Flavour materials with improved thermal release for aerosol-generating articles - Patent Application 20070122999

Abstract

A flavoring material (50) for use in an aerosol-generating article is provided, wherein the flavoring agent is releasable from the flavoring material upon heating. The flavoring material (50) includes a polysaccharide matrix structure and a flavoring agent formulation dispersed within the polysaccharide matrix structure. The flavoring agent formulation is at least partially entrapped within the polysaccharide matrix structure and is releasable from the polysaccharide matrix structure upon heating of the flavoring material. The flavoring material includes greater than 0.1 weight percent carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers. Also provided is an aerosol-generating article (10) including the 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 that include one such flavoring material. [Background technology]

[0002] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate or a non-tobacco, nicotine-containing substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles, an 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 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. These devices include, for example, electrically heated aerosol generating devices in which aerosols are 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, International Publication No. 2015 / 176898 proposes an inductively heatable aerosol-generating article that includes an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate.

[0004] It has been proposed to include a flavor source in addition to the aerosol-generating substrate in an aerosol-generating article. Indeed, this practice is relatively common in conventional filter cigarettes, and numerous solutions have been described in the art for providing flavor at locations within the mouthpiece filter or within the tobacco cut filler rod.

[0005] However, given how aerosols are generated within an aerosol-generating article and delivered to the consumer, it can be difficult to ensure consistent flavor delivery during use, and consumers may perceive fluctuations or a decrease in flavor intensity over time. In addition, even before the aerosol-generating article is used, some flavor species may be lost during certain manufacturing processes 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 through the encapsulation of flavorants during storage, for example, in the form of capsules or microcapsules containing flavorant formulations.The encapsulated flavor species can be released before or during smoking of the filter cigarette, for example, by breaking open the encapsulation structure, for example, by manually crushing the structure.However, the encapsulated flavorant is typically released from the encapsulation structure with a single rupture, and therefore, one such solution may fail to provide a consistently strong flavor delivery during use of the article.

[0007] Therefore, a need is felt to provide aerosol-generating articles containing flavoring materials as well as flavoring materials that are associated with an enhanced flavor perception for the consumer, particularly towards the end of the use cycle of the aerosol-generating article.

[0008] The present disclosure relates to a flavorant for use in an aerosol-generating article, wherein the flavorant formulation is releasable from the flavorant upon heating of the flavorant. The flavorant may include 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 is releasable from the matrix structure upon heating of the flavorant. The matrix structure may be a polysaccharide matrix structure. The flavorant may include greater than 0.1 weight percent carbon particles. The carbon particles may have a volume average particle size greater than 10 micrometers. Summary of the Invention

[0009] According to a first aspect of the present invention, there is provided a flavoring material for use in an aerosol-generating article, the flavoring material 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 flavoring material. The flavoring material comprises greater than 0.1 weight percent carbon particles. The carbon particles have a volume average particle size greater than 10 micrometers.

[0010] As used herein with respect to 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 an inhalable aerosol for delivery to a user.

[0011] As used herein with respect to the present invention, the term "aerosol-generating substrate" is used to describe a substrate that includes an aerosol-generating material that has the ability to release, upon heating, a volatile compound capable of generating an aerosol.

[0012] As used herein with respect to 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. An aerosol may be visible or invisible. An aerosol may include not only vapor of a substance that is normally a liquid or solid at room temperature, but also solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0013] As used herein with respect to 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.

[0014] The aerosol-generating article according to the present invention has a proximal end through which, in use, the aerosol exits the aerosol-generating article for delivery to a user. 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. In 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.

[0015] 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.

[0016] 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.

[0017] As used herein with respect to the present invention, the term "longitudinal" 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.

[0018] As used herein with respect to the present invention, the term "length" is used to describe the maximum dimension along the longitudinal axis of an aerosol-generating article or a component of an aerosol-generating article.

[0019] As used herein with respect to the present invention, the term "transverse" is used to describe a direction perpendicular to the longitudinal axis. Unless otherwise specified, references to a "cross section" of an aerosol-generating article or a component of an aerosol-generating article refer to a transverse cross section.

[0020] As used herein with respect to the present invention, the term "width" refers to the largest transverse dimension of an aerosol-generating article or a component of an aerosol-generating article. When an 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. When a component of an 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.

[0021] As used herein with respect to the present invention, the term "hollow tubular element" is used to describe a generally cylindrical element having a lumen along its longitudinal axis. The tubular portion may have a substantially circular, oval, or elliptical cross-section. The lumen may have a substantially circular, oval, or elliptical cross-section. Specifically, the term "hollow tubular element" is used to denote 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 tubular element.

[0022] It has been found that the inclusion of carbon-based materials, such as graphite, expanded graphite, graphene, etc., in a flavoring material according to the present invention enhances flavor release, particularly at lower temperatures, relative to a flavoring material of comparable composition and structure but lacking the carbon-based material. Without wishing to be bound by theory, this is hypothesized to be related to the enhanced thermal conductivity of the flavoring material, which may cause a certain threshold temperature to be reached more quickly, thereby causing the flavoring agent formulation to be released more quickly from the polysaccharide matrix structure.

