Carried flavor materials for aerosol-generating articles or nicotine-containing products

Abstract

A flavoring material (50) for use in an aerosol-generating article is provided, wherein the flavoring agent is releasable from the flavoring agent upon heating of the flavoring agent. The flavoring material (50) includes a polysaccharide matrix structure including gellan gum and an emulsifier, a flavoring agent formulation dispersed within the polysaccharide matrix structure, the flavoring agent formulation being at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavoring agent, and a carrier sheet material, wherein the polysaccharide matrix structure and the flavoring agent formulation are carried by the carrier sheet material. Also provided is an aerosol-generating article (10) including one such flavoring material (50).

Description

[Technical Field]

[0001] The present disclosure relates to flavoring materials for use in aerosol-generating articles. Additionally, the present disclosure relates to aerosol-generating articles comprising one such flavoring material. [Background technology]

[0002] Aerosol-generating articles that heat, rather than burn, an aerosol-generating substrate, such as a tobacco-containing substrate or a non-tobacco nicotine-containing substrate, are known in the art. Typically, in such heated smoking articles, the aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] Several aerosol generating devices for consuming aerosol-generating articles have been disclosed in the art. Such devices include, for example, electrically heated aerosol generating devices in which an aerosol is generated by heat transfer from one or more electric heater elements of the aerosol generating device to an aerosol-generating substrate of the aerosol-generating article. For example, an electrically heated aerosol generating device has been proposed that includes an internal heater blade adapted to be inserted into the aerosol-generating substrate. Alternatively, WO 2015 / 176898 proposes an inductively heated aerosol-generating article that includes an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate.

[0004] It has been proposed that aerosol-generating articles include a flavor source in addition to the aerosol-generating substrate. In fact, this approach is relatively common in conventional filter cigarettes, and many solutions have been described in the art for providing flavorants at locations within the mouthpiece filter or within the tobacco cut filler rod.

[0005] However, given how aerosols are generated and delivered to consumers in aerosol-generating articles, it can be difficult to ensure consistent flavor delivery during use, which can result in consumers experiencing fluctuations or a decrease in flavor intensity over time. Furthermore, even before the aerosol-generating article is used, some flavor species can be lost during certain manufacturing steps or during transportation and storage of the aerosol-generating article.

[0006] It has previously been proposed to reduce the loss of volatile flavorants from smoking conventional filter cigarettes during storage, for example, by encapsulating the flavorants in capsules or microcapsules containing the flavorant formulation. The encapsulated flavor species can be released by disrupting the encapsulated structure, for example, by manually crushing the structure, before or during smoking of the filter cigarette. However, because the encapsulated flavorants are typically released from the encapsulated structure in a burst, such a solution may not consistently deliver a strong flavor during use of the article.

[0007] Therefore, there is a felt need to provide flavor materials, and aerosol-generating articles comprising flavor materials, that lead to an improved consumer flavor perception, particularly towards the end of the use cycle of the aerosol-generating article. Summary of the Invention

[0008] The present disclosure relates to a flavoring material for use in an aerosol-generating article, wherein a flavoring agent formulation is released from the flavoring material upon heating. The flavoring material may include a matrix structure and a flavoring agent formulation dispersed within the matrix structure. The flavoring agent formulation is at least partially entrapped within the matrix structure and releasable from the matrix structure upon heating of the flavoring material. The matrix structure may be a polysaccharide matrix structure. The flavoring material may include a carrier sheet material, a polysaccharide matrix structure, and a flavoring agent formulation carried by the carrier sheet material.

[0009] According to one aspect of the present invention, there is provided a flavorant for use in an aerosol-generating article, the flavorant comprising a polysaccharide matrix structure and a flavorant formulation dispersed within the polysaccharide matrix structure. The flavorant formulation is at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant. The flavorant comprises a carrier sheet material, a polysaccharide matrix structure, and a flavorant formulation carried by the carrier sheet material.

[0010] As used herein, the term "sheet material" refers to a layered material having a width and length that are substantially greater than its thickness. For example, the carrier sheet material may be a sheet of homogenized tobacco material or a sheet of paper material. Examples of homogenized tobacco materials suitable for producing flavoring materials according to the present invention are described in more detail below.

[0011] As used herein in connection with the present invention, the term "aerosol-generating article" is used to describe an article that includes an aerosol-generating substrate that is heated to generate and deliver an inhalable aerosol to a user.

[0012] As used herein in connection with the present invention, the term "aerosol-generating substrate" is used to describe a substrate that includes an aerosol-forming material that is capable of releasing, upon heating, a volatile compound that is capable of generating an aerosol.

[0013] As used herein in connection with the present invention, the term "aerosol" is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. Aerosols can be visible or invisible. Aerosols may contain not only vapors of substances that are normally liquids or solids at room temperature, but also solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0014] As used herein in connection with the present invention, the term "aerosol-generating device" is used to describe a device that interacts with the aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0015] The aerosol-generating article according to the present invention has a proximal end through which the aerosol exits the aerosol-generating article for delivery to a user during use. The proximal end of the aerosol-generating article may also be referred to as the downstream end or mouth end of the aerosol-generating article. During use, a user draws directly or indirectly on the proximal end of the aerosol-generating article to inhale the aerosol generated by the aerosol-generating article.

[0016] The aerosol-generating article according to the present invention has a distal end. The distal end is opposite the proximal end. The distal end of the aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0017] Components of an aerosol-generating article according to the present invention may be described as being upstream or downstream of one another based on their relative location between the proximal end of the aerosol-generating article and the distal end of the aerosol-generating article.

[0018] As used herein in connection with the present invention, the term "longitudinal direction" is used to describe the direction between the upstream and downstream ends of the aerosol-generating article. During use, air is drawn longitudinally through the aerosol-generating article.

[0019] As used herein in connection with the present invention, the term "length" is used to describe the greatest dimension along the longitudinal axis of an aerosol-generating article or a component of an aerosol-generating article.

[0020] As used herein in connection with the present invention, the term "transverse" is used to describe a direction perpendicular to the longitudinal axis. Unless otherwise specified, a "cross section" of an aerosol-generating article or a component of an aerosol-generating article refers to a cross section.

[0021] As used herein with respect to the present invention, the term "width" refers to the largest lateral dimension of an aerosol-generating article or a component of an aerosol-generating article. If the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. If the component of the aerosol-generating article has a substantially circular cross-section, the width of the component of the aerosol-generating article corresponds to the diameter of the component of the aerosol-generating article.

[0022] As used herein in connection with the present invention, the term "hollow tubular element" is used to describe a generally cylindrical element having a tubular space along its longitudinal axis. The tubular portion may be generally circular, oval, or elliptical in cross section. The tubular space may be generally circular, oval, or elliptical in cross section. Specifically, the term "hollow tubular element" is used to describe an element that defines at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end of the hollow tubular element and a downstream end of the hollow tubular element.

[0023] It has been found that the inclusion of a carrier sheet material in a flavorant according to the invention improves the structural strength of the flavorant, with the carrier sheet material supporting and holding in place the polysaccharide matrix that entraps the flavorant formulation. By selecting and adjusting certain properties of the carrier sheet material (e.g., its thickness), a flavorant can be obtained that is particularly resistant to wear and tear and has particularly good mechanical properties.

[0024] Thus, compared to flavorants of comparable composition and matrix structure but without the support of a carrier sheet material, flavorants according to the present invention have been found to be easier to handle and more conveniently store, for example in the form of bobbins, which advantageously facilitates their incorporation into aerosol-generating articles, particularly within the framework of high-speed automated manufacturing processes.

[0025] The flavoring material according to the present invention also has the advantage that the polysaccharide matrix structure and flavoring agent formulation entrapped therein can be disposed on a carrier sheet material to form a flavoring material that is sheet-like in nature and can therefore be cut into pieces having a predetermined average size (e.g., a predetermined cut width or a predetermined cut length, or both), which facilitates combining the flavoring material according to the present invention with aerosol-generating substrates in certain aerosol-generating articles, as described in more detail below.

[0026] Alternatively, in some embodiments, the carrier sheet material is comprised of a plurality of pieces cut from the sheet material, the pieces having a predetermined average size (e.g., a predetermined cut width or a predetermined cut length, or both). Alternatively, the carrier material may be comprised of a plurality of pieces cut from a natural plant material, preferably plant leaf material (e.g., tobacco mesophyll).

[0027] In flavorants according to the present invention, the polysaccharide matrix structure entrapping the flavor formulation may be formed in situ on the carrier sheet material. If this in situ forming step follows the manufacturing process by which the carrier sheet material is obtained, the in situ forming step may be carried out at a later date or at a different location.

[0028] It is generally recognized that the use of flavoring materials in aerosol-generating articles, which generate an aerosol by heating an aerosol-generating substrate, presents different challenges and presents different constraints compared to situations previously faced with traditional cigarettes, which generate smoke by burning a substrate. The inventors have discovered that by adjusting the relative proportions of the various components in the formulation, or by modifying the composition of the matrix (e.g., by selecting a particular combination of polysaccharides to form the matrix), or both, it may be advantageous to fine-tune some properties of the flavoring material to the specific needs associated with its use in an aerosol-generating article. For example, the flavor release profile may be tailored so that the flavor is released in more continuous "waves" during use. As a result, consumers may perceive the flavor characteristics as being stronger or more long-lasting during use. Thus, flavoring materials according to the present invention may provide a broader flavor profile than previously available with known flavoring materials.

[0029] It has been found that when flavor materials according to the present invention are incorporated into an aerosol-generating article, such as a heat-and-burn article configured to generate an aerosol upon heating of a tobacco-containing aerosol-generating substrate, flavor release per puff is generally more efficient.

[0030] Because the flavor formulation is at least partially entrapped within the matrix until released upon heating, the flavor materials according to the invention have been found to have improved stability. For example, significantly reduced loss of flavor species is observed, even under stress conditions, during storage, transportation, etc. This allows for particularly efficient use of the flavor and other components of the flavor formulation, in addition to improved flavor release.

