terpene, thyme, tobacco, tropical fruits, turmeric, valerian, vanilla, verbena, wasabi, whiskey, wintergreen, Withania somnifera, yerba mate, yerba santa, ilang-ilang, and combinations thereof are included.

[0183] The flavoring substance may further contain a flavor enhancer, a bitter receptor site blocker, a sensory receptor site activator or stimulant, and a trigeminal nerve sensing substance. As used herein, "trigeminal nerve sensing substance" refers to a flavoring agent that exerts an effect on the trigeminal nerve and generates sensations including heat, cold, tingling and the like. Non-limiting examples of trigeminal nerve sensing substance flavoring agents include capsaicin, citric acid, menthol, Sichuan buttons, erythritol and cube sugar. Suitable heat agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

[0184] Further non-limiting examples include flavorings and flavor packages of the types and characteristics traditionally used in the flavoring of cigarettes, cigars, and pipe tobaccos. See also Tobacco Flavoring for Smoking Products by Leffingwell et al., R.J. Reynolds Tobacco Company (1972), which is incorporated herein by reference. The flavoring agent may include components such as terpenes, terpenoids, aldehydes, ketones, esters, and the like. Syrups such as high fructose corn syrup can also be used. Some examples of plant-derived compositions that may be suitable are disclosed in U.S. Patent No. 9,107,453 and U.S. Patent Application Publication No. 2012 / 0152265, both by Dube et al., the entire disclosures of which are incorporated herein by reference. The selection of such additional components varies based on factors such as the sensory characteristics desired in the smoking article, their affinity for the substrate material, and other physicochemical properties. The present disclosure is intended to encompass any such additional components readily apparent to those of ordinary skill in the art of tobacco and tobacco-related or tobacco-derived products. See, for example, Tobacco Flavoring Substances and Methods by Gutcho, Noyes Data Corp. (1972) and Tobacco Flavoring for Smoking Products by Leffingwell et al. (1972), the entire disclosures of which are incorporated herein by reference. It should be noted that the reference to flavor substances should not be limited to any single flavor substance described above, but in fact represents a combination of one or more flavor substances. Additional flavor substances, flavoring agents, additives, and other possible enhancing constituents are described in U.S. Patent Application No. 15 / 707,461 by Phillips et al., the entire disclosure of which is incorporated herein by reference.

[0185] In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus and / or redberry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco.

[0186] The flavoring substance may be a component of the aerosol-forming agent material or may be separately impregnated into the aerosol-generating material. The impregnation may be carried out during the preparation of the aerosol-generating material, after the formation of the aerosol-generating material, or both.

[0187] The amount of flavoring substance present may vary and, when present, is generally less than about 30% by weight, or less than about 20% by weight, of the aerosol-generating material. For example, the flavoring substance may be present in an amount of about 0.1%, about 0.5%, about 1% or about 5% to about 10%, about 20% or about 30% by weight of the aerosol-generating material.

[0188] Colorant In some embodiments, the aerosol-generating material includes a colorant. The addition of the colorant can change the visual appearance of the aerosol-generating material. The presence of the colorant can enhance the visual appearance of the aerosol-generating element including the aerosol-generating material and / or the substrate. By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color-matched to other parts of the aerosol-generating element or other components of an article containing the aerosol-generating material.

[0189] Various colorants can be used depending on the desired color of the aerosol - generating material. The color of the aerosol - generating material may be, for example, white, green, red, purple, blue, brown or black. Other colors are also contemplated herein. Natural or synthetic colorants such as natural or synthetic dyes, food - grade colorants and pharmaceutical - grade colorants may be used. In certain embodiments, the colorant is caramel which can give the substrate a brown appearance. In such embodiments, the color of the aerosol - generating material may be similar to the color of other components (such as tobacco materials) in the aerosol - generating element containing the aerosol - generating material. In some embodiments, the addition of the colorant to the aerosol - generating material makes it visually indistinguishable from other components.

[0190] The colorant may be incorporated during the formation of the aerosol - generating material (e.g., when forming a slurry containing the materials for forming the aerosol - generating material), or may be applied to the aerosol - generating material after its formation (e.g., by spraying it onto the aerosol - generating material).

[0191] Method for forming an aerosol - generating material In another aspect, a method for forming an aerosol - generating material is provided, which takes the form of a sheet having a surface and has a tobacco material embedded in or adhered to its surface. The method comprises (a)(i) one or more binders and / or foaming agents; (ii) a filler; (iii) an aerosol - forming agent material; and (iv) a solvent preparing a slurry comprising; (b) optionally, aerating the slurry to form an aerated slurry; (c) forming a layer of the slurry; (d) depositing a tobacco material on the layer of the slurry; and (e) drying the slurry having the tobacco material deposited on its surface to form the aerosol - generating material is included.

[0192] Each of the foam forming agent, filler, aerosol forming agent material, and tobacco material is as described in the above specification.

[0193] The amount of the solvent may vary. In some embodiments, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% of the solvent. In some embodiments, the solvent is water. In embodiments where the solvent is water, the dry weight content of the slurry matches the dry weight content of the aerosol generating material.

[0194] "Ventilating the slurry" means introducing a gas into the slurry to form bubbles, which are stabilized against collapse due to the presence of the foam forming agent(s). In some embodiments, the gas is air. Thus, in some embodiments, ventilating the slurry includes mixing the slurry under high shear conditions such that bubbles are incorporated into the slurry. In some embodiments, the slurry components are mixed to form the slurry before ventilating the slurry. In other embodiments, the slurry components are mixed under high shear conditions such that ventilation occurs during the formation of the slurry (i.e., preparing the slurry includes mixing the slurry under high shear conditions such that ventilation is performed as part of step (a)).

[0195] In some embodiments, ventilating the slurry includes bubbling a gas through the slurry. In some embodiments, the gas is air, nitrogen, or carbon dioxide.

[0196] In some embodiments, ventilating the slurry includes adding a foaming agent to the slurry. As described in the above specification, a foaming agent such as a mixture of carbonate or bicarbonate and an acid generates carbon dioxide gas when reacted with each other as can occur when added to a slurry containing water as a solvent. At least a portion of the bubbles thus formed are trapped in the slurry by the foam forming agent such that a ventilated slurry is provided.

[0197] The slurry layer may be formed by various techniques. For example, the formation of the slurry layer may include spraying, casting, or extruding the slurry. In some embodiments, the slurry layer is formed by electrospraying the slurry. In certain cases, the slurry layer is formed by casting the slurry. In some embodiments, the slurry is adhered to a support, and a vented slurry layer is formed on the support. In some embodiments, the slurry is cast onto a belt to form a layer.

[0198] The tobacco material described above in the specification is then deposited on the slurry layer. For example, the tobacco material may be adhered to the upper surface of the wet slurry from a hopper positioned above the slurry layer. In certain embodiments, the slurry is cast onto a casting belt to form the slurry layer, and the tobacco material is dropped from a hopper positioned above the casting belt and the casting belt is moved therewith, thereby uniformly distributing the tobacco material on the surface of the casting layer. One non-limiting embodiment of this method of depositing the tobacco material is provided in FIG. 1. Referring to FIG. 1, individual particles of tobacco material of various shapes are deposited from hopper 404 onto casting foam sheet 400 cast on moving belt 402, providing a randomly oriented layer of tobacco material 406 adhered to and / or embedded in casting foam sheet 400. The size of the tobacco particles 406 in FIG. 1 is emphasized for illustrative purposes.