[0023] The improved flavor release is believed to be linked to a more uniform temperature distribution throughout the flavorant during use: a greater proportion of the flavorant reaches a temperature high enough to release the flavor species from the matrix structure, allowing for greater use efficiency of the flavor formulation.

[0024] The improved release of flavor species brought about by flavorant heat according to the present invention may also enable heaters configured to supply heat to aerosol-generating articles incorporating flavorants to operate at lower temperatures and therefore require less power.

[0025] By adjusting the amount and size of the carbon particles within the ranges described in more detail below, it may be possible to control and fine-tune the flavor release enhancement. For example, a relatively narrow particle size distribution may provide a more homogeneous flavor material with respect to thermal conductivity. This may mean that temperature gradients within the flavor material provided to different parts of the aerosol-generating article exposed to the same heating profile during use are minimized.

[0026] It is generally recognized that the use of flavoring materials in aerosol-generating articles, which involves heating an aerosol-generating substrate to generate the aerosol, presents different challenges and brings different constraints compared to conditions previously encountered with conventional cigarettes, in which the substrate is burned to generate smoke. The inventors have found that by adjusting the relative ratios of the various components in the formulation or by changing the composition of the matrix, for example, by selecting a specific combination of polysaccharides to form the matrix, or by doing both, it may be advantageously possible to fine-tune certain characteristics 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 to have flavors released in more continuous "waves" during use. As a result, consumers may perceive flavor notes that are stronger or linger longer during use. Therefore, flavoring materials according to the present invention may offer a broader range of flavor profiles not accessible with known flavoring materials.

[0027] It has been found that when the 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.

[0028] Because the flavor formulation is at least partially entrapped within the matrix until released upon heating, flavor materials according to the present invention have been found to exhibit increased stability. For example, a significant reduction in loss of flavor species has been observed during storage, transportation, etc., even under stress conditions. Combined with enhanced flavor release, this creates a particularly efficient use of flavors and other components of the flavor formulation.

[0029] In certain embodiments, the flavorant further comprises a carrier material, wherein the polysaccharide matrix structure and the flavorant formulation entrapped therein are supported by the carrier material, and the carrier material comprises carbon particles.

[0030] This may be advantageous from a manufacturing standpoint, as the carbon particles may be incorporated into the support material during the manufacture of the support material itself.

[0031] In some embodiments, the carrier material is a carrier sheet material. As used herein, the term "sheet material" refers to a layered material having a width and length substantially greater than its thickness. For example, the carrier material may be a sheet of homogenized tobacco material or a sheet of paper material. Advantageously, the carbon particles may be mixed with other components of the sheet material; for example, in the case of homogenized tobacco material, the carbon particles may be added to a slurry containing tobacco particles from which the homogenized tobacco material is formed. The use of homogenized tobacco material to produce flavoring materials according to the present invention is described in more detail below.

[0032] Embodiments in which the carrier material is a carrier sheet material also have the advantage that the polysaccharide matrix structure and the flavorant formulation entrapped therein may be deposited onto the carrier sheet material to form a flavorant that is in actual sheet form and can therefore be cut into pieces having a predetermined average size (e.g., a predetermined cutting width or a predetermined cutting length, or both), which simplifies combining the flavorant with an aerosol-generating substrate within certain aerosol-generating articles, as described in more detail below.

[0033] In other embodiments, the carrier material may comprise a plurality of pieces cut from a 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 comprise a plurality of pieces cut from a natural plant material, preferably a plant leaf material (e.g., tobacco blade). In some embodiments, the carrier material may be tobacco cut filler.

[0034] In all embodiments of the flavoring material that include a carrier material, the polysaccharide matrix structure that entraps the flavoring agent formulation may be formed in situ on the carrier material. If this in situ forming step follows the manufacturing process from which the carrier material may be obtained, the in situ forming step may also be performed at a later date or at a different location.

[0035] The use of a carrier sheet material to support the polysaccharide matrix structure and entrapped flavorant formulation may have the additional advantage that, by selecting and adjusting certain properties of the carrier sheet material (e.g., its thickness), one may obtain a flavorant that is easier to form into a bobbin and therefore easier to handle and process when the flavorant is incorporated into an aerosol-generating article. In terms of high-speed automated manufacturing processes, the increased structural strength provided by the carrier sheet material may be particularly beneficial.

[0036] At the same time, incorporating the carbon particles into the carrier sheet material may facilitate obtaining a homogeneous distribution of the carbon particles per unit of surface area of ​​the carrier sheet material. Combined with the intimate contact between the polysaccharide matrix structure that entraps the flavorant formulation and the carrier sheet material containing the carbon particles, this may ensure that the flavorant exhibits an increased thermal conductivity uniformly throughout. Advantageously, this may result in a particularly uniform temperature distribution throughout the flavorant during use.