[0031] The polysaccharide matrix structure preferably comprises gellan gum and an emulsifier. The term "gellan gum" is used to identify a water-soluble anionic polysaccharide produced by the bacterium Sphingomonas elodia. The repeating unit of the polymer is a tetrasaccharide, consisting of two D-glucose residues and one L-rhamnose and one D-glucuronic acid residue. Gellan gum has been approved for use in food, non-food, cosmetic, and pharmaceutical applications by authorities in many jurisdictions, including Japan, the United States, Canada, China, South Korea, and the European Union.

[0032] Two forms of gellan gum are known, high acyl gellan gum and low acyl gellan gum, which differ in the degree / percentage of substitution with O-acyl groups.

[0033] In the flavoring material according to the present invention, the gellan gum is preferably low-acyl gellan gum, which is either partially deacylated or fully deacylated, the most common form being the fully deacylated form with no detectable acyl groups, also known as deacetylated gellan gum.

[0034] Low acyl gellan gum is preferably used to form the polysaccharide matrix of the flavor material according to the present invention because low acyl gellan gum can form gels at very low concentrations. Furthermore, the texture of gellan gum-based gels varies depending on the acyl content, with low acyl gellan gums typically forming firmer, less elastic, and more brittle gels than high acyl gellan gums.

[0035] In embodiments where the polysaccharide matrix structure comprises gellan gum and an emulsifier, it can be advantageous to provide a flavoring material where a significantly larger proportion of the flavoring formulation is effectively entrapped within the polysaccharide matrix structure. This is beneficial in terms of improving the stability of the flavoring material. Furthermore, as described in more detail below, this can affect how flavor species are released upon heating of the flavoring material, thereby helping to tailor the flavoring release profile during use.

[0036] Furthermore, from a manufacturing perspective, by providing heat to the starting reagents, a stable polysaccharide matrix structure containing gellan gum and an emulsifier can be formed without the need for a cross-linking agent. Indeed, by emulsifying a flavor formulation with gellan gum in a heated water bath, the polysaccharide-coated flavor can be in an emulsified state that can be subsequently dried and cooled and subsequently preserved. Advantageously, this allows a significant amount of flavor to be formed immobilized within the polysaccharide matrix, potentially resulting in a flavor material with a high flavor content.

[0037] Preferably, the emulsifier is lecithin.The use of lecithin as an emulsifier has the advantage that it is commonly available and generally recognized as non-toxic.Like gellan gum, lecithin is commonly used as an additive in the food industry, and is approved for such use by both the US Food and Drug Administration and EU authorities.Therefore, the combination of gellan gum and lecithin is particularly suitable for being included in flavoring materials intended for human consumption.

[0038] When the polysaccharide matrix comprises gellan gum and an emulsifier, the gellan gum preferably comprises from 5 percent to 99.9 percent by weight of the flavor material on a dry weight basis.

[0039] More preferably, gellan gum comprises at least 7 weight percent of the flavor material on a dry weight basis, and even more preferably at least 10 weight percent of the flavor material on a dry weight basis.

[0040] Preferably, gellan gum comprises up to 80 weight percent of the flavoring material on a dry weight basis, more preferably up to 60 weight percent of the flavoring material on a dry weight basis, even more preferably up to 40 weight percent of the flavoring material on a dry weight basis, and especially preferably up to 30 weight percent of the flavoring material on a dry weight basis.

[0041] In some embodiments, gellan gum comprises from 5 weight percent to 80 weight percent of the flavor materials on a dry weight basis, preferably from 5 weight percent to 60 weight percent of the flavor materials on a dry weight basis, more preferably from 5 weight percent to 40 weight percent of the flavor materials on a dry weight basis, and even more preferably from 5 weight percent to 30 weight percent of the flavor materials on a dry weight basis.

[0042] In other embodiments, gellan gum comprises from 10 weight percent to 80 weight percent of the flavor materials on a dry weight basis, preferably from 10 weight percent to 60 weight percent of the flavor materials on a dry weight basis, more preferably from 10 weight percent to 40 weight percent of the flavor materials on a dry weight basis, and even more preferably from 10 weight percent to 30 weight percent of the flavor materials on a dry weight basis.

[0043] The emulsifier may comprise from 0.01 weight percent to 2 weight percent of the flavor material on a dry weight basis. Preferably, the emulsifier comprises from 0.02 weight percent to 2 weight percent of the flavor material on a dry weight basis. More preferably, the emulsifier comprises from 0.05 weight percent to 2 weight percent of the flavor material on a dry weight basis. Even more preferably, the emulsifier comprises from 0.1 weight percent to 2 weight percent of the flavor material on a dry weight basis.

[0044] In a preferred embodiment, the emulsifier is lecithin and comprises 0.01 to 2 weight percent of the flavor material on a dry weight basis. Preferably, the lecithin comprises 0.02 to 2 weight percent of the flavor material on a dry weight basis. More preferably, the lecithin comprises 0.05 to 2 weight percent of the flavor material on a dry weight basis. Even more preferably, the lecithin comprises 0.1 to 2 weight percent of the flavor material on a dry weight basis.

[0045] In certain embodiments, the polysaccharide matrix structure comprises gellan gum as the only polysaccharide.

[0046] In other embodiments, the polysaccharide matrix structure comprises gellan gum in combination with at least one other polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose.

[0047] It has been found that flavoring materials according to the present invention, in which the polysaccharide matrix structure comprises gellan gum in combination with one or more of the above polysaccharides, exhibit different flavor release profiles upon heating. For example, in embodiments in which the polysaccharide matrix structure comprises a combination of gellan gum with another of the above polysaccharides, a flavor release profile characterized by two distinct peaks at two different temperatures has been observed. Without wishing to be bound by any theory, it is hypothesized that this is due to different strengths of interaction between the flavoring and each polysaccharide within the matrix structure, and may also be related to the thermal decomposition of each polysaccharide at slightly different temperatures.

[0048] Because different combinations of polysaccharides within a matrix structure generally lead to slightly different flavor release profiles when the flavoring material is heated, embodiments in which gellan gum is combined with one or more of the other polysaccharides listed above can be advantageously used to fine-tune flavor release during use of an aerosol-generating article containing the flavoring material. Furthermore, different flavoring materials, each comprising a polysaccharide matrix structure containing a different polysaccharide combination, can be combined within a single aerosol-generating article to further tailor and control flavor delivery throughout the use cycle of the aerosol-generating article. For example, when different flavoring materials are incorporated into a single aerosol-generating article according to the present invention, the different flavoring materials may be adapted to release a majority of their flavor at different temperatures or at different times during the use cycle, helping to maintain a substantially consistent overall flavor delivery throughout.

[0049] In flavor material embodiments in which the matrix structure is comprised of a combination of gellan gum and at least one of the above-described additional polysaccharides, the at least one additional polysaccharide can comprise at least 0.01 weight percent of the flavor delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide comprises at least 0.1 weight percent of the flavor delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide comprises at least 1.0 weight percent of the flavor delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide comprises at least 2.0 weight percent of the flavor delivery material on a dry weight basis. In particularly preferred embodiments, the at least one additional polysaccharide comprises at least 5 weight percent of the flavor delivery material on a dry weight basis.

[0050] In flavor material embodiments in which the matrix structure is comprised of a combination of gellan gum and at least one of the additional polysaccharides described above, the at least one additional polysaccharide can comprise 80 weight percent or less of the flavor delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide comprises 35 weight percent or less of the flavor delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide comprises 25 weight percent or less of the flavor delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide comprises 15 weight percent or less of the flavor delivery material on a dry weight basis.

[0051] In some embodiments, the at least one additional polysaccharide comprises from 1.0 weight percent to 35 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to 35 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to 35 weight percent or less of the flavor delivery material on a dry weight basis.

[0052] In other embodiments, the at least one additional polysaccharide comprises from 1.0 weight percent to 25 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to 25 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to 25 weight percent or less of the flavor delivery material on a dry weight basis.

[0053] In another embodiment, the at least one additional polysaccharide comprises from 1.0 weight percent to 15 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to 15 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to 15 weight percent or less of the flavor delivery material on a dry weight basis.

[0054] The flavoring material may comprise at least 0.01 weight percent flavoring agent on a dry weight basis. Preferably, the flavoring material comprises at least 1 weight percent flavoring agent on a dry weight basis. More preferably, the flavoring material comprises at least 5 weight percent flavoring agent on a dry weight basis. Even more preferably, the flavoring material comprises at least 10 weight percent flavoring agent on a dry weight basis.

[0055] In certain embodiments, the flavoring material comprises at least 20 weight percent flavor on a dry weight basis, preferably at least 25 weight percent flavor on a dry weight basis, and more preferably at least 30 weight percent flavor on a dry weight basis.

[0056] The flavoring material may comprise up to 90 weight percent flavoring agent on a dry weight basis. Preferably, the flavoring material may comprise up to 85 weight percent flavoring agent on a dry weight basis. More preferably, the flavoring material may comprise up to 80 weight percent flavoring agent on a dry weight basis. Even more preferably, the flavoring material may comprise up to 75 weight percent flavoring agent on a dry weight basis.

[0057] In some preferred embodiments, the flavoring material comprises from 20 weight percent to 80 weight percent flavoring on a dry weight basis, preferably from 25 weight percent to 80 weight percent flavoring on a dry weight basis, and more preferably from 30 weight percent to 80 weight percent flavoring on a dry weight basis.

[0058] In another preferred embodiment, the flavoring material comprises from 20 weight percent to 75 weight percent flavoring on a dry weight basis, preferably from 25 weight percent to 75 weight percent flavoring on a dry weight basis, and more preferably from 30 weight percent to 75 weight percent flavoring on a dry weight basis.