[0199] After depositing the tobacco material, a layer of slurry having the tobacco material deposited on the surface is dried to remove at least a portion of the solvent (e.g., water) present in the slurry. In some embodiments, the drying removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% to about 80 wt%, 90 wt% or 95 wt% of the solvent in the slurry. In some embodiments, the drying includes heating the slurry. In some embodiments, after drying, the thickness of the cast material is reduced relative to the thickness of the wet cast material. For example, in some embodiments, the thickness of the wet slurry layer is reduced by at least about 80%, such as about 85% - 90%. For example, in one non-limiting embodiment, the slurry is cast at a thickness of about 2 mm and the resulting dried aerosol-generating material has a thickness of about 0.2 mm.

[0200] In some embodiments, the aerosol-generating material may be coated or laminated to avoid loss of the tobacco material embedded in or adhered to the surface of the sheet during a subsequent process (e.g., cutting). Such coating or lamination may be performed before or after drying. For example, in some embodiments, the aerosol-generating material takes a laminated form having the tobacco material embedded between the layers of the sheet. To provide such an embodiment, a second layer of slurry is cast onto the initial layer of the cast sheet having the tobacco material deposited on or adhered to the surface. This second layer may be deposited either before or after drying the initial cast sheet layer having the tobacco material deposited on or adhered to the surface. The laminated sheet is then dried as described above to form a laminated aerosol-generating material with the tobacco material embedded therein. Referring further to FIG. 1, a second slurry is introduced into an applicator 408 configured to deposit the slurry onto the initial layer of the cast sheet having the tobacco material deposited on or adhered to the surface.

[0201] In some embodiments, the aerosol generating material is in the form of a topcoat, and the tobacco material embedded or adhered to the surface of the sheet is topcoated with a film-forming agent. Suitable film-forming agents include, but are not limited to, hydroxypropyl cellulose, hydroxypropyl methylcellulose, modified starch, maltodextrin, carboxymethyl cellulose, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, monoglyceride, diglyceride, triethyl citrate, and the like, including combinations thereof. In some embodiments, the film-forming agent is an alginate, such as ammonium alginate, propylene glycol alginate, potassium alginate, and sodium alginate. In some embodiments, the film-forming agent is a cellulose derivative, such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, or sodium carboxymethyl cellulose. In some embodiments, the film-forming agent is a combination of hydroxypropyl cellulose, monoglyceride, diglyceride, and triethyl citrate. Exemplary film-forming agents are commercially available under the trade names WALOCEL™ and TEXTURECEL™. In some embodiments, the film-forming agent is a starch, such as corn starch, rice starch, or modified food starch. In some embodiments, the film-forming agent is a gum, such as xanthan gum, guar gum, gum arabic, locust bean gum, pullulan, or tragacanth gum.

[0202] Such a topcoat material may be formed by depositing a film-forming agent on a sheet having a tobacco material deposited on or adhered to its surface. The deposition may be carried out by any suitable method, such as spraying or flowing the film-forming agent in the form of a solution on the sheet, optionally in a suitable solvent, or dipping the sheet into the film-forming agent. In some embodiments, the film-forming agent is sprayed or deposited on the sheet. Further referring to FIG. 1, the film-forming agent is fed into an applicator 408 configured to spray or deposit a slurry on a layer of a cast sheet having a tobacco material deposited on or adhered to its surface. In embodiments where the film-forming agent is deposited in solution form, the final topcoat aerosol-generating material is formed by drying the resulting layer of the film-forming agent so as to remove at least a portion of the solvent present in the solution, and the topcoat aerosol-generating material is formed.

[0203] Properties of the aerosol-generating material The aerosol-generating material is generally provided as a sheet. The aerosol-generating material may be continuous. For example, in a cast foam sheet, the foam may comprise or be the continuous sheet of material. The sheet may be cut into strips, such as about 20 to 30 cut pieces per inch, and used as a consumable or a filler for a roll-your-own cigarette. The sheet may be shredded to form shredded sheets and collected into strands or bundles for use in the consumables or roll-your-own cigarettes described hereinbelow. The sheet may take the form of a wrapper or may be collected to form a sheet collected as described hereinbelow.

[0204] The thickness of the aerosol generating material may vary. As used herein, the term "thickness" when used with respect to the aerosol generating material describes the shortest distance between the first surface and the second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between the first plane of the sheet and the second plane of the sheet that faces the first plane of the sheet. In some cases, the aerosol generating material may have a thickness of from about 0.015 mm to about 10 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 5 mm, 3 mm, 2 mm, 1 mm, 0.5 mm or 0.3 mm. The aerosol generating material may comprise a plurality of layers, and the thickness described herein refers to the combined thickness of those layers. The thickness values defined herein are the average values of the thicknesses in question. In some cases, the thickness may vary by 25%, 20%, 15%, 10%, 5% or 1% or less.

[0205] An aerosol generating material in the form of a cast bubble sheet is a porous material. The density of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material has a density of about 0.02 g / cm 3 , 0.06 g / cm 3 , 0.1 g / cm 3 or 0.15 g / cm 3 to about 0.25 g / cm 3 , 0.4 g / cm 3 , 0.6 g / cm 3 or 0.7 g / cm 3 . In some embodiments, the aerosol generating material has a density of 0.02 - 0.7 g / cm 3 , 0.02 - 0.6 g / cm 3 , 0.02 - 0.5 g / cm 3 , 0.02 - 0.4 g / cm 3 or 0.1 - 0.3 g / cm 3 .

[0206] The filling value of the aerosol generating material may vary. For example, in some embodiments, the aerosol generating material has a volume of about 380 cm 3Greater than 100 g, about 400 cm 3 Greater than 100 g, or 420 cm 3 Has a filling value greater than 100 g. The filling value may be measured using a densitometer. In one embodiment, the filling value is measured according to Method A: Weigh about 70 - 80 g of the aerosol - generating material. Then transfer the weighed aerosol - generating material to the container assembly of the densitometer and measure the bulk volume. Then calculate the filling value according to Equation 1: Filling value=(Bulk volume / Weight)×100 (Equation 1) Calculate according to

[0207] The Gurley porosity of the aerosol - generating material may vary. For example, in some embodiments, the aerosol - generating material has a Gurley porosity of about 100 seconds / 100 mL or more, 125 seconds / 100 mL or more, or 150 seconds / 100 mL or more. The Gurley porosity may be measured using a Gurley densitometer. In one embodiment, the Gurley porosity is measured according to Method B: The aerosol - generating material is placed between the clamp plates of the Gurley densitometer. Then lower the inner cylinder and measure the time required to flow 100 cc of air into the material.

[0208] Aerosol - generating element In another aspect, an aerosol - generating element is provided. The aerosol - generating element includes the aerosol - generating material disclosed herein. The aerosol - generating element may take any suitable form, such as a shredded sheet, a corrugated sheet, or a sheet gathered into a crimped cylindrical rod. In some embodiments, the aerosol - generating element includes a crimped and gathered sheet or a corrugated sheet of the aerosol - generating material formed on a rod, and the rod has a wrapping material surrounding the rod. An aerosol - generating element in the form of a crimped cylindrical rod according to a non - limiting embodiment is illustrated in FIG. 2. Referring to FIG. 2, the rod 500 includes a wrapping material 502, an outermost layer 504 of crimped paper, and an inner crimped bundle 506 of the aerosol - generating material.

[0209] Figures 3A - 3C provide additional exemplary configurations of an aerosol - generating element that includes an aerosol - generating material. For example, as shown in Figure 3A, the aerosol - generating element can be composed of a single layer of an aerosol - generating material in the form of a corrugated sheet that is wound in a tube form and surrounded by a wrapping material. Alternatively, as shown in Figure 3B, the aerosol - generating material can be used in a laminated form where multiple layers are stacked together and surrounded by a wrapping material. Still further, as shown in Figure 3C, the aerosol - generating material can be used in the form of a corrugated sheet that is coiled and surrounded by a wrapping material.