[0037] This advantage is particularly desirable when the carrier sheet material onto which the flavorant formulation-entrapping polysaccharide matrix structure is applied is cut or broken into smaller pieces for incorporation into an aerosol-generating article, as the various smaller pieces tend to have similar flavor release profiles when exposed to the same heating profile.

[0038] As previously mentioned, in some preferred embodiments, the carrier sheet material may be in the form of a sheet of homogenized tobacco material.

[0039] As used herein, the term "homogenized tobacco material" includes 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.

[0040] A sheet or web of homogenized tobacco material for use 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.

[0041] A sheet or web of homogenized tobacco material for use as a carrier sheet material may include one or more inherent binders to help hold the particulate tobacco together, such as one or more intrinsic binders (i.e., tobacco-intrinsic binders), one or more extrinsic binders (i.e., tobacco-extrinsic binders), or combinations thereof. Alternatively, or additionally, 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.

[0042] Suitable extrinsic binders for inclusion within 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 (e.g., guar gum, xanthan gum, gum arabic, locust bean gum, etc.); cellulosic binders (e.g., hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, ethyl cellulose, etc.); polysaccharides (e.g., starch, organic acids (e.g., alginic acid), conjugate base salts of organic acids (e.g., sodium alginate), agar, pectin, etc.); and combinations thereof.

[0043] Suitable non-tobacco fibers for inclusion within a sheet or web 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 within 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.

[0044] Preferably, the sheet or web of homogenized tobacco material comprises 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.

[0045] 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.).

[0046] Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] In a preferred embodiment, the sheet of homogenized tobacco material has an aerosol former content of approximately 20 percent on a dry weight basis.

[0051] Sheets or webs of homogenized tobacco for use as carrier sheet materials in the flavoring materials of the present invention may be made by methods known in the art (e.g., the methods disclosed in International Patent Application WO-A-2012 / 164009 A2). In a preferred embodiment, sheets of homogenized tobacco material for use as carrier sheet materials are formed from a slurry comprising particulate tobacco, guar gum, cellulose fibers, and glycerin by a casting process.

[0052] 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 Application WO-A-2015 / 082652. Additionally or alternatively, the carrier sheet material may be a sheet of homogenized non-tobacco plant material, such as flavored non-tobacco plant material.

[0053] In certain embodiments, the carrier sheet material may be in the form of a paper wrapper material. This has the advantage that the flavoring material may be used as a replacement for, or in addition to, conventional paper wrapper materials in the manufacture of aerosol-generating articles. Thus, the flavoring material may be incorporated into the aerosol-generating article without significantly changing existing manufacturing processes and without requiring significant modification of existing manufacturing equipment.

[0054] Preferably, the polysaccharide matrix structure 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 residues of D-glucose and one residue each of L-rhamnose and D-glucuronic acid. 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 EU.

[0055] Two forms of gellan gum are known, namely high acyl gellan gum and low acyl gellan gum, which differ by the degree / percentage of substitution with O-acyl groups.

[0056] In the flavoring material according to the present invention, the gellan gum is preferably low-acyl gellan gum, which may be partially deacylated or completely deacylated, the most common form being the completely deacylated form with no detectable acyl groups, also called deacetylated gellan gum.

[0057] The use of low acyl gellan gum to form the polysaccharide matrix of the flavor material according to the present invention is preferred because of its ability to form gels at very low concentrations. In addition, the texture of gellan gum-based gels varies with acyl content, with low acyl gellan gum typically forming firmer, less elastic, and more brittle gels compared to high acyl gellan gum.

[0058] In embodiments in which the polysaccharide matrix structure comprises gellan gum and an emulsifier, flavorants may be advantageously provided in which a substantial fraction of the flavor formulation is effectively entrapped within the polysaccharide matrix structure. This is beneficial in terms of improving flavorant stability. Furthermore, as discussed in more detail below, this may have an impact on how flavor species are released upon heating of the flavorant, and thus may be useful for tailoring the flavorant release profile during use.

[0059] Additionally, from a manufacturing perspective, a stable polysaccharide matrix structure comprising gellan gum and an emulsifier can be formed by providing heat to the initiator reagent without the need for a cross-linking agent. Indeed, by kneading and emulsifying the flavor formulation and gellan gum in a heated aqueous bath, the polysaccharide-coated flavor can be brought into an emulsified state, which is then substantially preserved after drying and cooling. Advantageously, this allows for a significant amount of flavor to be immobilized within the polysaccharide matrix, and thus flavor materials with high flavor content may be provided.

[0060] Preferably, the emulsifier is lecithin.The use of lecithin as emulsifier is advantageous in that it is generally available and generally recognized as non-toxic.Similar to 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.Thus, the combination of gellan gum and lecithin is particularly suitable for being contained in flavor materials intended for human use.