[0059] Suitable flavorants for inclusion in flavor formulations of flavoring materials according to the present invention include, but are not limited to, menthol, limonene, and eugenol.

[0060] Menthol is a monoterpenoid that can be synthesized or obtained from the oils of peppermint and other mints. It gives mint its refreshing flavor.

[0061] Limonene is a cyclic monoterpene typically found in the oils of citrus fruit peels. It is also a component of the aromatic resins of many coniferous and broad-leaved trees. It imparts a citrus flavor.

[0062] Eugenol is an allyl-substituted guaiacol commonly found in the essential oils of clove, nutmeg, cinnamon, basil, and bay leaf. It imparts spicy, clove-like flavor notes.

[0063] The inventors have found that flavor materials, including flavor formulations containing menthol, limonene, or mixtures thereof, exhibit very good stability because menthol and limonene can be fairly easily entrapped and immobilized within the polysaccharide matrix.

[0064] In a preferred embodiment, the flavor formulation comprises menthol.

[0065] The flavoring material may comprise at least 0.01 weight percent menthol on a dry weight basis. Preferably, the flavoring material comprises at least 1 weight percent menthol on a dry weight basis. More preferably, the flavoring material comprises at least 5 weight percent menthol on a dry weight basis. Even more preferably, the flavoring material comprises at least 10 weight percent menthol on a dry weight basis.

[0066] In certain embodiments, the flavoring material comprises at least 20 weight percent menthol on a dry weight basis, preferably at least 25 weight percent menthol on a dry weight basis, and more preferably at least 30 weight percent menthol on a dry weight basis.

[0067] The flavoring material may comprise up to 90 weight percent menthol on a dry weight basis. Preferably, the flavoring material may comprise up to 85 weight percent menthol on a dry weight basis. More preferably, the flavoring material may comprise up to 80 weight percent menthol on a dry weight basis. Even more preferably, the flavoring material may comprise up to 75 weight percent menthol on a dry weight basis.

[0068] In certain preferred embodiments, the flavoring material comprises from 20 weight percent to 80 weight percent menthol on a dry weight basis, preferably from 25 weight percent to 80 weight percent menthol on a dry weight basis, and more preferably from 30 weight percent to 80 weight percent menthol on a dry weight basis.

[0069] In another preferred embodiment, the flavoring material comprises 20 weight percent to 75 weight percent menthol on a dry weight basis, preferably 25 weight percent to 75 weight percent menthol on a dry weight basis, and more preferably 30 weight percent to 75 weight percent menthol on a dry weight basis.

[0070] In some embodiments, the flavor formulation comprises particulate plant material, which can be obtained by grinding, crushing, or pulverizing plant material, such as plant leaves, plant stems, flowers, seeds, etc.

[0071] In accordance with the present invention, it has been found to be advantageous that the use of particulate plant material provides a stable method of incorporating flavor compounds into flavor materials, thereby optimizing the delivery of flavor to the aerosol during use.

[0072] In some preferred embodiments, the particulate plant material is selected from one or more of clove particles, star anise particles, rosemary particles, peppermint particles, sage particles, chamomile particles, and lavender particles. Preferably, the particulate plant material is selected from clove particles, star anise particles, and rosemary particles. More preferably, the particulate plant material consists of clove particles.

[0073] As is known, cloves are the effectively dried flower buds and stems of Syzygium aromaticum, a tree in the Myrtaceae family, and are commonly used as a spice. Thus, each clove includes a calyx of sepals and a corolla of unopened petals that form a ball-like portion attached to the calyx. As used herein, the term "clove particles" encompasses particles derived from the buds and stems of clove trees, and may include whole cloves, crushed or crushed cloves, or cloves that have been physically processed in another way to reduce particle size.

[0074] The addition of clove particles to flavoring materials for use in aerosol-generating articles is desirable in certain markets because it provides a unique organoleptic user experience that is popular with some users.

[0075] Cloves have a distinctive, pleasant aroma due to the presence of one or more flavoring agents, which are volatile compounds that volatilize upon heating. The primary component of clove essential oil is eugenol (4-allyl-2-methoxyphenol, chemical formula: CHO, Chemical Abstracts Service Registry Number 97-53-0). Eugenol is considered the compound primarily responsible for the clove flavor and typically accounts for approximately 70% to 90% of clove essential oil. However, clove flavor also includes other compounds, such as, but not limited to, acetyleugenol, β-caryophyllene, and vanillin; tannins such as maslinic acid and bicoruline; gallotannic acid; methyl salicylate; the flavonoids eugenin, kaempferol, rhamnetin, and eugenitin; triterpenoids such as oleanolic acid; and sesquiterpenes. The presence of clove flavor can be confirmed by measuring the eugenol content in the aerosol produced when the plant material is heated. However, the presence of clove flavor may also be determined by measuring the content of other compounds found in clove essential oil, including but not limited to those listed above.

[0076] Preferably, the flavoring material comprises at least 0.001 weight percent particulate plant material. More preferably, the flavoring material comprises at least 0.01 weight percent particulate plant material. Even more preferably, the flavoring material comprises at least 0.1 weight percent particulate plant material.

[0077] In particularly preferred embodiments, the flavoring material comprises at least 1 weight percent particulate plant material, preferably at least 2 weight percent particulate plant material, more preferably at least 5 weight percent particulate plant material, and even more preferably at least 10 weight percent particulate plant material.

[0078] Preferably, the flavoring material comprises no more than 80 weight percent particulate plant material. More preferably, the flavoring material comprises no more than 70 weight percent particulate plant material. Even more preferably, the flavoring material comprises no more than 60 weight percent particulate plant material.

[0079] In some embodiments, the flavoring material comprises between 1 weight percent and 80 weight percent particulate plant material, preferably between 2 weight percent and 80 weight percent particulate plant material, more preferably between 5 weight percent and 80 weight percent particulate plant material, and even more preferably between 10 weight percent and 80 weight percent particulate plant material.

[0080] In other embodiments, the flavoring material comprises from 1 weight percent to 70 weight percent particulate plant material, preferably from 2 weight percent to 70 weight percent particulate plant material, more preferably from 5 weight percent to 70 weight percent particulate plant material, and even more preferably from 10 weight percent to 70 weight percent particulate plant material.

[0081] In another embodiment, the flavoring material comprises from 1 weight percent to 60 weight percent particulate plant material, preferably from 2 weight percent to 60 weight percent particulate plant material, more preferably from 5 weight percent to 60 weight percent particulate plant material, and even more preferably from 10 weight percent to 60 weight percent particulate plant material.

[0082] In some embodiments, the flavorant has the formula C n H 2n+2 O n The polyol further comprises:

[0083] The term "polyol" is used herein to describe an organic compound containing two or more hydroxyl groups. Polyols containing two, three, and four hydroxyl groups can also be called diols, triols, and tetrols, respectively.

[0084] Preferred polyols for inclusion in flavoring materials according to the present invention include glycerol, sorbitol, xylitol, mannitol, and erythritol.

[0085] The incorporation of polyols in the flavorant has a beneficial effect on its flexibility, which may make it easier to handle and give it a defined form, which may facilitate its incorporation into the aerosol-generating article.

[0086] Preferably, in embodiments in which the flavorant comprises a polyol as described above, the polyol comprises from 0.01 weight percent to 20 weight percent of the flavorant on a dry weight basis. More preferably, the polyol comprises from 0.01 weight percent to 15 weight percent of the flavorant on a dry weight basis. Even more preferably, the polyol comprises from 0.01 weight percent to 10 weight percent of the flavorant on a dry weight basis.

[0087] In some embodiments, the flavoring material comprises fibers, preferably cellulose fibers. The incorporation of fibers, particularly cellulose fibers, may advantageously improve the tensile strength of the flavoring material, especially when provided in sheet form. This facilitates the manufacturing process for both the flavoring material itself and the aerosol-generating article containing the flavoring material. This advantage is particularly felt in embodiments in which the polysaccharide matrix encapsulating the flavoring agent formulation is not supported by a carrier material.

[0088] The inventors have found that the inclusion of fiber can improve the structural strength of the flavoring material, which is particularly beneficial in embodiments where the polysaccharide matrix that entraps the flavoring agent formulation is not carried by a carrier sheet material.

[0089] In embodiments of the flavoring material comprising cellulose fiber, the cellulose fiber may comprise at least 0.01 weight percent of the flavoring material on a dry weight basis. Preferably, the cellulose fiber comprises at least 0.05 weight percent of the flavoring material on a dry weight basis. More preferably, the cellulose fiber comprises at least 0.5 weight percent of the flavoring material on a dry weight basis. Even more preferably, the cellulose fiber comprises at least 1.0 weight percent of the flavoring material on a dry weight basis. In particularly preferred embodiments, the cellulose fiber comprises at least 2.0 weight percent of the flavoring material on a dry weight basis.

[0090] The cellulose fibers may comprise 10 weight percent or less of the flavoring material on a dry weight basis. Preferably, the cellulose fibers comprise 8.0 weight percent or less of the flavoring material on a dry weight basis. More preferably, the cellulose fibers comprise 7.0 weight percent or less of the flavoring material on a dry weight basis. Even more preferably, the cellulose fibers comprise 5.0 weight percent or less of the flavoring material on a dry weight basis.

[0091] In some embodiments, the fiber comprises from 0.01 weight percent to 10 weight percent of the flavoring material on a dry weight basis. Preferably, the fiber comprises from 0.01 weight percent to 8.0 weight percent of the flavoring material on a dry weight basis. More preferably, the fiber comprises from 0.01 weight percent to 7.0 weight percent of the flavoring material on a dry weight basis. Even more preferably, the fiber comprises from 0.01 weight percent to 5 weight percent of the flavoring material on a dry weight basis.