[0210] In some embodiments, the aerosol - generating element further includes additional tobacco material (e.g., reconstituted or laminated tobacco). To avoid confusion, this additional tobacco material is separate and distinct from the tobacco material that is present in or on the cast sheet of the aerosol - generating material and does not form part of the aerosol - generating material. Instead, this additional tobacco material is physically combined with a cast sheet having adhered or embedded tobacco material. In some embodiments, the aerosol - generating element comprises from about 10 to about 100 weight percent of the aerosol - generating material, with the remainder being a component that comprises or consists of tobacco material. In some embodiments, the tobacco material is present in the aerosol - generating element in an amount of about 50 - 90 weight percent, or about 60 - 90 weight percent, or about 70 - 90 weight percent, or about 80 - about 90 weight percent of the aerosol - generating element. In some embodiments, the aerosol - generating material is present in the aerosol - generating element in an amount of about 5 - 40 weight percent, 5 - 30 weight percent, 5 - 25 weight percent, or 10 - 25 weight percent, or 10 - 20 weight percent. In some embodiments, the aerosol - generating element consists of or consists essentially of the aerosol - generating material and the tobacco material.

[0211] Any suitable form of tobacco material may be used, such as tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco and / or tobacco extracts.

[0212] In some embodiments, the aerosol - generating material is present as a shredded sheet blended with the tobacco material. In some embodiments, the tobacco material is finely cut and / or shredded, such that, for example, the aerosol - generating material and the tobacco material take on a similar form. In some embodiments, the tobacco material comprises reconstituted tobacco, tobacco laminas, fine cut tobacco, cut rag tobacco or combinations thereof.

[0213] The tobacco used to produce the tobacco material may be any suitable tobacco, such as single - grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. The tobacco particles may be "fine" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may contain tobacco fibers and may be formed by casting, Fourdrinier - based papermaking - type techniques with the further addition of tobacco extracts, or extrusion. In some embodiments, the tobacco material comprises or consists of laminar tobacco (such as cut rag tobacco) that provides desirable sensory characteristics. In some embodiments, the tobacco material comprises reconstituted tobacco in an amount of less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% on a dry - weight basis of the tobacco material. In some embodiments, the tobacco material is substantially free of reconstituted tobacco.

[0214] In some embodiments, the tobacco material is finely cut (e.g., cut into thin strips). The finely cut tobacco material may be advantageously blended with the aerosol generating material so as to provide an aerosol generating element having a uniform dispersion of the tobacco material and the aerosol generating material throughout the aerosol generating element. Finely cut tobacco (such as cut rag tobacco) has a cut width, typically expressed as CPI (cuts per inch) and referring to the shredded width of the tobacco. In some examples where the tobacco material is finely cut (e.g., where the tobacco material includes cut rag tobacco), the cut width of the aerosol generating material is about 90-110% of the cut width of the cut rag tobacco. That is, the aerosol generating material and the tobacco material have similar cut widths or shredded widths. By configuring the aerosol generating material and the tobacco material to have similar cut widths, a better blend of the aerosol generating material and the tobacco material is possible. For example, shredded aerosol generating material sheets and cut rag tobacco having similar cut widths can be blended to provide a more homogeneous aerosol generating element (e.g., a better distribution of each material throughout the aerosol generating element). The tobacco material may have a length of 1-4 cm.

[0215] In some embodiments, the tobacco material includes one or more of ground tobacco, tobacco fibers, cut shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extracts. It is possible to use a relatively large amount of lamina tobacco in the aerosol generating element and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Lamina tobacco typically provides excellent sensory properties. In an example, the tobacco material includes lamina tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material includes cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0216] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0217] In some embodiments, the aerosol - generating material is shredded and blended with other materials, such as a support, instead of or in addition to tobacco, to form an aerosol - generating element.

[0218] In some embodiments, the aerosol - generating material is top - coated or laminated. In some embodiments, the aerosol - generating material takes a laminated form. In such embodiments, a layer of a dried, optionally ventilated slurry forms a second sheet over the aerosol - generating material such that the tobacco material is embedded between two sheet layers. Without being bound by theory, such a laminated form is thought to be useful in avoiding loss of the adhered or embedded tobacco material in subsequent processing (e.g., cutting, shredding, forming, and the like). A non - limiting example of an aerosol - generating material 600 taking a laminated form is shown in FIG. 11. Referring to FIG. 11, a second sheet 606, optionally in the form of a foam sheet, is adhered to and overlays tobacco material 604 embedded in base sheet 602 and can contact either directly the tobacco material 604 alone or both the tobacco material and the base sheet.

[0219] In some embodiments, the aerosol - generating material is in the form of a top - coat, and the tobacco material embedded or adhered to the surface of the sheet is top - coated with a film - forming agent as described hereinabove. Without being bound by theory, such a top - coat form is thought to be useful for avoiding loss of the adhered or embedded tobacco material during subsequent processing (e.g., cutting, shredding, forming, and the like). In some embodiments, the aerosol - generating material is top - coated with a film - forming agent selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, modified starch, maltodextrin, carboxymethyl cellulose, alginate, carrageenan, xanthan, gellan, acacia gum, tragacanth gum, and combinations thereof. In some embodiments, the aerosol - generating material is top - coated with a film - forming agent selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, and carboxymethyl cellulose. In some embodiments, the film - forming agent is hydroxypropyl methylcellulose. A non - limiting embodiment of the aerosol - generating material 700 in top - coat form is shown in FIG. 12. Referring to FIG. 12, the coating 712 is adhered and overlaid on the tobacco material 710 embedded in the base sheet 708 and can be in direct contact with either only the tobacco material 710 or both the tobacco material and the base sheet.

[0220] Support In some embodiments, the aerosol generating material described herein may be present on or in a support to form a substrate (synonymous with the term "consumable" in some embodiments). In such embodiments, the support functions as a scaffold on which the aerosol generating material layer is formed, facilitating manufacturing. The support may provide hardness to the aerosol generating material layer and ease handling. The support may be any suitable material that can be used to support the aerosol generating material. In some embodiments, the support may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. In some embodiments, the support may include or consist of a tobacco material such as a reconstituted tobacco sheet. In some embodiments, the support may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some embodiments, the support includes paper. In some embodiments, the support itself may be a laminate structure including layers of materials selected from the preceding list. In some embodiments, the support may function as a flavor support. For example, the support may be impregnated with a flavoring substance or a tobacco extract.

[0221] The thickness of the support may vary. In some embodiments, the thickness of the support layer may be in the range of about 10 μm, 15 μm, 17 μm, 20 μm, 23 μm, 25 μm, 50 μm, 75 μm or 0.1 mm to about 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm or 0.5 mm. The support may include multiple layers, and the thicknesses described herein refer to the combined thickness of those layers.

[0222] In some embodiments, the support may be magnetic. This functionality may be used to hold the support in the assembly during use or to generate a particular shape of the aerosol generating material. In some cases, the aerosol generating substrate may include one or more magnets that can be used to hold the substrate in an induction heater during use.

[0223] In some embodiments, the support may be substantially or entirely impermeable to gases and / or aerosols. This prevents the passage of aerosols or gases through the support layer, thereby controlling the flow and ensuring delivery to the user. This can also be used, for example, to prevent condensation or other deposition of the gas / aerosol during use on the surface of a heater provided in the aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.