[0061] Preferably, when the polysaccharide matrix comprises gellan gum and an emulsifier, the gellan gum comprises from 5 percent to 99.9 percent by weight of the flavor material on a dry weight basis.

[0062] More preferably, gellan gum comprises at least 7 weight percent of the flavor material on a dry weight basis, and even more preferably, comprises at least 10 weight percent of the flavor material on a dry weight basis.

[0063] Gellan gum preferably 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.

[0064] In some embodiments, gellan gum comprises from 5 weight percent to 80 weight percent of the flavor material on a dry weight basis, preferably from 5 weight percent to 60 weight percent of the flavor material on a dry weight basis, more preferably from 5 weight percent to 40 weight percent of the flavor material on a dry weight basis, and even more preferably from 5 weight percent to 30 weight percent of the flavor material on a dry weight basis.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] In certain embodiments, the polysaccharide matrix structure comprises gellan gum as the only polysaccharide.

[0069] In other embodiments, the polysaccharide matrix structure comprises gellan gum in combination with at least one additional polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropylmethylcellulose.

[0070] 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 polysaccharides listed above, provide different flavor release profiles upon heating. For example, in embodiments in which the polysaccharide matrix structure comprises gellan gum in combination with another of the polysaccharides listed above, a flavor release profile characterized by two distinct peaks at two different temperatures has been observed. Without wishing to be bound by theory, this is hypothesized to be due to different strengths of interaction between the flavor and each polysaccharide within the matrix structure, and may need to be done with each polysaccharide undergoing thermal degradation at slightly different temperatures.

[0071] Because different combinations of polysaccharides within the matrix structure generally lead to slightly different flavor release profiles when the flavor material is heated, embodiments in which gellan gum is combined with one or more of the other polysaccharides listed above may be advantageously used to fine-tune flavor release during use of an aerosol-generating article containing the flavor material. In addition, different flavor materials, each containing a polysaccharide matrix structure with a different combination of polysaccharides, may be used in combination with a single aerosol-generating article to further adjust and control flavor delivery throughout the use cycle of the aerosol-generating article. For example, incorporating different flavor materials according to the present invention into a single aerosol-generating article, where the different flavor materials are adapted to release the majority of their flavor at different temperatures or at different times during the use cycle, may help maintain a substantially consistent overall flavor delivery throughout.

[0072] In flavor material embodiments in which the matrix structure comprises gellan gum in combination with at least one of the additional polysaccharides listed above, the at least one additional polysaccharide may 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.

[0073] In flavor material embodiments in which the matrix structure comprises gellan gum in combination with at least one of the additional polysaccharides listed above, the at least one additional polysaccharide may 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.

[0074] In some embodiments, the at least one additional polysaccharide comprises from 1.0 weight percent to no more than 35 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to no more than 35 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to no more than 35 weight percent of the flavor delivery material on a dry weight basis.

[0075] In other embodiments, the at least one additional polysaccharide comprises from 1.0 weight percent to no more than 25 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to no more than 25 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to no more than 25 weight percent of the flavor delivery material on a dry weight basis.

[0076] In a further embodiment, the at least one additional polysaccharide comprises from 1.0 weight percent to no more than 15 weight percent of the flavor delivery material on a dry weight basis, preferably from 2.0 weight percent to no more than 15 weight percent of the flavor delivery material on a dry weight basis, and more preferably from 5.0 weight percent to no more than 15 weight percent of the flavor delivery material on a dry weight basis.

[0077] 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.

[0078] In certain embodiments, the flavoring material comprises at least 20 weight percent flavorant on a dry weight basis, preferably at least 25 weight percent flavorant on a dry weight basis, and more preferably at least 30 weight percent flavorant on a dry weight basis.

[0079] The flavoring material may be up to 90 weight percent flavoring on a dry weight basis. Preferably, the flavoring material may be up to 85 weight percent flavoring on a dry weight basis. More preferably, the flavoring material may be up to 80 weight percent flavoring on a dry weight basis. Even more preferably, the flavoring material may be up to 75 weight percent flavoring on a dry weight basis.

[0080] In certain 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.

[0081] In other preferred embodiments, 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.

[0082] Flavoring agents suitable for inclusion in flavor formulations of flavoring materials according to the present invention include, but are not limited to:

[0083] Flavoring agents suitable for inclusion in flavor formulations of flavoring materials according to the present invention include, but are not limited to, menthol, limonene, and eugenol.

[0084] Menthol is a monoterpenoid that may be produced synthetically or obtained from peppermint or other mint oils, and it imparts a minty, cooling flavor note.

[0085] Limonene is a cyclic monoterpene typically found in the peel oils of citrus fruits. It is also a component of the aromatic resins of many coniferous and broadleaf trees. It imparts citrus-flavored notes.

[0086] Eugenol is an allyl-chain substituted guaiacol commonly found in the essential oils of clove, nutmeg, cinnamon, basil, and bay leaf, where it imparts a spicy, clove-like flavor note.