[0092] In other embodiments, the fiber comprises from 1.0 weight percent to 10 weight percent of the flavoring material on a dry weight basis. Preferably, the fiber comprises from 1.0 weight percent to 8.0 weight percent of the flavoring material on a dry weight basis. More preferably, the fiber comprises from 1.0 weight percent to 7.0 weight percent of the flavoring material on a dry weight basis. Even more preferably, the fiber comprises from 1.0 weight percent to 5 weight percent of the flavoring material on a dry weight basis.

[0093] In another embodiment, the fiber comprises 2.0 to 10 weight percent of the flavoring material on a dry weight basis. Preferably, the fiber comprises 2.0 to 8.0 weight percent of the flavoring material on a dry weight basis. More preferably, the fiber comprises 2.0 to 7.0 weight percent of the flavoring material on a dry weight basis. Even more preferably, the fiber comprises 2.0 to 5 weight percent of the flavoring material on a dry weight basis.

[0094] In some embodiments, flavoring materials according to the present invention may include a salt of calcium, such as calcium chloride or calcium lactate, or a salt of magnesium, or both.

[0095] In embodiments where the flavoring material includes a calcium salt or a magnesium salt, or both, the salt comprises from 0.01 to 10 weight percent on a dry weight basis. Preferably, the salt comprises from 0.01 to 5 weight percent on a dry weight basis.

[0096] The flavoring material according to the present invention may typically contain water, since the flavoring material is generally produced by mixing the various compounds mentioned above in a water bath. After drying, the water content is reduced, but generally may not be zero.

[0097] Thus, the flavoring material according to the present invention may comprise from 0.01 weight percent to 10 weight percent water, preferably from 0.01 weight percent to 8 weight percent water, more preferably from 0.01 weight percent to 6 weight percent water, and even more preferably from 0.01 weight percent to 4 weight percent water.

[0098] In some embodiments, the flavoring material may comprise between 0.5 weight percent and 10 weight percent water, preferably between 0.01 weight percent and 8 weight percent water, more preferably between 0.5 weight percent and 6 weight percent water, and even more preferably between 0.5 weight percent and 4 weight percent water.

[0099] In other embodiments, the flavoring material comprises between 1.0 weight percent and 10 weight percent water, preferably between 1.0 weight percent and 8 weight percent water, more preferably between 1.0 weight percent and 6 weight percent water, and even more preferably between 1.0 weight percent and 4 weight percent water.

[0100] In another embodiment, the flavoring material comprises between 1.5 weight percent and 10 weight percent water, preferably between 1.5 weight percent and 8 weight percent water, more preferably between 1.5 weight percent and 6 weight percent water, and even more preferably between 1.5 weight percent and 4 weight percent water.

[0101] As noted above, in some preferred embodiments, the carrier sheet material may be in the form of a sheet of homogenized tobacco material.

[0102] As used herein, the term "homogenized tobacco material" encompasses any tobacco material formed by agglomeration of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco lamina and tobacco stem. In addition, the homogenized tobacco material may contain one or more small amounts of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. A sheet of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0103] The sheets or webs of homogenized tobacco material used in the present invention may have a tobacco content of at least about 40 weight percent on a dry weight basis, more preferably at least about 60 weight percent on a dry weight basis, even more preferably at least about 70 weight percent on a dry weight basis, and most preferably at least about 90 weight percent on a dry weight basis.

[0104] A sheet or web of homogenized tobacco material for use as a carrier sheet material may include one or more intrinsic binders (i.e., binders intrinsic to the tobacco), one or more extrinsic binders (i.e., binders extrinsic to the tobacco), or a combination thereof, to aid in the cohesion of the particulate tobacco. Alternatively, or in addition, a sheet of homogenized tobacco material for use as a carrier sheet material may include other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

[0105] Extrinsic binders suitable for inclusion in sheets or webs of homogenized tobacco material for use as carrier sheet materials are known in the art and include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulosic binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides such as starch; organic acids such as alginic acid; conjugate base salts of organic acids such as sodium alginate, agar, and pectin; and combinations thereof.

[0106] Non-tobacco fibers suitable for inclusion in sheets or webs of homogenized tobacco material for use as a carrier sheet material are known in the art and include, but are not limited to, cellulose fibers, softwood fibers, hardwood fibers, jute fibers, and combinations thereof. Prior to inclusion in a sheet of homogenized tobacco material for use as a carrier sheet material, the non-tobacco fibers may be processed by any suitable process known in the art, including, but not limited to, mechanical pulping, refining, chemical pulping, bleaching, sulfate pulping, and combinations thereof.

[0107] Preferably, the sheet or web of homogenized tobacco material includes an aerosol former. As used herein, the term "aerosol former" describes any suitable known compound or mixture of compounds that facilitates the formation of an aerosol during use and that is substantially resistant to thermal decomposition at the operating temperatures of the aerosol-generating article.

[0108] Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0109] Preferred aerosol formers are polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin, or mixtures thereof.

[0110] The sheet or web of homogenized tobacco material may include a single aerosol former. Alternatively, the sheet or web of homogenized tobacco material may include a combination of two or more aerosol formers.

[0111] The homogenized sheet or web of tobacco material has an aerosol former content of greater than 10 percent on a dry weight basis. Preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 12 percent on a dry weight basis. More preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 14 percent on a dry weight basis. Even more preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 16 percent on a dry weight basis.

[0112] The sheet of homogenized tobacco material may have an aerosol former content of from about 10 percent to about 30 percent on a dry weight basis. Preferably, the sheet or web of homogenized tobacco material has an aerosol former content of less than 25 percent on a dry weight basis.

[0113] In one preferred embodiment, the sheet of homogenized tobacco material has an aerosol former content of approximately 20 percent on a dry weight basis.

[0114] Sheets or webs of homogenized tobacco for use as carrier sheet materials for flavoring materials of the present invention can be manufactured by methods known in the art, such as the method disclosed in International Patent Application WO 2012 / 164009 A2. In a preferred embodiment, a sheet of homogenized tobacco material for use as a carrier sheet material is formed by a casting process from a slurry comprising particulate tobacco, guar gum, cellulose fibers, and glycerin.

[0115] In other embodiments, the carrier sheet material may be in the form of a sheet of non-tobacco aerosol-generating material. For example, the carrier sheet material may be a sheet of absorbent non-tobacco material loaded with nicotine (e.g., in the form of a nicotine salt) and an aerosol former. Examples of such rods are described in International Patent Application WO 2015 / 082652. Additionally or alternatively, the carrier sheet material may be a sheet of homogenized non-tobacco plant material, such as an aromatic non-tobacco plant material.

[0116] In certain embodiments, the carrier sheet material may be in the form of a paper wrapper material, which has the advantage that the flavoring material can be used in place of, or in addition to, conventional paper wrapper materials in the manufacture of aerosol-generating articles. Thus, the flavoring material can be incorporated into the aerosol-generating article without significant changes to existing manufacturing processes and equipment.

[0117] In certain embodiments, the carrier sheet material comprises carbon particles. Preferably, the carrier sheet material comprises greater than 0.1 weight percent carbon particles, and the carbon particles have a volume average particle size greater than 10 micrometers.

[0118] It has been found that the inclusion of a carbon-based material, such as graphite, expanded graphite, graphene, etc., in the carrier sheet material of a flavorant according to the present invention improves flavor release, particularly at low temperatures, compared to a flavorant of comparable composition and structure but not including a carbon-rich carrier sheet material. Without wishing to be bound by any theory, this is hypothesized to be related to the improved thermal conductivity of the carrier sheet material, which may allow a certain threshold temperature to be reached more quickly, resulting in a more rapid release of the flavorant formulation from the polysaccharide matrix structure.

[0119] The improved flavor release is believed to be related to a more uniform temperature distribution throughout the flavorant during use, allowing for a greater use efficiency of the flavorant formulation, as a larger proportion of the flavorant reaches a temperature high enough to release the flavorant from the matrix structure.

[0120] As noted above, the improved release of flavor species provided by embodiments of flavor materials according to the present invention that include carbon particles also allows heaters configured to provide heat to aerosol-generating articles incorporating flavor delivery materials to operate at lower temperatures and therefore require less power.

[0121] Adjusting the amount and size of the carbon particles can allow for control and fine-tuning of the flavor release enhancement. For example, a relatively narrow particle size distribution can result in a more homogeneous carrier sheet material in terms of thermal conductivity. This can mean that temperature gradients in the flavor delivery material formed in different parts of the aerosol-generating article exposed to the same heating profile during use are minimized.

[0122] Preferably, the carbon particles consist of one or more of graphite particles, expanded graphite particles, and graphene particles. In a preferred embodiment, the carbon particles consist of one or both of expanded graphite particles and graphene particles.

[0123] Advantageously, such particles, particularly graphite and expanded graphite, may have high thermal conductivity and low density, and therefore may be able to significantly improve the thermal conductivity of the carrier sheet material without significantly increasing the density of the flavoring material. This may be advantageous in that increasing density increases weight and, therefore, may increase the cost of shipping a given amount of flavoring material itself. Similarly, increasing density may have a proportional impact on shipping costs when the flavoring material is incorporated into an aerosol-generating article.

[0124] Furthermore, such particles have the advantage that they are inductively heatable, and therefore can provide heat directly into the flavoring material according to the invention when the flavoring material is exposed to an electromagnetic field generated by an induction coil.

[0125] The carbon particles preferably have a volume average particle size of 30 micrometers to 150 micrometers.

[0126] As used herein, the term "volume average particle size" may refer to the average calculated using the following formula, where d[4,3] is the volume average particle size and d is the particle size:

number

[0127] In other words, the volume average particle size may refer to the average calculated by dividing the sum of the fourth power of the particle size by the sum of the third power of the particle size.

[0128] Surprisingly, the inventors have found that these relatively small particle size ranges are particularly effective in increasing the thermal conductivity of the carrier material, especially when the carrier material is in sheet form. Moreover, these relatively small particle sizes may advantageously result in sheets having a more uniform distribution of thermal conductivity and a more uniform thickness than would be possible using larger particle sizes. Furthermore, it may be easier to blend particles in this size range with similarly sized particles used to manufacture the carrier sheet material, such as in the case of sheets of homogenized tobacco or other plant material.