[0224] In some embodiments, the surface of the support in contact with the aerosol generating material may be porous. For example, in some embodiments, the support includes paper. A porous support such as paper is particularly suitable for the present invention; the porous (e.g., paper) layer is in contact with the aerosol generating layer and forms a strong bond. The aerosol generating material is formed by drying a gel, and without being bound by theory, it is believed that the slurry from which the gel is formed impregnates the porous support (e.g., paper) such that the support binds partially to the gel when the gel cures and forms crosslinks. This provides a strong bond between the gel and the support (and between the dried gel and the support).

[0225] Furthermore, surface roughness can contribute to the strength of the bond between the aerosol generating material and the support. The roughness of the paper (in the case of the surface in contact with the support) may suitably be in the range of 50 to 1000 Bekk seconds, suitably 50 to 150 Bekk seconds, suitably 100 Bekk seconds (measured at an air pressure interval of 50.66 to 48.00 kPa). (The Bekk smoothness tester is a device used to determine the smoothness of the surface of paper. The air at the specified pressure leaks between the smooth glass surface and the paper sample, and the time (in seconds) for a fixed volume of air to exude between these surfaces is the "Bekk smoothness".).

[0226] Conversely, the surface of the support facing away from the aerosol generating material may be arranged in contact with the heater, and a smoother surface may result in more efficient heat transfer. Thus, in some cases, the support is arranged to have a rougher surface in contact with the aerosol generating material and a smoother surface facing away from the aerosol generating material.

[0227] In some specific embodiments, the support may be a foil lined with paper; the paper layer is in contact with the aerosol generating material layer, and the properties discussed in the previous paragraph are provided by this contact. The lining of the foil is substantially impermeable and provides control of the aerosol flow path. The lining of the metal foil may also serve to conduct heat to the aerosol generating material.

[0228] In another embodiment, the foil layer of the foil lined with paper is in contact with the aerosol generating material. The foil is substantially impermeable, thereby preventing the water provided to the aerosol generating material from being absorbed by the paper and weakening its structural integrity.

[0229] In some embodiments, the support is formed from or includes a metal foil such as aluminum foil. The metal support may allow for better conduction of thermal energy to the aerosol generating material. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the support includes a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, such as from about 1 μm to about 10 μm, suitably about 5 μm.

[0230] In some embodiments, the support may have a thickness between about 0.017 mm and about 2.0 mm, suitably about 0.02 mm, 0.05 mm or 0.1 mm to about 1.5 mm, 1.0 m or 0.5 mm.

[0231] Consumable In another aspect of the present disclosure, an article (also referred to herein as a consumable) is provided. A consumable is an article that is intended to be at least partially consumed during use by a user. The consumable may include or consist of the aerosol generating element described herein. The consumable may include one or more other elements, such as a filter or an aerosol modifying substance. The consumable may include a heating element that releases heat to generate an aerosol from the aerosol generating element during use. The heating element may include, for example, a combustible material or a susceptor that is heatable by transmission in a changing magnetic field.

[0232] A susceptor is a material that is heatable by transmission in a changing magnetic field, such as an alternating magnetic field. The heating material may be a conductive material such that its transmission in a changing magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that its transmission in a changing magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both conductive and magnetic, and thus the heating material is heatable by both heating mechanisms.

[0233] Inductive heating is a process in which a conductive object is heated by transmitting a changing magnetic field through the object. The process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may include an electromagnet and a device that passes a changing current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to each other such that the magnetic field generated by the electromagnet and consequently changing penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Thus, when such eddy currents are generated within the object, the flow of the current through the electrical resistance of the object heats the object. This process is called Joule, Ohmic, or resistive heating.

[0234] In some embodiments, the susceptor takes the form of a closed circuit. When the susceptor takes the form of a closed circuit, the magnetic coupling between the susceptor in use and the electromagnet is enhanced, and as a result, it has been found that the Joule heat becomes larger or is improved.

[0235] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by transmitting a changing magnetic field through the object. A magnetic material can be regarded as containing many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles are aligned with the magnetic field. Therefore, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the changing applied magnetic field. Such reorientation of the magnetic dipoles generates heat in the magnetic material.

[0236] When an object is conductive and magnetic, both Joule heating and magnetic hysteresis heating can be induced within the object by transmitting a changing magnetic field through the object. Furthermore, the use of a magnetic material can enhance the magnetic field and thus enhance Joule heating.

[0237] In each of the above processes, since heat is generated inside the object itself rather than by an external heat source through heat conduction, a rapid temperature rise and a more uniform heat distribution within the object can be achieved, particularly through the selection of an appropriate object material and geometry, as well as an appropriate magnitude of the changing magnetic field and its orientation with respect to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the changing magnetic field and the object, so the degree of design freedom and control of the heating profile can be increased, and the cost can be reduced.

[0238] The delivery system described herein can be implemented as a flammable aerosol delivery system or a non-flammable aerosol delivery system.

[0239] Flammable aerosol delivery system Aspects of the present invention provide a combustible aerosol delivery system in which a component aerosol generating material of an aerosol delivery system (or a component thereof) burns or is combusted during use to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol delivery system such as a system selected from the group consisting of cigarettes, cigars, and cigarillos.

[0240] Non-combustible aerosol delivery device Aspects of the present invention provide a non-combustible aerosol delivery system comprising an article described herein (i.e., an aerosol generating material, component, or consumable) and a non-combustible aerosol delivery device comprising a heater configured to heat rather than burn the aerosol generating article. The non-combustible aerosol delivery system may also be referred to as an aerosol generating assembly. The non-combustible aerosol delivery device may also be referred to as an aerosol generating device.

[0241] In some cases, during use, the heater may heat the aerosol generating material to a temperature equal to or less than 350°C, for example a temperature between 120°C and 350°C, rather than burning it. In some cases, the heater may heat the aerosol generating element to between 140°C and 250°C or between 220°C and 280°C during use rather than burning it. In some cases, during use, substantially all of the aerosol generating material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the material is disposed between about 0.010 mm and 2.0 mm from the heater, suitably between about 0.02 mm and 1.0 mm, and suitably between 0.1 mm and 0.5 mm. These minimum distances may in some cases reflect the thickness of a support supporting the aerosol generating material. In some cases, the surface of the aerosol generating material may be in direct contact with the heater.

[0242] The heater is configured to heat, rather than burn, the aerosol-generating article and thus the aerosol-generating element. In some cases, the heater may be a thin-film electrical-resistance heater. In other cases, the heater may include an induction heater or the like. The heater may be a combustible or chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol-generating assembly may include a plurality of heaters. The heater(s) may be powered by a battery.

[0243] The aerosol-generating article may further include a cooling element and / or a filter. The cooling element, if present, may act or function to cool the gaseous or aerosol components. In some cases, it may act to cool the gaseous components so as to condense to form the aerosol. It may act to keep the very hot parts of the non-combustible aerosol-providing device away from the user. The filter, if present, may include any suitable filter known in the art, such as a cellulose acetate plug.

[0244] In some cases, the aerosol-generating assembly may be a device that heats without burning. Devices that heat without burning are disclosed in International Patent Application Publication No. WO2015 / 062983, which is incorporated herein by reference in its entirety.

[0245] In some cases, the aerosol generating assembly may be an e-cigarette hybrid device. That is, it may contain a solid aerosol generating element and a liquid aerosol generating material. In some cases, the aerosol generating material may contain nicotine. In some cases, the aerosol generating material may contain tobacco material. In some cases, the aerosol generating material may contain tobacco material and an individual nicotine source. The individual aerosol generating elements may be heated by individual heaters, or the same heater or, in some cases, the downstream aerosol generating material may be heated by the hot aerosol generated from the upstream aerosol generating elements. The e-cigarette hybrid device is disclosed in International Patent Application Publication No. WO2016 / 135331 which is incorporated herein by reference in its entirety.