[0087] The inventors have found that menthol and limonene can be relatively easily entrapped and immobilized within a polysaccharide matrix, and that flavor materials, including flavor formulations containing menthol, limonene, or mixtures thereof, therefore exhibit very good stability.

[0088] In a preferred embodiment, the flavor formulation comprises menthol.

[0089] 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.

[0090] 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.

[0091] The flavoring material may be up to 90 weight percent menthol on a dry weight basis. Preferably, the flavoring material may be up to 85 weight percent menthol on a dry weight basis. More preferably, the flavoring material may be up to 80 weight percent menthol on a dry weight basis. Even more preferably, the flavoring material may be up to 75 weight percent menthol on a dry weight basis.

[0092] 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.

[0093] In other preferred embodiments, the flavoring material comprises 20 to 75 weight percent menthol on a dry weight basis, preferably 25 to 75 weight percent menthol on a dry weight basis, and more preferably 30 to 75 weight percent menthol on a dry weight basis.

[0094] 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.

[0095] Advantageously, particles such as those listed above, particularly graphite and expanded graphite, can have high thermal conductivity and low density, and therefore can substantially improve the thermal conductivity of flavoring materials without significantly increasing the density of the flavoring materials. This can be advantageous in that increasing density increases the weight of the flavoring material itself for a given volume and therefore may also increase shipping costs. Similarly, increasing density can potentially have a proportional impact on shipping costs when the flavoring material is incorporated into an aerosol-generating article.

[0096] Additionally, particles such as those listed above have the advantage that they may be inductively heated and therefore heat may be supplied directly into the flavor material according to the present invention when the flavor material is exposed to an electromagnetic field generated by an induction coil.

[0097] Preferably, the carbon particles have a volume average particle size of 30 micrometers to 150 micrometers.

[0098] 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

[0099] 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 sizes by the sum of the third power of the particle sizes.

[0100] Surprisingly, the inventors have found that these relatively small particle size ranges are particularly effective in increasing the thermal conductivity of the flavor material, especially when the flavor material is in the form of or comprises a sheet. In addition, these relatively small particle sizes may advantageously result in a more homogeneous distribution of thermal conductivity and may also result in a sheet having a more uniform thickness than when larger particle sizes are used.

[0101] In embodiments where the carbon particles are included within a carrier sheet material that supports a polysaccharide structure that entraps the flavor formulation, it may also be easier to mix particles in this size range with similarly sized particles used in the manufacture of the carrier sheet material, such as in the case of sheets of homogenized tobacco or other plant material.

[0102] 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, such that 50% of the particles have a particle size equal to or less than the D50 particle size.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] In certain preferred embodiments, in the flavorant according to the present invention, the carbon particles have a particle size distribution having a D90 particle size and a D10 particle size, and the D90 particle size is no more than 25 or 15 times the D10 particle size.

[0107] 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 more expensive to achieve. The inventors have found that the particle size distribution described above may provide an optimal compromise between these two factors.

[0108] 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.

[0109] 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 diameter of 1, 2, 3, 5, 10, 20, 30, 35, 50, 75, 100, 150, 200, 250, 500, or 900 micrometers or more.

[0110] 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.

[0111] 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.

[0112] 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 greater. 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 greater.

[0113] The carbon particles may have one or both of a D50 particle size and 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.

[0114] The carbon particles may have a D50 particle size and / or a volume average particle size of 1000, 900, 500, 200, 100, 150, 100, 75, 50, 35, 30, 20, 10, 5, 3, or 2 micrometers or less.

[0115] One or both of the D50 particle size and volume average particle size of the carbon particles may be from 1 to 1000, preferably from 10 to 200, more preferably from 30 to 150, or even more preferably from 50 to 75 micrometers. Alternatively, or additionally, each of the carbon particles may have a particle size from 1 to 1000, preferably from 10 to 200, more preferably from 30 to 150, or even more preferably from 50 to 75 micrometers.

[0116] Surprisingly, the inventors have found that these relatively small particle size ranges are particularly effective in increasing the thermal conductivity of flavoring materials according to the present invention, particularly in embodiments in which the flavoring material comprises a carrier sheet material supporting a polysaccharide matrix in which the flavoring agent is entrapped. In addition, these relatively small particle sizes may advantageously result in a carrier sheet material that is more homogeneous in terms of thermal conductivity and that 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.

[0117] 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.

[0118] It may be particularly preferred for the carbon particles to have a volume average particle size of greater than 10 micrometers.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] It may be particularly preferred that the thermally conductive particles are or include graphite particles.

[0123] 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 have been found by the inventors to provide a significant increase in the thermal conductivity of the flavoring material.

[0124] It may be particularly preferred that the thermally conductive particles are or include expanded graphite particles.

[0125] 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 have been found by the inventors to provide a significant increase in the thermal conductivity of the flavoring material. The expanded graphite particles may also advantageously reduce the overall density of the flavoring material.