[0129] The carbon particles may have a particle size distribution having a D10 particle size, a D50 particle size, and a D90 particle size. In such a particle size distribution, 10% of the particles have a particle size equal to or less than the D10 particle size, and 90% of the particles have a particle size equal to or less than the D90 particle size. The D50 particle size is the median particle size, so that 50% of the particles have a particle size equal to or less than the D50 particle size.

[0130] The D90 particle size may be 50, 40, 30, 25, 20, 15, 10, 8, 5, or 3 times or less the D10 particle size. The D90 particle size may be 2, 3, 5, or 8 times or more the D10 particle size.

[0131] The D90 particle size may be 3 to 50, 3 to 40, 3 to 30, 3 to 25, 3 to 20, 3 to 15, 3 to 10, 3 to 8, 3 to 5, 5 to 50, 5 to 40, 5 to 30, 5 to 25, 5 to 20, 5 to 15, 5 to 10, 5 to 8, 8 to 50, 8 to 40, 8 to 30, 8 to 25, 8 to 20, 8 to 15, 8 to 10, 10 to 50, 10 to 40, 10 to 30, 10 to 25, 10 to 20, 10 to 15, 15 to 50, 15 to 40, 15 to 30, 15 to 25, or 15 to 20 times the D10 particle size.

[0132] A preferred particle size distribution may have a D90 particle size that is 3 to 25, or 3 to 15 times the D10 particle size. A particularly preferred particle size distribution may have a D90 particle size that is 5 to 20, or 5 to 10 times the D10 particle size.

[0133] In certain preferred embodiments, in the flavourant according to the present invention, the carbon particles have a particle size distribution having a D90 particle size and a D10 particle size, the D90 particle size being no more than 25 or 15 times the D10 particle size.

[0134] A compromise must be made regarding particle size distribution. A tighter particle size distribution may advantageously provide a more uniform thermal conductivity throughout the flavoring material. This is because there is less variation in particle size at different locations within the flavoring material. This may advantageously allow for more efficient use of the flavoring agent formulation throughout the flavoring material. However, a tighter particle size distribution may disadvantageously be more difficult and expensive to achieve. The inventors have found that the particle size distribution described above may provide an optimal compromise between these two factors.

[0135] The desired D10 and D90 particle sizes may be obtained by sieving. Thus, if desired, sieving may be used to obtain a narrow particle size distribution.

[0136] The carbon particles may have a D10 particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more. Each of the carbon particles may have a particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more.

[0137] The carbon particles may have a D10 particle size of 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers or less. Each of the carbon particles may have a particle size of 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers or less.

[0138] The carbon particles may have a D90 particle size of 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers or less. Each of the carbon particles may have a particle size of 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers or less.

[0139] The carbon particles may have a D90 particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more. Each of the carbon particles may have a particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more.

[0140] The carbon particles may have a D50 particle size and / or a volume average particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or greater.

[0141] The carbon particles may have a D50 particle size and / or a volume average particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers.

[0142] The carbon particles may have one or both of a D50 particle size and a volume average particle size of 1 to 1000, preferably 10 to 200, more preferably 30 to 150, or even more preferably 50 to 75 micrometers. Alternatively, or additionally, each of the carbon particles may have a particle size of 1 to 1000, preferably 10 to 200, more preferably 30 to 150, or even more preferably 50 to 75 micrometers.

[0143] Surprisingly, the inventors have found that these relatively small particle size ranges are particularly effective in improving the thermal conductivity of flavor materials according to the present invention, particularly in embodiments in which the flavor material comprises a carrier sheet material carrying a polysaccharide matrix that encapsulates the flavor compound. Furthermore, these relatively small particle sizes may advantageously result in a carrier sheet material that is more homogeneous in terms of thermal conductivity and has a more uniform thickness than when larger particle sizes are used. It may also be easier to blend particles in this size range with similarly sized particles used in some manufacturing processes to form carrier sheet materials.

[0144] The carbon particles may have a volume average particle size of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more.

[0145] It may be particularly preferred that the carbon particles have a volume average particle size of greater than 10 micrometers.

[0146] The carbon particles may have a volume average particle size of less than or equal to 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers.

[0147] The carbon particles may have a volume average particle size of 1 to 1000, 10 to 200, 30 to 150, or 50 to 75 micrometers. These volume average particle size ranges may be particularly preferred when the flavoring material comprises or is in the form of a sheet.

[0148] The carbon particles may have a volume average particle size that is at least 2, 3, 5, 8, 10, 15, or 20 times the number average particle size.

[0149] It may be particularly preferred that the thermally conductive particles are or include graphite particles.

[0150] The graphite particles may have a particle size distribution with a D10 particle size of 5 to 20, such as 10 to 14 micrometers, e.g., approximately 12 micrometers. The graphite particles may have a particle size distribution with a D50 particle size of 25 to 45 micrometers, e.g., approximately 35 micrometers. The graphite particles may have a particle size distribution with a D90 particle size of 45 to 75 micrometers, e.g., approximately 55 micrometers. Advantageously, such particles are commercially available and the inventors have found that they significantly enhance the thermal conductivity of flavoring materials.

[0151] It may be particularly preferred that the thermally conductive particles are or include expanded graphite particles.

[0152] The expanded graphite particles may have a particle size distribution with a D10 particle size of 5 to 20, e.g., 9 to 12 micrometers, e.g., approximately 10.5 micrometers. The expanded graphite particles may have a particle size distribution with a D50 particle size of 15 to 25 micrometers, e.g., approximately 20 micrometers. The expanded graphite particles may have a particle size distribution with a D90 particle size of 46 to 66 micrometers, e.g., approximately 56 micrometers. Advantageously, such particles are commercially available, and the inventors have found that they significantly improve the thermal conductivity of flavoring materials. The expanded graphite particles may also advantageously reduce the overall density of the flavoring material.

[0153] Each of the carbon particles may have three mutually perpendicular dimensions. The largest of the three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the smallest of the three dimensions. The largest of the three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the second largest of the three dimensions. Each of the three dimensions may be substantially equal. Each of the carbon particles may be approximately spherical.

[0154] The carbon particles may include at least 10, 20, 50, 100, 200, 500, or 1000 particles.

[0155] In the flavor material according to the present invention, the carbon particles comprise between 0.01 weight percent and 10 weight percent of the flavor material on a dry weight basis.

[0156] In the flavourant according to the invention, the polysaccharide matrix structure and flavour formulation form a layer on the carrier sheet material, which layer may have a thickness of at least 5 micrometers.

[0157] In the flavouring material according to the invention, the polysaccharide matrix structure and flavouring formulation form a layer on a carrier sheet material, preferably the layer is at least 10 micrometers thick, more preferably the layer is at least 15 micrometers thick, and even more preferably the layer is at least 20 micrometers thick.

[0158] In the flavouring material according to the present invention, the polysaccharide matrix structure and flavouring formulation form a layer on a carrier sheet material, preferably the layer is no more than 150 micrometers thick, more preferably the layer is no more than 125 micrometers thick, and even more preferably the layer is no more than 100 micrometers thick.

[0159] In some embodiments, the polysaccharide matrix structure and flavor formulation form a layer on a carrier sheet material, preferably the layer is from 10 micrometers to 150 micrometers thick, more preferably the layer is from 10 micrometers to 125 micrometers thick, and even more preferably the layer is from 10 micrometers to 100 micrometers thick.

[0160] In other embodiments, the polysaccharide matrix structure and flavor formulation form a layer on a carrier sheet material, preferably the layer is from 15 micrometers to 150 micrometers thick, more preferably the layer is from 15 micrometers to 125 micrometers thick, and even more preferably the layer is from 15 micrometers to 100 micrometers thick.

[0161] In another embodiment, the polysaccharide matrix structure and flavor formulation form a layer on a carrier sheet material, preferably the layer is from 20 micrometers to 150 micrometers thick, more preferably the layer is from 20 micrometers to 125 micrometers thick, and even more preferably the layer is from 20 micrometers to 100 micrometers thick.

[0162] The flavoring material according to the present invention can be prepared by various methods. The present invention also relates to a method for producing a flavoring material according to the present invention, which may include a first step of heating water to a temperature of at least 50°C. The method may include a second step of dispersing gellan gum in heated water to form an aqueous gellan gum dispersion. The method may include a third step of heating the aqueous gellan gum dispersion to a temperature of at least 80°C to dissolve the gellan gum and form an aqueous gellan gum solution. The method may include a fourth step of cooling the aqueous gellan gum solution to a temperature of 65°C to 75°C. The method may include a fifth step of adding a flavor formulation and an emulsifier to the cooled aqueous gellan gum solution to form a precursor composition. The method may include a sixth step of applying the precursor composition to a carrier sheet material. The method may include a seventh step of drying the carrier sheet material with the applied precursor composition to obtain a flavor-delivering material.

[0163] According to another aspect of the present invention, there is provided a method for producing a flavor material according to the present invention, the method comprising: a first step of heating water to a temperature of at least 50 degrees Celsius; a second step of dispersing gellan gum in the heated water to form an aqueous gellan gum dispersion; a third step of heating the aqueous gellan gum dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form an aqueous gellan gum solution; a fourth step of cooling the aqueous gellan gum solution to a temperature of 65 to 75 degrees Celsius; a fifth step of adding a flavor agent formulation and an emulsifier to the cooled aqueous gellan gum solution to form a precursor composition; a sixth step of applying the precursor composition onto a carrier sheet material; and a seventh step of drying the carrier sheet material with the applied precursor composition to obtain a flavor agent delivery material.