[0246] The aerosol generating article (which may be referred to herein as an article, cartridge or consumable) may be adapted for use in a THP, e-cigarette hybrid device or another aerosol generating device. In some cases, the article may further include a filter and / or a cooling element (already described). In some cases, the aerosol generating article may be surrounded by a wrapping material such as paper.

[0247] The aerosol generating article may further include a ventilation aperture. These may be provided in the sidewall of the article. In some cases, the ventilation aperture may be provided within the filter and / or the cooling element. These apertures may draw cooling air into the article during use, mix with the heated volatile components and thereby cool the aerosol.

[0248] Ventilation enhances the generation of visible heated volatile components from the article when heated during use. The heated volatile components become visible by a process of cooling the heated volatile components such that supersaturation of the heated volatile components occurs. The heated volatile components then undergo droplet formation, known as nucleation under normal circumstances, and ultimately the size of the aerosol particles of the heated volatile components increases by further condensation of the heated volatile components and aggregation of newly formed droplets from the heated volatile components.

[0249] In some cases, the ratio of the cooling air to the sum of the heated volatile components and the cooling air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% makes the heated volatile components visible by the method described above. Due to the visibility of the heated volatile components, the user can confirm that the volatile components are generated and the sensory experience of the smoking experience is enhanced.

[0250] In another embodiment, the ventilation ratio is between 50% and 85% so as to provide additional cooling to the heated volatile components. In some cases, the ventilation ratio may be at least 60% or 65%.

[0251] In some cases, the aerosol generating element may be included in the article / assembly in the form of a sheet as described in the present specification above. In some cases, the aerosol generating element may be included in a flat sheet. In some cases, the aerosol generating element may be included as a flat sheet, as a bundled or assembled sheet, as a crimped sheet, or as a rolled sheet (i.e., in the form of a rod or tube), as described in the present specification above. In some such cases, the aerosol generating material of these embodiments may be included in the aerosol generating article / assembly as a sheet, such as a sheet surrounding a rod of aerosol generating material (e.g., tobacco). In some other cases, the aerosol generating element may be formed as a sheet and then shredded and incorporated into the article. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the article.

[0252] In some cases, both the first and second aerosol generating materials described herein may be formed as sheets, then shredded and mixed together to form an aerosol generating element. The components may then be incorporated into an article. In some cases, the shredded sheets may be mixed with cut rag tobacco and incorporated into an article.

[0253] In some embodiments, the aerosol generating material is formed as a foam on a support. The aerosol generating foam may be a continuous foam or a discontinuous foam, for example, an arrangement configuration of individual portions of the foam on the support.

[0254] Referring to FIGS. 4 and 5, partial cutaway cross-sectional views and perspective views of an example of an aerosol generating article 101 are shown. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in FIGS. 8-10 described below. In use, the article 101 can be removably inserted into the device shown in FIG. 8 at the insertion portion 20 of the device 1.

[0255] An article 101 of one example takes the form of a substantially cylindrical rod including a body of an aerosol generating element 103 and a filter assembly 105 in the form of a rod. The aerosol generating element includes the aerosol generating material described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in the form of shredded sheets. In some embodiments, the aerosol generating element described herein may be incorporated in sheet form and in shredded form.

[0256] The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109, and a mouthpiece segment 111. The article 101 has a first end 113, also known as the mouthpiece or proximal end, and a second end 115, also known as the distal end. The body of the aerosol generating element 103 is positioned towards the distal end 115 of the article 101. In one embodiment, the cooling segment 107 is positioned adjacent to the body of the aerosol generating element 103 between the aerosol generating element 103 and the filter segment 109 such that the cooling segment 107 is in contact with the aerosol generating element 103 and the filter segment 103. In other embodiments, there may be a gap between the body of the aerosol generating element 103 and the cooling segment 107, and between the body of the aerosol generating element 103 and the filter segment 109. The filter segment 109 is positioned between the cooling segment 107 and the mouthpiece segment 111. The mouthpiece segment 111 is positioned adjacent to the filter segment 109 towards the proximal end 113 of the article 101. In one embodiment, the filter segment 109 is in contact with the mouthpiece segment 111. In one embodiment, the overall length of the filter assembly 105 is between 37 mm and 45 mm, more preferably, the overall length of the filter assembly 105 is 41 mm.

[0257] In one embodiment, the rod of the aerosol generating element 103 has a length between 34 mm and 50 mm, suitably between 38 mm and 46 mm, suitably 42 mm in length.

[0258] In one embodiment, the overall length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

[0259] The axial end of the body of the aerosol generating element 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers the axial end of the body of the aerosol generating element 103.

[0260] The body of the aerosol generating element 103 is joined to the filter assembly 105 by an annular chip paper (not shown) that surrounds the filter assembly 105 and is positioned substantially around the periphery of the filter assembly 105 so as to extend partially along the length of the body of the aerosol generating element 103. In one embodiment, the chip paper is made of 58 GSM standard chip base paper. In one embodiment, the chip paper has a length between 42 mm and 50 mm, suitably 46 mm.

[0261] In one embodiment, the cooling segment 107 is an annular tube and is positioned around the cooling segment and defines an internal void. The void provides a chamber for flowing the heated volatile components generated from the body of the aerosol generating element 103. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation that remains rigid to withstand axial compressive forces and bending moments that may occur during manufacture and during use while the article 101 is inserted into the device 1. In one embodiment, the wall thickness of the cooling segment 107 is about 0.29 mm.

[0262] The cooling segment 107 provides a physical displacement between the aerosol generating element 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the entire length of the cooling segment 107. In one embodiment, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In one embodiment, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol generating element 103 when the device 1 is heated. If no physical displacement is provided between the filter segment 109, the body of the aerosol generating element 103, and the heating element of the device 1, the temperature-sensitive filter segment 109 may be damaged during use and thus its required function may not be effectively exerted.

[0263] In one embodiment, the length of the cooling segment 107 is at least 15 mm. In one embodiment, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly between 23 mm and 27 mm, more particularly between 25 mm and 27 mm, suitably 25 mm.

[0264] The cooling segment 107 is made of paper, which means it is composed of a material that does not generate the compounds of concern, such as toxic compounds, when used adjacent to the heater of the device 1. In one embodiment, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while still maintaining mechanical stiffness. The spirally wound paper tube can meet the tight dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and straightness of the tube.

[0265] In another embodiment, the cooling segment 107 is a recess created from a hard plug wrap or chip paper. The hard plug wrap or chip paper is manufactured to have a hardness sufficient to withstand the axial compressive forces and bending moments that can occur during manufacture and during use when the article 101 is inserted into the device 1.

[0266] The filter segment 109 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components of the aerosol generating material. In one embodiment, the filter segment 109 is made of a monoacetate material such as cellulose acetate. The filter segment 109 provides cooling and irritation reduction from the heated volatile components without depleting the amount of heated volatile compounds to an unsatisfactory level for the user.

[0267] In some embodiments, a capsule (not shown) may be provided in the filter segment 109. It may be disposed substantially at the center of the filter segment 109 both across the diameter of the filter segment 109 and along the length of the filter segment 109. In other cases, it may be offset in one or more dimensions. The capsule may, in some cases, if present, contain volatile components such as flavoring substances or aerosol forming agent materials.

[0268] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, i.e., the draw resistance of the article 101. Thus, the selection of the material of the filter segment 109 is important for controlling the resistance to draw of the article 101. Further, the filter segment performs a filtering function in the article 101.