[0126] Each of the carbon particles may have three mutually perpendicular dimensions. The largest of these three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the smallest of these three dimensions. The largest of these three dimensions may be no more than 10, 8, 5, 3, or 2 times larger than the second largest of these three dimensions. Each of these three dimensions may be substantially equal. Each of the carbon particles may be substantially spherical.

[0127] The carbon particles may include at least 10, 20, 50, 100, 200, 500, or 1000 particles.

[0128] 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.

[0129] In some embodiments, the flavorant has the formula C n H 2n+2 O n The polyol further comprises:

[0130] 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 may also be called diols, triols, and tetrols, respectively.

[0131] Preferred polyols for inclusion in flavoring materials according to the present invention include glycerol, sorbitol, xylitol, mannitol, and erythritol.

[0132] The incorporation of polyols in the flavorant has a beneficial effect on its flexibility, making it easier to handle and giving it a defined shape, which may facilitate its incorporation into an aerosol-generating article.

[0133] 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.

[0134] In some embodiments, the flavoring material comprises fiber, preferably cellulose fiber.

[0135] The incorporation of fibers, especially cellulose fibers, may advantageously improve the tensile strength of the flavoring material, especially when provided in sheet form. This facilitates the manufacturing process of 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 entrapping the flavoring agent formulation is not supported by a carrier material.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] In a further 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.

[0141] In some embodiments, flavoring materials according to the present invention may include calcium salts or magnesium salts, such as calcium chloride or calcium lactate, or both.

[0142] 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.

[0143] In embodiments where the flavoring material includes citrate, the citrate comprises from 0.01 to 5 weight percent on a dry weight basis. Preferably, the citrate comprises from 0.01 to 1 weight percent on a dry weight basis.

[0144] Flavoring materials according to the present invention may generally contain water, since flavoring materials are generally produced by combining the various compounds described above in an aqueous bath. After drying, the water content is reduced, but generally may not be zero.

[0145] Therefore, 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.

[0146] In some embodiments, the flavoring material comprises 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.

[0147] 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.

[0148] In a further 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.

[0149] The flavouring material according to the invention can be prepared by different routes.

[0150] A method for producing a flavoring material according to the present invention may include a first step of preparing an aqueous composition containing a flavoring agent, a polysaccharide, and an emulsifier, a second step of casting the aqueous composition onto a substantially flat support surface, a third step of gelling the aqueous composition on the support surface, and a fourth step of drying the gelled aqueous composition. The dried flavoring material may then be removed from the support surface. The support surface may be a metal plate.

[0151] Another method of producing flavor delivery according to the present invention may include a first step of preparing an aqueous composition comprising a flavor agent, a polysaccharide, and an emulsifier, a second step of casting the aqueous composition onto a carrier sheet material placed on a substantially flat support surface, a third step of jelling the aqueous composition onto the carrier sheet material, and a fourth step of drying the jelled aqueous composition and carrier sheet material, where the carrier sheet material supports a polysaccharide matrix that entraps the flavor agent, which may then be removed from the support surface.

[0152] A further method of manufacturing a flavor delivery device according to the present invention may include a first step of preparing an aqueous composition comprising a flavor formulation, a polysaccharide, and an emulsifier, a second step of spraying the aqueous composition onto a carrier sheet material (e.g., homogenized tobacco material) placed on a substantially flat support surface, a third step of gelling the aqueous composition onto the carrier sheet material, and a fourth step of drying the gelled aqueous composition and carrier sheet material. The dried flavor formulation-entrapping polysaccharide matrix of the carrier sheet material may then be removed from the support surface.

[0153] The present disclosure relates to an aerosol-generating article including a flavorant, wherein a flavorant formulation is releasable from the flavorant upon heating of the flavorant. The flavorant may include 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 is releasable from the matrix structure upon heating of the flavorant. The matrix structure may be a polysaccharide matrix structure. The flavorant may include greater than 0.1 weight percent carbon particles. The carbon particles may have a volume average particle size greater than 10 micrometers.

[0154] According to a second 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 is releasable from the polysaccharide matrix structure upon heating of the flavorant. The flavorant comprises greater than 0.1 weight percent carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers.

[0155] As is apparent from the foregoing description of flavoring materials according to the present invention, by incorporating one such flavoring material into an aerosol-generating article, it is possible to advantageously provide a new range of aerosol-generating articles capable of delivering flavor to consumers in a more consistent and controlled manner. In addition, 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 transportation of the aerosol-generating article can be significantly reduced. Combined with enhanced flavor release, this creates a particularly efficient use of the flavoring agent and other components of the flavoring formulation.

[0156] Consistent with the foregoing, aerosol-generating articles according to the present invention have been found to provide more efficient release of flavor species during use compared to corresponding aerosol-generating articles containing equivalent flavor materials that do not contain carbon particles. Specifically, release of flavor species has been observed to remain consistently higher and to vary less significantly from one puff to the next.