[0164] In some embodiments, the method further comprises adding to the cooled aqueous gellan gum solution a polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose. This additional step may be performed prior to the sixth step of applying the precursor composition onto a carrier sheet material.

[0165] In the process according to the invention, the emulsifier is preferably lecithin.

[0166] In certain embodiments, the sixth step of applying the precursor composition onto the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material.

[0167] The sixth step of applying the precursor composition onto a carrier sheet material includes forming a layer of the precursor composition on the carrier sheet material having a thickness of at least 10 micrometers.

[0168] The present disclosure also relates to an aerosol-generating article comprising a flavorant, wherein the flavorant formulation is releasable from the flavorant upon heating of the flavorant. The flavorant may comprise a matrix structure and a flavorant formulation dispersed within the matrix structure. The flavorant formulation is at least partially entrapped within the matrix structure and releasable from the matrix structure upon heating of the flavorant. The matrix structure may be a polysaccharide matrix structure. The flavorant may comprise a carrier sheet material, wherein the polysaccharide matrix structure and the flavorant formulation are carried by the carrier sheet material.

[0169] According to a further aspect of the present invention, there is provided an aerosol-generating article comprising a flavorant, the flavorant being releasable from the flavorant upon heating of a flavor-delivery material. The flavorant comprises a polysaccharide matrix structure and a flavorant formulation dispersed within the polysaccharide matrix structure. The flavorant formulation is entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant. The flavorant further comprises a carrier sheet material, the polysaccharide matrix structure and the flavorant formulation being carried by the carrier sheet material.

[0170] As is apparent from the foregoing description of flavoring materials according to the present invention, by incorporating such flavoring materials into aerosol-generating articles, it is possible to advantageously provide a new range of aerosol-generating articles that are able to deliver flavor to the consumer in a more consistent and controlled manner. Furthermore, because the flavoring formulation is at least partially trapped within the matrix until released when heat is supplied to the aerosol-generating article during use, loss of flavor species during storage and transport of the aerosol-generating article can be significantly reduced.

[0171] Tailoring the composition and shape of the carrier sheet material can facilitate the manufacture of the aerosol-generating article, as the carrier sheet material forms a reinforced structural support for the polysaccharide matrix structure that entraps the flavor formulation. In some embodiments, as described in more detail below, the carrier sheet material is also a source of aerosolizable ingredients, and thus, by intimately combining them with flavor sources at specific locations within the aerosol-generating article, several objectives can be served.

[0172] In certain embodiments, the aerosol-generating article comprises a rod of aerosol-generating substrate, a downstream section disposed downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section disposed downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, and a flavourant is provided on at least one of the rod of aerosol-generating substrate, the downstream section and optionally the upstream section.

[0173] As noted above, the carrier sheet material may specifically be a sheet of homogenized tobacco material. In embodiments in which the flavorant comprises one such carrier sheet material, the aerosol-generating article may include a rod of aerosol-generating substrate, a downstream section located downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section located downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, wherein the flavorant is provided within the rod of aerosol-generating substrate.

[0174] Incorporation of flavoring materials into aerosol-generating articles according to the present invention may be accomplished according to one of several methods.

[0175] For example, pieces of flavorant can be mixed with solid particles of aerosol-generating material, such as tobacco cuts, to form the rod of aerosol-generating substrate of the aerosol-generating article.

[0176] Alternatively, or additionally, the pieces of flavourant may be located elsewhere within the aerosol-generating article, for example along the downstream section of the aerosol-generating article, which may be comprised of multiple components, such that the flavourant may be incorporated within any one of such components.

[0177] As another alternative, a flavoring material comprising a carrier sheet material in the form of a paper wrapper may be used as a plug wrap for the rod of the aerosol-generating article, either alone or in combination with another paper wrapper.

[0178] This list of possible arrangements is not intended to be exhaustive, and it will be apparent that different arrangements of the flavoring material in the aerosol-generating article are possible, provided that sufficient heat is supplied to the flavoring material to release the flavor compound from the polysaccharide matrix during use of the aerosol-generating article.

[0179] Aerosol-generating articles containing flavorants according to the present invention may be used in combination with an aerosol-generating device, such as a portable electric heater configured to supply heat in a controlled manner to the aerosol-generating article, which can heat the aerosol-generating substrate and flavorant, thereby delivering a flavorful aerosol to the consumer.

[0180] Thus, the aerosol-generating article according to the present invention finds particular application in aerosol generation systems comprising an aerosol-generating device having a heating chamber in which the aerosol-generating article is housed so as to be able to supply heat to the aerosol-generating substrate. This may be achieved by providing one or more heating elements arranged around the periphery of the heating chamber, the one or more heating elements being resistively or inductively heated. Alternatively, this may also be achieved by a resistively heated blade-shaped component of the aerosol-generating device that is inserted into the aerosol-generating substrate when the aerosol-generating article is inserted into the heating chamber.

[0181] According to yet another alternative, a susceptor element may be provided within the aerosol-generating substrate, and the aerosol-generating device may include an inductor for generating an alternating or fluctuating electromagnetic field. When an aerosol-generating article engages the aerosol-generating device, the fluctuating electromagnetic field generated by the inductor induces currents in the susceptor element, heating it. Electrically operated aerosol-generating devices are preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kiloamperes per meter (kA / m), preferably 2 to 3 kA / m, e.g., about 2.5 kA / m. [Example]

[0182] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0183] Example 1: 1. A flavoring material for use in an aerosol-generating article, wherein a flavoring agent is releasable from the flavoring agent upon heating of the flavoring agent, the flavoring material comprising: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavoring agent formulation dispersed within the polysaccharide matrix structure, the flavoring agent formulation being at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavoring agent; and a carrier sheet material, wherein the polysaccharide matrix structure and the flavoring agent formulation are carried by the carrier sheet material. Example 2: 2. The flavoring material of Example 1, wherein the polysaccharide matrix structure comprises gellan gum as the only polysaccharide or gellan gum in combination with at least one other polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose. Example 3: The flavoring material of Example 1 or 2, wherein the gellan gum comprises 5 weight percent to 99.9 weight percent of the flavoring material on a dry weight basis. Example 4: formula C n H 2n+2 O n 4. The flavor material according to any one of Examples 1 to 3, further comprising a polyol having the formula: Example 5: The flavoring material of Example 4, wherein the polyol is selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol. Example 6: The flavoring material of Examples 4 or 5, wherein the polyol comprises from 0.01 weight percent to 20 weight percent of the flavoring material on a dry weight basis. Example 7: 7. The flavoring material of any one of Examples 1 to 6, further comprising fiber. Example 8: The flavoring material of Example 7, wherein the fiber comprises from 0.01 weight percent to 10 weight percent of the flavoring material on a dry weight basis. Example 9: 9. The flavoring material of any one of Examples 1 to 8, comprising 0.01 weight percent to 80 weight percent menthol. Example 10: 10. The flavoring material according to any one of Examples 1 to 9, wherein the carrier sheet material is a sheet of homogenized tobacco material. Example 11: 11. The flavourant of any one of Examples 1 to 10, wherein the carrier sheet material is a sheet of plug paper wrapper material. Example 12: 12. The flavoring material of any one of Examples 1 to 11, wherein the polysaccharide matrix structure and flavoring agent formulation form a layer on a carrier sheet material, the layer having a thickness of at least 10 micrometers. Example 13: The flavoring material of Example 12, wherein the layer thickness is less than 150 micrometers. Example 14: 14. The flavoring material of any one of Examples 1-13, wherein the carrier sheet material comprises greater than 0.1 weight percent carbon particles, and the carbon particles have a volume average particle size greater than 10 micrometers. Example 15: The flavoring material of Example 14, wherein the carbon particles have a volume average particle size of greater than 10 micrometers. Example 16: 16. The flavor material according to Example 14 or 15, wherein the carbon particles have a volume average particle size of 30 micrometers to 150 micrometers. Example 17: 17. The flavoring material of any one of Examples 14 to 16, wherein the carbon particles are one or more of graphite particles, expanded graphite particles, and graphene particles. Example 18: 18. The flavoring material of any one of Examples 14 to 17, wherein the carbon particles comprise 0.01 weight percent to 10 weight percent of the flavoring material on a dry weight basis. Example 19: 19. The flavoring material according to any one of Examples 14 to 18, wherein the carbon particles have a particle size distribution having a D90 particle size and a D10 particle size, and the D90 particle size is 25 times or 15 times or less the D10 particle size. Example 20: A method for preparing a flavoring material for use in an aerosol-generating article, the method comprising: heating water to a temperature of at least 50 degrees Celsius; dispersing gellan gum in the heated water to form an aqueous gellan gum dispersion; heating the aqueous gellan gum dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form an aqueous gellan gum solution; cooling the aqueous gellan gum solution to a temperature of 65 degrees Celsius to 75 degrees Celsius; adding a flavoring agent formulation and an emulsifier to the cooled aqueous gellan gum solution to form a precursor composition; applying the precursor composition onto a carrier sheet material; and drying the carrier sheet material with the applied precursor composition to obtain the flavoring material. Example 21: The method of Example 20, further comprising adding to the cooled aqueous gellan gum solution a polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose. Example 22: The method of example 20 or 21, wherein the emulsifier is lecithin. Example 23: The method of any one of Examples 20-22, wherein the step of applying the precursor composition onto the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material. Example 24: 24. The method of any one of Examples 20-23, wherein the step of applying the precursor composition onto a carrier sheet material comprises forming a layer of the precursor composition on the carrier sheet material having a thickness of at least 10 micrometers. Example 25: 20. An aerosol-generating article comprising a flavoring material, wherein the flavoring agent is releasable from the flavoring material upon heating of the aerosol-generating article, the flavoring material being as defined in any one of Examples 1 to 19. Example 26: 1. An aerosol-generating article comprising a flavorant, the flavorant being releasable from the flavorant upon heating of the aerosol-generating article, the flavorant comprising: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavorant formulation dispersed within the polysaccharide matrix structure, the flavorant formulation being at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant; and a carrier sheet material, wherein the polysaccharide matrix structure and the flavorant formulation are carried by the carrier sheet material. Example 27: An aerosol-generating article as described in Example 25, wherein the article comprises a rod of aerosol-generating substrate, a downstream section provided downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section provided downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, and wherein a flavor material is provided in at least one of the rod of aerosol-generating substrate, the downstream section, and optionally the upstream section. Example 28: An aerosol-generating article as described in Example 26 or 27, wherein the carrier sheet material is a sheet of homogenized tobacco material, the aerosol-generating article comprises a rod of aerosol-generating substrate, a downstream section provided downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section provided downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, and the flavor material is provided in the rod of aerosol-generating substrate.