[0269] In one embodiment, the filter segment 109 is made of a filter tow material of grade 8Y15, which provides a filtering effect on the heated volatile material but also reduces the size of the condensed aerosol droplets resulting from the heated volatile material.

[0270] The presence of the filter segment 109 also provides an insulating effect by causing further cooling of the heated volatile components exiting the cooling segment 107. This further cooling effect reduces the contact temperature of the user's lips at the surface of the filter segment 109. In one embodiment, the filter segment 109 is between 6 mm and 10 mm in length, suitably 8 mm.

[0271] The mouthpiece segment 111 is an annular tube that is positioned around and defines an internal void therewithin. The void provides a chamber for the heated volatile components flowing from the filter segment 109. The mouthpiece segment 111 is hollow to provide a chamber for aerosol accumulation that remains sufficiently rigid to withstand the axial compressive forces and bending moments that can occur during manufacture and during use when the article is inserted into the device 51. In one embodiment, the wall thickness of the mouthpiece segment 111 is approximately 0.29 mm. In one embodiment, the length of the mouthpiece segment 111 is between 6 mm and 10 mm, suitably 8 mm.

[0272] The mouthpiece segment 111 provides a hollow internal chamber but may be made from a helically wound paper tube that still maintains a very important mechanical stiffness. The helically wound paper tube can meet the tight dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and linearity of the tube. The mouthpiece segment 111 provides the function of preventing any liquid condensate accumulated at the outlet of the filter segment 109 from coming into direct contact with the user.

[0273] It should be understood that in one embodiment, the mouthpiece segment 111 and the cooling segment 107 may be formed from a single tube and the filter segment 109 is positioned within the tube that separates the mouthpiece segment 111 and the cooling segment 107.

[0274] Referring to FIGS. 6 and 7, there are shown a partial cutaway cross-sectional view and a perspective view of an embodiment of an article 301 having an aerosol generating element 303, a filter assembly 305, a cooling segment 307, a filter segment 309, an inlet segment 311, a proximal end 313, a distal end 315, and a ventilation region 317. The reference numerals in FIGS. 6 and 7 are equivalent to those shown in FIGS. 4 and 5, except that they are increased by 200 only.

[0275] In the embodiment of the article shown in FIGS. 6 and 7, a ventilation region 317 is provided in the article 301 to enable air to flow from outside the article 301 into the article 301. In one embodiment, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through an outer layer of the article 301. The ventilation holes may be positioned in the cooling segment 307 to assist in cooling the article 301. In one embodiment, the ventilation region 317 includes one or more rows of holes, and preferably the holes in each row are arranged circumferentially along the article 301 in a cross-section substantially perpendicular to the longitudinal axis of the article 301.

[0276] In one embodiment, there are ventilation holes between 1 and 4 rows that provide ventilation to the article 301. Each row of ventilation holes may have between 12 and 36 ventilation holes 317. The ventilation holes 317 may be, for example, between 100 and 500 μm in diameter. In one embodiment, the axial separation between rows of ventilation holes 317 is between 0.25 mm and 0.75 mm, and suitably 0.5 mm.

[0277] In one embodiment, the ventilation holes 317 are of uniform size. In another embodiment, the ventilation holes 317 are of various sizes. The ventilation holes can be made using any suitable technique, such as one or more of the following techniques: laser technology, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The ventilation holes 317 are positioned to provide effective cooling to the article 301.

[0278] In one embodiment, the row of ventilation holes 317 is positioned at least 11 mm away from the proximal end 313 of the article, and suitably between 17 mm and 20 mm from the proximal end 31 of the article 301. The location of the ventilation holes 317 is positioned so that the user does not block the ventilation holes 317 when the article 301 is in use.

[0279] By providing a row of ventilation holes between 17 mm and 20 mm from the proximal end 313 of the article 301, as seen in FIGS. 9 and 10, when the article 301 is fully inserted into the device 1, the ventilation holes 317 can be positioned outside the device 1. By positioning the ventilation holes outside the device, unheated air can enter the article 301 through the ventilation holes from outside the device 1 to assist in cooling the article 301.

[0280] The length of the cooling segment 307 is such that when the article 301 is fully inserted into the device 1, the cooling segment 307 is partially inserted into the device 1. The length of the cooling segment 307 serves a first function of providing a physical gap between the arrangement of the heater of the device 1 and the heat-sensitive filter arrangement 309, and a second function of being able to position the ventilation holes 317 in the cooling segment while also being positioned outside the device 1 when the article 301 is fully inserted into the device 1. As can be seen from FIGS. 9 and 10, most of the cooling element 307 is positioned within the device 1. However, there is a portion of the cooling element 307 that extends outside the device 1. The ventilation holes 317 are positioned in this portion of the cooling element 307 that extends outside the device 1.

[0281] Next, referring more particularly to FIGS. 8 - 10, an embodiment of a device 1 is shown that is arranged to heat an aerosol-generating element to volatilize at least one component of the aerosol-generating element, typically to form an inhalable aerosol. The device 1 is a heating device that releases a compound by heating the aerosol-generating element rather than burning it.

[0282] Referring to FIGS. 8 and 9, the first end 3 is sometimes referred to herein as the suction port or proximal end 3 of the device 1, and the second end 5 is sometimes referred to herein as the distal end 5 of the device 1. The device 1 has an on / off button 7 that allows the user to switch the device 1 on and off as desired.

[0283] The device 1 includes a housing 9 for positioning and protecting various internal components of the device 1. In the illustrated embodiment, the housing 9 includes a unibody sleeve 11 that encompasses the periphery of the device 1 capped by a top panel 17 that generally defines the "top" of the device 1 and a bottom panel 19 that generally defines the "bottom" of the device 1. In another embodiment, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and the bottom panel 19.

[0284] The top panel 17 and / or the bottom panel 19 may be removably fixed to the unibody sleeve 11 to allow easy access to the interior of the device 1, or may be "permanently" fixed to the unibody sleeve 11, for example, to prevent the user from accessing the interior of the device 1. In an embodiment, the panels 17 and 19 are made of a plastic material including glass-filled nylon formed, for example, by injection molding, and the unibody sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

[0285] The top panel 17 of the device 1 has an opening 20 at the suction port 3 of the device 1 through which articles 101, 301 including an aerosol generating element may be inserted into and removed from the device 1 by the user during use.

[0286] Inside the housing 9, a heater arrangement 23, a control circuit 25, and a power source 27 are positioned or fixed. In this embodiment, the heater arrangement 23, the control circuit 25, and the power source 27 are adjacent to each other in the lateral direction (i.e., adjacent when viewed from the end), and this control circuit 25 is generally positioned between the heater arrangement 23 and the power source 27, although other locations are possible.

[0287] The control circuit 25 may include a controller such as a microprocessor arrangement configured and arranged to control the heating of the aerosol generating elements within the articles 101, 301, as further discussed below.

[0288] The power source 27 may be a battery, for example, a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and / or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply power, when needed and under the control of the control circuit 25, to heat the aerosol generating elements within the article (to volatilize the aerosol generating material without burning the aerosol generating elements, as discussed).

[0289] The advantage of positioning the power source 27 adjacent to the side of the heater arrangement 23 is that a physically large power source 25 can be used without making the device 1 overly long as a whole. As understood, a physically large power source 25 generally has a higher capacity (i.e., the total electrical energy that can be supplied, often measured in ampere-hours or the like), and thus can increase the battery life of the device 1.