[0157] In certain embodiments, in an aerosol-generating article according to the present invention, the flavoring material further comprises a carrier sheet material, the polysaccharide matrix structure and flavoring agent formulation being supported by the carrier sheet material, and the carrier sheet material comprises carbon particles.

[0158] The carrier sheet material provides support for the polysaccharide matrix structure that entraps the flavorant formulation, and therefore, by adjusting the composition and geometry of the carrier sheet material, it may be possible to facilitate the manufacture of the aerosol-generating article.

[0159] In certain embodiments, 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, wherein a flavourant is provided in at least one of the rod of aerosol-generating substrate, the downstream section, and the optional upstream section.

[0160] Where the flavourant comprises a carrier sheet material as described above, the carrier sheet material may be a sheet of homogenized tobacco material. In these embodiments, the aerosol-generating article may comprise a rod of aerosol-generating substrate, a downstream section provided downstream from the rod of aerosol-generating substrate and extending to the mouth end of the aerosol-generating article, and optionally an upstream section provided downstream from the rod of aerosol-generating substrate and extending to the distal end of the aerosol-generating article, and the flavourant may be provided within the rod of aerosol-generating substrate.

[0161] Incorporation of flavoring materials according to the present invention into aerosol-generating articles may be carried out according to one of several routes.

[0162] For example, small pieces of flavouring material may be mixed with solid particles of aerosol-generating material, such as tobacco, to form the rod of aerosol-generating substrate of the aerosol-generating article.

[0163] Alternatively, or additionally, the flavorant particles may be provided elsewhere within the aerosol-generating article, such as along a downstream section of the aerosol-generating article, which may comprise multiple components, and the flavorant may therefore be incorporated into any one of those components.

[0164] As a further alternative, the flavoring material comprising a carrier sheet material in the form of a paper wrapper may be used alone or in combination with another paper wrapper as a plug wrap for the rod of aerosol-generating article.

[0165] It will be apparent that this list of possible arrangements is not intended to be exhaustive and that different placements of the flavoring material within the aerosol-generating article may be possible, provided that sufficient heat is supplied to the flavoring material during use of the aerosol-generating article to release the flavor formulation from the polysaccharide matrix.

[0166] Aerosol-generating articles containing flavorants according to the present invention may be used in combination with an aerosol-generating device, such as a handheld electric heater, configured to supply heat in a controlled manner to the aerosol-generating article, thereby heating the aerosol-generating substrate and flavorant, thereby delivering a flavor-rich aerosol to the consumer.

[0167] Thus, the aerosol-generating article according to the present invention finds particular application in aerosol-generating systems comprising an aerosol-generating device having a heating chamber into which an aerosol-generating article according to the second aspect of the present invention can be received and thereby 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.

[0168] Alternatively, 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 current in the susceptor element, causing it to heat. The electrically operated aerosol-generating device may be 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.

[0169] 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 described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0170] Example 1: A flavorant for use in an aerosol-generating article, wherein the flavorant is releasable from the flavorant upon heating of the flavorant, the flavorant comprising: a polysaccharide matrix structure; 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 greater than 0.1 weight percent carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers.

[0171] Example 2: A flavoring material according to Example 1, further comprising a carrier sheet material, wherein the polysaccharide matrix structure and flavoring agent formulation are supported by the carrier sheet material, and the carrier sheet material comprises carbon particles.

[0172] Example 3: A flavorant according to Example 2, wherein the carrier sheet material is one of a sheet of homogenized tobacco material, a sheet of non-tobacco aerosol-generating material, or a paper wrapper material.

[0173] Example 4: A flavoring material according to any one of the preceding examples, wherein the polysaccharide matrix structure comprises gellan gum and an emulsifier.

[0174] Example 5: A flavoring material according to Example 4, wherein the emulsifier is lecithin.

[0175] Example 6: A flavoring material according to Examples 4 or 5, wherein the polysaccharide matrix structure comprises gellan gum as the only polysaccharide or gellan gum in combination with at least one further polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropylmethylcellulose.

[0176] Example 7: The flavoring material according to any one of Examples 4, 5, and 6, wherein the gellan gum comprises between 5 weight percent and 99.9 weight percent of the flavoring material on a dry weight basis.

[0177] Example 8: Formula Cn H 2n+2 O n 10. A flavoring material according to any one of the preceding claims, further comprising a polyol having

[0178] Example 9: A flavoring material according to Example 8, wherein the polyol is selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol.

[0179] Example 10: A flavoring material according to Examples 8 or 9, wherein the polyol comprises from 0.01 weight percent to 20 weight percent of the flavoring material on a dry weight basis.

[0180] Example 11: A flavoring material according to any one of the preceding examples, wherein the carbon particles consist of one or more of graphite particles, expanded graphite particles, and graphene particles.

[0181] Example 12: A flavoring material according to any one of the preceding claims, wherein the carbon particles have a volume average particle size of from 30 micrometers to 150 micrometers.

[0182] Example 13: A flavoring material according to any one of the preceding claims, 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 no more than 25 or 15 times the D10 particle size.