[0184] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0185] [Figure 1]FIG. 1 shows a schematic cross-sectional side view of an aerosol-generating article according to the present invention, which comprises a flavorant on a rod within an aerosol-generating substrate. [Figure 2] FIG. 2 shows a scanning electron microscope image of the flavoring material used in the aerosol-generating article of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0186] Figure 1 shows an aerosol-generating article 10 according to the present invention. The aerosol-generating article 10 shown in Figure 1 comprises a rod of aerosol-generating substrate 12 and a downstream section 14 located downstream of the rod of aerosol-generating substrate 12. The aerosol-generating article 10 further comprises an upstream section 16 located upstream of the rod of aerosol-generating substrate 12.

[0187] A ventilation zone 60 is provided at a location downstream of the rod 12 of the aerosol-generating substrate.

[0188] More particularly, in the embodiment of Figure 1, the downstream section 14 comprises a mouthpiece element 18 and a hollow section 20. The hollow section 20 comprises an aerosol-cooling element 22 comprising a hollow tubular element and a ventilation zone 60 comprising a plurality of openings formed through the wall of the hollow tubular element. The aerosol-cooling element 22 is located immediately downstream of the rod of aerosol-generating substrate 12. As shown in the drawing of Figure 1, the upstream end of the aerosol-cooling element 22 abuts the downstream end of the rod of aerosol-generating substrate 12. The mouthpiece element 18 is positioned immediately downstream of the aerosol-cooling element 22. As shown in the drawing of Figure 1, the upstream end of the mouthpiece element 18 abuts the downstream end of the aerosol-cooling element 22. The mouthpiece element 18 comprises a plug 24 of low-density filtration material.

[0189] The rod 12 includes an aerosol-generating substrate in the form of a collection of sheets of homogenized tobacco material, although other types of tobacco-containing substrates, such as tobacco cut filler, can replace the collection of sheets of homogenized tobacco material.

[0190] The upstream section 16 comprises a cylindrical plug 26 of compressed plasticized cellulose acetate surrounded by a wrapper 28. The plug 26 in the upstream section 16 is approximately 5 millimeters in length.

[0191] The aerosol-generating article further includes a flavorant 50. More particularly, a plurality of pieces of sheet-like flavorant are dispersed within the rod 12. The flavorant 50 is of the type described in detail above.

[0192] Examples of suitable formulations of flavorant 50 and processes for forming flavorant 50 are provided below.

[0193] Preparation Method A - A flavoring material containing a menthol formulation entrapped in a gellan gum polysaccharide matrix supported on a carrier sheet material (paper wrapper) 100g of water is heated to approximately 60°C and 3.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.1g of lecithin and 8.0g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. The resulting aqueous composition is then cast onto a sheet of paper wrapper material placed on a metal tray, allowed to stand until it becomes gelatinous, and dried in a static oven at 75°C. This results in a layer containing a gellan gum matrix that encapsulates the menthol formulation fixed onto the paper wrapper.

[0194] Preparation method B1 - A flavor material comprising a menthol formulation entrapped in a gellan gum-guar polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 100g of water is heated to approximately 60°C and 1.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.1g of lecithin and 8.0g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. 2.0g of guar is then added to the mixture, and the mixture is homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material, placed on a metal tray, left to gel, and dried in a static oven at 75°C. This results in a layer containing a gellan gum / guar matrix that encapsulates the menthol formulation fixed onto the homogenized tobacco material.

[0195] Preparation method B2 - A flavor material comprising a menthol formulation entrapped in a gellan gum-guar polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 100g of water is heated to approximately 60°C and 1.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.1g of lecithin and 8.0g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. 2.0g of guar is then added to the mixture, and the mixture is homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a sheet of paper wrapper material, placed on a metal tray, left to gel, and dried in a static oven at 75°C. This results in a layer containing a gellan gum / guar matrix that encapsulates the menthol formulation fixed onto the paper wrapper material.

[0196] Preparation Method C - Flavoring material containing a menthol formulation entrapped in a gellan gum-alginate polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 100g of water is heated to approximately 60°C, and 2.0g of gellan gum and 0.5g of alginate are added to the water bath. The resulting mixture is homogenized and heated to a temperature between 90-95°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.1g of lecithin and 8.0g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material, placed on a metal tray, and left to gel. The mixture is then dried in a static oven at 75°C. This results in a layer containing a gellan gum / alginate matrix that encapsulates the menthol formulation fixed onto the homogenized tobacco material.

[0197] Preparation D1 - Aerosol-generating articles containing flavoring materials prepared according to Preparation A An amount of flavoring material produced according to Preparation A, making up a total menthol content of 5 mg, was added to a rod of a commercially available air roll generating article (HEET® from Philip Morris Products SA).

[0198] Preparation D2 - Aerosol-generating articles containing flavoring materials prepared according to Preparation A An amount of flavoring material produced according to Preparation A, making up a total menthol content of 35 mg, was added to a rod of a commercially available air roll-generating article (HEET® from Philip Morris Products SA).

[0199] Preparation D3 - Aerosol-generating articles containing flavoring materials prepared according to Preparation A The amount of flavor material produced according to Preparation A was adjusted to an overall menthol content of 37 mg and added to a rod of a commercially available aerosol-generating article (HEET® by Philip Morris Products SA).

[0200] Morphological characterization 2 shows a scanning electron microscope (SEM) image of flavorant 50 produced according to Preparation B1 embedded in wax. The image shows that the internal structure of the flavorant comprises a matrix 52 having a plurality of small pockets 54 adapted to entrap flavor compositions, the pockets 54 being dispersed throughout the matrix 52. The pockets are relatively evenly dispersed throughout the material and relatively consistent in size. Flavorant 50 further comprises a carrier sheet material 56 in the form of a sheet of homogenized tobacco material, the carrier sheet material 56 supporting the matrix 52.

[0201] thermogravimetric analysis The flavor release profile of the flavor material prepared according to the above-described method can be analyzed by thermogravimetric analysis (TGA). TGA testing is performed using a thermogravimeter coupled to a mass spectrometer or similar TGA device. In the analysis, the flavor material is heated from 25°C to 400°C in an inert nitrogen atmosphere at a rate of 15°C per minute and an airflow of 60 ml per minute. As the temperature increases, the release of menthol is assessed by detecting the menthol molecule via a specific ion representing menthol.

[0202] Data collected from performing TGA tests on flavorants according to the present invention can be compared to data collected from performing equivalent TGA tests on the flavorant formulation alone (e.g., pure menthol). One such comparison can provide some information regarding the release mechanism and dynamics, which can be useful for fine-tuning the flavorant release profile when the flavorant is incorporated into an aerosol-generating article.

[0203] When heated in the described thermogravimetric analysis, pure menthol was released unimodally between 50°C and 166°C, with a maximum at approximately 138°C.

[0204] In contrast, the flavor material produced according to Formulation B2 was found to provide a multi-modal release of menthol when heated in the described thermogravimetric analysis. A first, very small fraction of menthol was released between about 57°C and about 137°C, with a maximum at about 116°C. A second, very stable fraction of menthol was released between about 229°C and about 264°C, with a maximum at about 243°C. A third, very small fraction of menthol was released between about 265°C and about 302°C, with a maximum at about 279°C.

[0205] The release of a first fraction of menthol maximizes at temperatures slightly above 115°C, which may suggest that a portion of the menthol formulation is solubilized or relatively weakly immobilized within the flavoring material. Meanwhile, the release of a second, significantly larger fraction of menthol maximizes at temperatures above 240°C (a temperature potentially associated with thermal decomposition of gellan gum), which may support the hypothesis that a large portion of the menthol formulation is actually trapped within the matrix structure and has a somewhat stronger interaction with the gellan gum within the matrix structure. The remainder of the menthol is released at even higher temperatures, which may suggest that the menthol formulation interacts differently with the guar within the matrix structure and is more stably held by the guar within the matrix structure.

[0206] The same TGA test was performed on a flavorant prepared according to Preparation A. This flavorant was also found to release menthol in a multimodal manner. A first, very small percentage of menthol was released between about 57°C and about 239°C, with a maximum at about 200°C. A second, much larger percentage of menthol was released between 240°C and 306°C, with a maximum at about 249°C. Another percentage of menthol was released between about 307°C and about 384°C, with a maximum at about 351°C.

[0207] The first fraction of menthol is released at about 200 degrees Celsius, which may suggest that a small fraction of the menthol preparation in the flavoring material is not as strongly fixed, while the majority of the menthol preparation in the flavoring material is released at higher temperatures, which may suggest a stronger interaction with gellan gum that results in effective fixation.

[0208] Comparison of the menthol release profiles between flavoring materials prepared according to Preparation Methods B2 and E demonstrates that, when flavoring materials are incorporated into an aerosol-generating article, adjusting the composition of the polysaccharide matrix (e.g., using gellan gum alone or in combination with another polysaccharide) may help fine-tune flavor delivery. Specifically, it may be possible to control the temperature at which flavor release begins and around which temperature flavor release is maximized. Furthermore, flavoring materials with different flavor release profiles with maxima at different temperatures, such as those prepared according to Preparation Methods B2 and E, can be combined into a single aerosol-generating article to provide consumers with an even wider range of flavor delivery options.