[0290] In one embodiment, the heater arrangement 23 generally takes the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which articles 101, 301 containing aerosol generating material are inserted for heating during use. Various arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may include a single heating element or may be formed of a plurality of heating elements arranged along the longitudinal axis of the heater arrangement 23. Each heating element may be annular or tubular, or at least partially annular or tubular around its periphery. In an embodiment, each heating element may be a thin film heater. In another embodiment, each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride, and silicon nitride ceramics that can be laminated and sintered. Other heating arrangements are possible, including, for example, induction heating, an infrared heater element that heats by emitting infrared radiation, or a resistive heating element formed, for example, by a resistive electrical winding.

[0291] In a particular embodiment, the heater arrangement 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater arrangement 23 is dimensioned such that when the articles 101, 301 are inserted into the device 1, substantially the entire body of the aerosol generating elements 103, 303 of the articles 101, 301 is inserted into the heater arrangement 23.

[0292] Each heating element may be arranged so as to be able to independently heat a selected zone of the aerosol generating material, for example in sequence (over time, as discussed above) or together (simultaneously) as desired.

[0293] In this embodiment, the heater arrangement 23 is surrounded by the heat insulation material 31 along at least a portion of its length. The heat insulation material 31 helps to reduce the heat passing from the heater arrangement 23 to the outside of the device 1. This generally reduces heat loss, thus helping to suppress the power requirements for the heater arrangement 23. The heat insulation material 31 also helps to keep the outside of the device 1 cool during operation of the heater arrangement 23. In one embodiment, the heat insulation material 31 may be a double-wall sleeve that provides a low-pressure region between two walls of the sleeve. That is, the heat insulation material 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. In addition to or instead of the double-wall sleeve, other arrangements for the heat insulation material 31 are possible, including using a heat insulation material that includes, for example, a suitable foam-type material.

[0294] The housing 59 may further include various internal support structures 37 for supporting all of the internal components, and may include the heating arrangement 23.

[0295] The device 1 further includes a collar 33 that extends around and protrudes into the interior of the housing 9 from the opening 20, and a generally tubular chamber 35 positioned between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f that includes a plurality of cooling fins 35f spaced along the outer surface of the chamber 35 in this embodiment, and each is circumferentially arranged along the outer surface of the chamber 35. When inserted into the device 1 over at least a portion of the length of the hollow chamber 35, there is a gap 36 between the hollow chamber 35 and the articles 101, 301. The gap 36 extends over at least a portion of the cooling segment 307 and around the entire circumference of the articles 101, 301.

[0296] Color 33 includes a plurality of ridges 60 that are circumferentially arranged around the periphery of the opening 20 and project into the opening 20. The ridges 60 take up space within the opening 20 such that the opening span of the opening 20 at the location of the ridges 60 is less than the opening span of the opening 20 at locations without the ridges 60. The ridges 60 are configured to engage articles 101, 301 inserted into the device to assist in securing within the device 51. The opening spaces (not shown in the figures) defined by adjacent pairs of the ridges 60 and the articles 101, 301 form ventilation paths around the outside of the articles 101, 301. These ventilation paths vent hot vapor escaping from the articles 101, 301 out of the device 1 and allow cooling air to flow into the device 1 around the articles 101, 301 within the void 36.

[0297] During operation, the articles 101, 301 are removably inserted into the insertion portion 20 of the device 1 as shown in FIGS. 8 - 10. Referring particularly to FIG. 9, in one embodiment, the bodies of the aerosol - generating elements 103, 303 positioned towards the distal ends 115, 315 of the articles 101, 301 are entirely received within the heater arrangement 23 of the device 1. The proximal ends 113, 313 of the articles 101, 301 extend from the device 1 and act as a mouthpiece assembly for the user.

[0298] During operation, the heater arrangement 23 heats the articles 101, 301 to volatilize at least one component of the aerosol - generating element from the bodies of the aerosol - generating elements 103, 303.

[0299] The primary flow path for the heated volatile material from the bodies of the aerosol generating elements 103, 303 passes axially through the articles 103, 301, through the chambers in the cooling segments 107, 303, through the filter segments 109, 309, and through the suction segments 111, 311 to the user. In one embodiment, the temperature of the heated volatile components generated from the body of the aerosol generating element is between 60°C and 250°C, which may be higher than the acceptable inhalation temperature for the user. As the heated volatile material passes through the cooling segments 107, 307, it will be cooled, and some of the volatile material will condense on the inner surfaces of the cooling segments 107, 307.

[0300] In the embodiment of the article 301 shown in FIGS. 6 and 7, cooling air can enter the cooling segment 307 through the ventilation holes 317 formed in the cooling segment 307. This cooling air will be mixed with the heated volatile components, providing additional cooling to the heated volatile components.

[0301] Method for generating an aerosol In another aspect of the present disclosure, a method for generating an aerosol using the non-flammable aerosol providing system described herein is provided. In some embodiments, the method includes heating the aerosol generating material to a temperature less than or equal to 350°C. In some embodiments, the method includes heating the aerosol generating material to a temperature of about 220°C to about 280°C. In some embodiments, the method includes heating at least a portion of the aerosol generating material to a temperature of about 220°C to about 280°C during a use operation. As used herein, "use operation" refers to a single period of use of the non-flammable aerosol providing system by the user. The use operation begins when power is first supplied to at least one heating unit present in the heating assembly.

[0302] The device will be ready for use after a certain period has elapsed since the start of the usage operation. The usage operation ends when power is no longer supplied to any of the heating elements in the aerosol generating device. The end of the usage operation may coincide with the time when the smoking article is depleted (the time when the total particulate matter yield (mg) per puff can be considered too low to be acceptable to the user). The operation will have a duration of multiple puffs. The operation may have a duration of less than 7 minutes or 6 minutes or 5 minutes or 4 minutes 30 seconds or 4 minutes or 3 minutes 30 seconds. In some embodiments, the usage operation may have a duration of 2 - 5 minutes or 3 - 4.5 minutes or 3.5 - 4.5 minutes or suitably 4 minutes. The operation may be started by a user actuating a button or switch on the device, and the temperature increase is started with at least one heating element.

Example

[0303] Aspects of the present invention are more fully described by the following examples, which are presented to illustrate and not to be construed as limiting certain aspects of the present invention. Unless otherwise noted, all parts and percentages are by dry weight.

[0304] Example 1. Foamed cast film coated with tobacco Examples of embodiments of the foamed cast sheet (aerosol generating material) of the present disclosure are prepared according to the formulations presented in Table 1. The actual components and percentages can vary depending on the desired properties of the final product.

[0305] A slurry containing the components listed in Table 1 is prepared in water and aerated as described in the present specification. The foamed slurry is then cast onto a 22-inch-wide stainless steel conveyor belt using a casting knife set with a gap opening of 2-5 mm. Tobacco material (short, 1-2 mm × 3 mm) is deposited onto the wet foam sheet and adhered to the wet slurry. The coated cast material is then dried to a sheet by conveying the coating through a 200-foot convection tunnel dryer containing a number of heating zones (e.g., in the range of 80-150 °C). The sheet is dried to about 8-10% moisture.

[0306] The aerosol generating material thus prepared provides a substrate having a reduced density but retaining good sensory performance characteristics. In particular, the use of a foaming agent (e.g., HPMC) makes it possible to incorporate air into thin films and reduce the density.

[0307] [Table 1]

Claims

1. An aerosol generating material having a surface and taking the form of a sheet that may or may not be foamed, (i) One or more binders, one or more foam-forming agents, or one or more binders and one or more foam-forming agents, (ii) Filler, (iii) Aerosol-forming agent material, and (iv) Tobacco material embedded in or attached to the surface of the sheet Aerosol-generating materials, including those mentioned above.