[0209] thermal stability The thermal stability of flavoring materials according to the present invention under stress conditions can be evaluated by aging the material at a constant temperature and monitoring its weight loss over time. To this end, samples of the flavoring material, cut into uniformly sized pieces, are weighed and distributed into a series of open Schott glass bottles. The samples are aged for two weeks in a laboratory oven set at 50°C. For flavoring materials produced according to Preparation Method A, a weight loss of approximately 35 percent was measured at the end of the test. Such weight loss values ​​are assumed to take into account not only the migration of some flavor species but also the loss of humidity and glycerol, and are therefore considered satisfactory.

[0210] Flavor delivery assessment per puff The flavor delivery of aerosol-generating articles incorporating flavor materials according to the present invention can be evaluated by heating the aerosol-generating article in a compatible commercially available heating device and measuring the menthol delivered to the mouth end of the article with each puff.

[0211] More specifically, the products emitted with each puff from an aerosol-generating article heated by a heating device may be analyzed using proton transfer mass spectrometry (PTR-MS).

[0212] The menthol delivery per puff of the aerosol-generating articles manufactured according to preparation methods D1, D2, and D3 was measured, and their performance was compared with that of a commercially available aerosol-generating article (HEET® by Philip Morris Products SA) loaded with 5 mg of pure menthol.

[0213] It was observed that the commercially available aerosol-generating articles loaded with pure menthol delivered a maximum of menthol at approximately the third puff, after which the amount of menthol gradually decreased. In contrast, for the aerosol-generating articles manufactured according to preparation methods D1, D2, and D3, menthol delivery increased by the third puff and then appeared to remain substantially the same throughout the entire use cycle of the article and up to the twelfth puff.

[0214] Preparation Method E1 - A flavoring material comprising clove particles entrapped in a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 160g of water is heated to approximately 60°C and 6.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.2g of lecithin and 8.0g of clove powder are added to the mixture. The clove-containing mixture is homogenized for 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material placed on a metal tray, allowed to stand until it becomes jelly-like, and dried in a static oven at 75°C. This results in a layer containing a gellan gum matrix that encapsulates the clove-containing compound fixed onto the homogenized tobacco material.

[0215] Preparation Method E2 - A flavoring material comprising clove particles entrapped in a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 160g of water is heated to approximately 60°C and 6.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.2g of lecithin and 8.0g of clove powder are added to the mixture. The clove-containing mixture is homogenized for 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material placed on a metal tray, allowed to stand until it becomes jelly-like, and dried in a static oven at 75°C. This results in a layer containing a gellan gum matrix that encapsulates the clove-containing compound fixed onto the homogenized tobacco material.

[0216] Preparation Method E3 - A flavoring material containing menthol and clove particles entrapped in a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 160g of water is heated to approximately 60°C and 6.0g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70-75°C, and 0.2g of lecithin, 4.0g of menthol, and 4.0g of clove powder are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material placed on a metal tray, allowed to stand until it becomes jelly-like, and dried in a static oven at 75°C. This results in a layer containing a gellan gum matrix that encapsulates the clove-containing compound fixed onto the homogenized tobacco material.

[0217] Preparation Method E4 - A flavoring material comprising clove particles entrapped in a gellan gum-guar polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 160 g of water is heated to approximately 60°C and 3.0 g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature between 80 and 85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature between 70 and 75°C, and 0.2 g of lecithin and 8.0 g of clove powder are added to the mixture. The clove-containing mixture is homogenized for 3 minutes. 2.0 g of guar is then added to the mixture, and the mixture is homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a paper wrapper material, placed on a metal tray, left to gel, and dried in a static oven at 75°C. This results in a layer containing a gellan gum / guar matrix that encapsulates the menthol formulation fixed onto the paper wrapper material.

[0218] thermogravimetric analysis The flavor release profiles of flavoring materials prepared according to Preparation Methods E1-E4 can be analyzed by thermogravimetric analysis (TGA). TGA testing is performed using a thermogravimeter coupled to a mass spectrometer or similar TGA device. The flavoring material is heated in an inert nitrogen atmosphere from 25°C to 400°C at a rate of 15°C per minute and an airflow of 60 ml per minute. As the temperature increases, the release of eugenol is assessed by detecting the eugenol molecule via specific ions representing eugenol.

[0219] Data collected from performing TGA tests on flavoring materials in accordance with the present invention can be compared to data collected from performing equivalent TGA tests on pure eugenol and clove materials alone. One such comparison can provide some information regarding the release mechanism and dynamics, which can be useful in fine-tuning the flavoring release profile when the flavoring material is incorporated into an aerosol-generating article.

[0220] When heated in the described thermogravimetric analysis, pure eugenol was released unimodally between 90°C and 199°C, with a maximum at approximately 191°C, whereas when clove powder was heated under the same conditions, eugenol was released unimodally between 88°C and 216°C, with a maximum at approximately 151°C.

[0221] In contrast, when heated in the described thermogravimetric analysis, the flavor material produced according to Preparation B2 was found to release eugenol in a multimodal manner. A first, very small fraction of eugenol was released between about 215°C and about 228°C, with a maximum at about 222°C. A second, very stable fraction of eugenol was released between about 229°C and about 300°C, with a maximum at about 248°C.

[0222] The release of a first fraction of eugenol, maximizing at approximately 215°C, may suggest that some of the clove powder is relatively weakly immobilized within the flavoring material, causing eugenol to be released at only slightly higher temperatures compared to pure eugenol and clove powder alone. On the other hand, the release of a second, much larger fraction of eugenol, maximizing at temperatures above 240°C (temperatures potentially associated with thermal decomposition of gellan gum), may support the hypothesis that a large portion of the clove powder is actually trapped within the matrix structure and has somewhat stronger interactions with the gellan gum within the matrix structure.

[0223] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 5%. Within this context, the number A may be considered to include a numerical value that is within the typical standard error for measurement of the property that the number A modifies. In some cases, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A flavoring material for use in an aerosol-generating article, wherein a flavoring agent is releasable from the flavoring material upon heating of the flavoring material, the flavoring material comprising: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavorant formulation dispersed within the polysaccharide matrix structure, the flavorant formulation being at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant; a carrier sheet material, wherein the polysaccharide matrix structure and the flavor formulation are carried by the carrier sheet material.

2. 2. The flavoring material of claim 1, wherein the polysaccharide matrix structure comprises gellan gum as the only polysaccharide or gellan gum in combination with at least one other polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose.

3. 3. The flavoring material of claim 1, wherein the gellan gum comprises from 5 percent to 99.9 percent by weight of the flavoring material on a dry weight basis.

4. Formula C n H 2n+2 O n wherein the polyol is preferably selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol, and / or the polyol preferably comprises from 0.01 to 20 percent by weight of the flavor material on a dry weight basis.

5. A flavouring material according to any one of claims 1 to 4, further comprising fibre, said fibre preferably comprising from 0.01 to 10 percent by weight of said flavouring material on a dry weight basis.

6. A flavourant according to any one of claims 1 to 5, wherein the carrier sheet material is a sheet of homogenised tobacco material or a sheet of plug paper wrapper material.

7. 7. The flavoring material of any one of claims 1 to 6, wherein the carrier sheet material comprises more than 0.1 weight percent carbon particles, the carbon particles having a volume average particle size of more than 10 micrometers.

8. 8. The flavoring material according to any one of claims 1 to 7, wherein the polysaccharide matrix structure and the flavoring agent formulation form a layer on the carrier sheet material, the layer having a thickness of at least 10 micrometers, preferably less than 150 micrometers.

9. 1. A method for preparing a flavoring material for use in an aerosol-generating article, said method comprising: heating the water to a temperature of at least 50 degrees Celsius; dispersing gellan gum in the heated water to form an aqueous gellan gum dispersion; heating the aqueous gellan gum dispersion to a temperature of at least 80 degrees Celsius to dissolve the gellan gum and form an aqueous gellan gum solution; cooling the gellan gum aqueous solution to a temperature of 65°C to 75°C; adding a flavor formulation and an emulsifier to the cooled aqueous gellan gum solution to form a precursor composition; applying the precursor composition onto a carrier sheet material; and drying the carrier sheet material having the precursor composition applied thereto to obtain a flavorant.

10. 10. The method of claim 9, further comprising adding to the cooled aqueous gellan gum solution a polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose.

11. 11. The method of claim 9 or 10, wherein the step of applying the precursor composition onto the carrier sheet material comprises casting or spraying the precursor composition onto the carrier sheet material.

12. 12. The method of any one of claims 9 to 11, wherein the step of applying the precursor composition onto the carrier sheet material comprises forming a layer of the precursor composition on the carrier sheet material having a thickness of at least 10 micrometers.

13. 1. An aerosol-generating article comprising a flavorant, wherein a flavoring agent is releasable from the flavorant upon heating of the aerosol-generating article, the flavorant comprising: a polysaccharide matrix structure comprising gellan gum and an emulsifier; a flavorant formulation dispersed within the polysaccharide matrix structure, the flavorant formulation being at least partially entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant; a carrier sheet material, wherein the polysaccharide matrix structure and the flavorant formulation are carried by the carrier sheet material.

14. 14. An aerosol-generating article according to claim 13, comprising: a rod of aerosol-generating substrate; a downstream section provided downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article; and optionally an upstream section provided downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, wherein the flavoring material is provided in at least one of the rod of aerosol-generating substrate, the downstream section, and any upstream section.

15. 15. The aerosol-generating article of claim 13 or 14, wherein the carrier sheet material is a sheet of homogenized tobacco material, the aerosol-generating article comprises a rod of aerosol-generating substrate, a downstream section provided downstream of the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section provided downstream of the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, and the flavor material is provided in the rod of aerosol-generating substrate.

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