2. The aerosol generating material according to claim 1, wherein the sheet is foamed, and the foamed sheet contains one or more foam-forming agents.

3. Furthermore, the aerosol generating material according to claim 2 further contains 1 to 6% by weight of a foam stabilizer.

4. The aerosol generating material according to claim 3, wherein the foam stabilizer comprises one or more surfactants or emulsifiers.

5. The aerosol generating material according to claim 3, wherein the foam stabilizer comprises sodium lauryl sulfate, sorbitan monostearate, sorbitan monooleate, polyoxyethylene sorbitan monostearate, polyethylene glycol sorbitan monooleate, cocamidopropyl betaine, lecithin, or a combination thereof.

6. The aerosol generating material according to claim 2, further comprising a foaming agent.

7. The foaming agent, Calcium carbonate, sodium carbonate, sodium bicarbonate, or combinations thereof; and Citric acid, tartaric acid, acetic acid, aluminum sulfate, or any combination thereof. The aerosol generating material according to claim 6, comprising:

8. The aerosol generating material according to claim 2, wherein the aerosol generating material contains 5 to 35% by weight of a foam-forming agent.

9. The aerosol generating material according to claim 2, wherein the foam-forming agent comprises hydroxypropyl methylcellulose (HPMC), gum, modified starch, maltodextrin, or a combination thereof.

10. The aerosol generating material according to claim 2, wherein the foam-forming agent comprises hydroxypropyl methylcellulose (HPMC).

11. The aerosol generating material according to claim 1, wherein the sheet is not foamed and the aerosol generating material contains one or more binders.

12. The aerosol generating material according to claim 11, wherein one or more binders include carboxymethylcellulose, alginate, natural gum, or a combination thereof.

13. The aerosol generating material according to claim 1, wherein the aerosol generating material contains 10 to 85% by weight of a filler.

14. The aerosol generating material according to claim 1, wherein the filler comprises wood pulp, microcrystalline cellulose, or a combination thereof.

15. The aerosol generating material according to claim 1, comprising 20 to 30% by weight of an aerosol-forming agent material.

16. The aerosol generating material according to claim 1, wherein the aerosol forming agent material comprises glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination thereof.

17. The aerosol generating material according to claim 1, wherein the aerosol forming agent material is glycerol, propylene glycol, or a combination thereof.

18. The sheet contains 0.02 g / cm³ ３ ~0.7 g / cm ３ The aerosol generating material according to claim 1, having a density in the range of [value].

19. The aerosol generating material is given by formula: Filling value = (bulk volume / weight) × 100; (In the formula, the bulk volume is determined using a densimeter.) Determined by, 380 g / cm³ ３ The aerosol generating material according to claim 1, having a higher filling value than the above.

20. The aerosol generating material according to claim 1, wherein the aerosol generating material has a porosity of 100 seconds / 100 ml or more, as determined using a Gurley densometer.

21. The aerosol generating material according to claim 1, wherein the tobacco material is granular or fibrous tobacco.

22. The aerosol generating material according to claim 21, wherein the fibrous tobacco material has a width in the range of 1 to 2 mm and a maximum length of 3 mm.

23. The aerosol generating material according to claim 21, wherein the granular tobacco material is powdered tobacco.

24. The aerosol generating material according to claim 1, wherein the aerosol generating material takes the form of a laminate.

25. The aerosol generating material according to claim 1, further comprising a top coat of a film-forming agent that is arranged on the surface of a sheet and covers tobacco material embedded in or adhered to the surface of a sheet.

26. The aerosol generating material according to claim 25, wherein the film-forming agent is selected from the group consisting of hydroxypropyl cellulose, hydroxypropyl methylcellulose, carboxymethylcellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan gum, gellan, acacia gum, tragacanth gum, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

27. An aerosol generating element comprising the aerosol generating material described in any one of claims 1 to 26.

28. The aerosol generating element according to claim 27, comprising 10 to 100% by weight of an aerosol generating material.

29. The aerosol generating element according to claim 27, wherein the aerosol generating material takes the form of a corrugated sheet.

30. The aerosol generating element according to claim 27, wherein the aerosol generating material takes the form of a shredded sheet.

31. The aerosol generating element according to claim 30, wherein the shredded sheet is blended with an additional tobacco material having properties different from the tobacco material embedded in or adhered to the surface of the sheet.

32. The aerosol generating element according to claim 31, wherein the additional tobacco material includes reconstituted tobacco, tobacco lamina, fine cut tobacco, cut rag tobacco, or a combination thereof.

33. The aerosol generating element according to claim 29, wherein a corrugated sheet is crimped and gathered to form a cylindrical rod, and the aerosol generating element further includes a wrapping material surrounding the rod.

34. A consumable used in a non-flammable aerosol dispensing device, comprising the aerosol generating element described in claim 27.

35. A non-flammable aerosol supplying system comprising a consumable and a non-flammable aerosol supplying device according to claim 34, wherein the non-flammable aerosol supplying device includes an aerosol generating device configured to generate an aerosol from the consumable when the consumable is used together with the non-flammable aerosol supplying device.

36. A flammable aerosol dispensing system comprising the consumables and flammable aerosol dispensing device described in claim 34.

37. A method for forming an aerosol generating material, which takes the form of a sheet having a surface and has tobacco material embedded in the sheet or adhered to the surface of the sheet, (a) (i) One or more binders, one or more foam-forming agents, or one or more binders and one or more foam-forming agents, (ii) Filler, (iii) Aerosol-forming agent material, and (iv) Solvent Prepare a slurry containing the following: (b) Selectively passing air through the slurry to form an aerated slurry. (c) Forming a layer of slurry that has been selectively permeated, (d) Depositing tobacco material on a layer of optionally aerated slurry, and (e) Drying a selectively permeable slurry layer having tobacco material deposited on its surface to form an aerosol generating material. Methods that include...

38. The method according to claim 37, wherein the sheet is foamed.

39. The method according to claim 38, wherein the slurry is aerated, and the slurry is mixed under high shear conditions.

40. The method according to claim 37, wherein preparing the slurry includes mixing the slurry under high shear conditions such that aeration is performed as part of step (a).

41. The method according to claim 38, wherein passing the slurry through includes passing a gas through the slurry and bubbling it.

42. The method according to claim 37, wherein the aeration of the slurry includes adding a foaming agent to the slurry and foaming the foaming agent, thereby introducing bubbles into the slurry.

43. The aerosol generating material is top-coated with a film-forming agent, and the method is (d) After this, a film-forming agent is placed on the slurry, and optionally the placed film-forming agent is dried to form a top-coated aerosol-generating material, or (e) After this, a film-forming agent is placed on the aerosol-generating material, and optionally the placed film-forming agent is dried to form a top-coated aerosol-generating material. The method according to claim 37, further comprising:

44. The method according to claim 43, wherein the film-forming agent is selected from the group consisting of hydroxypropylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, modified starch, maltodextrin, alginate, carrageenan, xanthan gum, gellan, acacia gum, tragacanth gum, monoglycerides, diglycerides, triethyl citrate, and combinations thereof.

45. The aerosol generating material takes the form of a laminate, and the method is (d) After this, a second layer of optionally aerated slurry is formed on top of the optionally aerated slurry layer to form a layered composite, and The layered composite is dried to form an aerosol generating material that takes on a laminated form. The method according to claim 37, further comprising:

46. The aerosol generating material takes the form of a laminate, and the method is (e) After this, a second layer of optionally aerated slurry is formed on the aerosol generating material to form a layered composite, and The layered composite is dried to form an aerosol generating material that takes on a laminated form. The method according to claim 37, further comprising:

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