[0183] Example 14: A flavoring material according to any one of the preceding claims, wherein the carbon particles comprise between 0.01 weight percent and 10 weight percent of the flavoring material on a dry weight basis.

[0184] Example 15: A flavoring material according to any one of the preceding claims, further comprising fiber.

[0185] Example 16: A flavoring material according to Example 15, wherein the fiber comprises 0.01 weight percent to 10 weight percent of the flavoring material on a dry weight basis.

[0186] Example 17: A flavoring material according to any one of the preceding claims, comprising 0.01 weight percent to 80 weight percent menthol on a dry weight basis.

[0187] Example 18: An aerosol-generating article comprising a flavorant according to any one of Examples 1-17.

[0188] Example 19: An aerosol-generating article comprising a flavorant, the flavorant being releasable from the flavorant upon heating of a flavor delivery material, the flavorant comprising a polysaccharide matrix structure and a flavorant formulation dispersed within the polysaccharide matrix structure, the flavorant formulation being entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant, the flavorant formulation comprising greater than 0.1 weight percent carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers, the flavorant further comprising a carrier sheet material, the polysaccharide matrix structure and the flavorant formulation being supported by the carrier sheet material, and the carrier sheet material comprising the carbon particles.

[0189] Example 20: An aerosol-generating article according to Example 18 or 19, 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 flavoring material is provided in at least one of the rod of aerosol-generating substrate, the downstream section, and optionally the upstream section.

[0190] Example 21: An aerosol-generating article according to Example 19, 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 wherein a flavor material is provided in the rod of aerosol-generating substrate.

[0191] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0192] [Figure 1] FIG. 1 shows a schematic cross-sectional side view of an aerosol-generating article according to the present invention, which comprises a flavourant in the form of a rod of 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. [Figure 3] FIG. 3 shows a scanning electron microscope image of another flavor material according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0193] An aerosol-generating article 10 according to the present invention is shown in Figure 1. The aerosol-generating article 10 shown in Figure 1 comprises a rod of aerosol-generating substrate 12 and a downstream section 14 at a location downstream of the rod of aerosol-generating substrate 12. The aerosol-generating article 10 further comprises an upstream section 16 at a location upstream of the rod of aerosol-generating substrate 12.

[0194] A ventilation zone 60 is provided at a location downstream of the rod 12 of the aerosol-generating substrate.

[0195] More specifically, 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 positioned 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.

[0196] 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.

[0197] 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 has a length of approximately 5 millimeters.

[0198] Additionally, the aerosol-generating article includes a flavorant 50. More specifically, a plurality of small pieces of flavorant in sheet form are dispersed within the rod 12. The flavorant 50 is of the type described in detail above.

[0199] Examples of suitable formulations for flavorant 50, and processes for forming flavorant 50, are described below.

[0200] Preparation A - Flavoring material containing a menthol formulation entrapped within a gellan gum polysaccharide matrix 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 in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1g of lecithin, 1.1g of graphite, 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 metal tray, allowed to stand to form a jelly, and dried in a static oven at 65°C. A sheet of flavor material is obtained.

[0201] Preparation B - Flavoring material containing a menthol formulation entrapped within a gellan gum-guar polysaccharide matrix 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 in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1g of lecithin, 1.1g of graphite, 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, which is then homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a metal tray, left to gel, and dried in a static oven at 75°C. A sheet of flavor material is obtained.

[0202] Preparation C - A flavor material containing a menthol formulation entrapped within a gellan gum polysaccharide matrix supported on a carrier sheet material (paper wrapper) 100 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 in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g 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 paper wrapper containing graphite particles placed on a metal tray, allowed to gel, and dried in a static oven at 65°C. A flavor material is obtained containing a layer of gellan gum matrix entrapping the menthol formulation immobilized on the graphite-containing paper wrapper.

[0203] Preparation D - A flavor material comprising a menthol formulation entrapped within a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material). 100 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 in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g 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 containing graphite particles placed on a metal tray, allowed to gel, and dried in a static oven at 65°C. A flavor material is obtained containing a layer of gellan gum matrix entrapping the menthol formulation immobilized on the graphite-containing homogenized tobacco material.

[0204] Prepared E - flavor material containing a menthol formulation entrapped within a gellan gum-guar polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 100 g of water is heated to approximately 60°C, and 1.0 g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. 2.0 g of guar is then added to the mixture, which is then homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material containing graphite particles and placed on a metal tray, allowed to gel, and dried at 65°C in a static oven. A flavor material is obtained containing a layer of gellan gum / guar matrix that entraps the menthol formulation immobilized on the graphite-containing homogenized tobacco material.

[0205] Preparation F - A flavor material comprising a menthol formulation entrapped within a gellan gum-alginate matrix supported on a carrier sheet material (homogenized tobacco material). 100 g of water is heated to approximately 60°C, and 2.0 g of gellan gum and 0.5 g of alginate are added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range of 90-95°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. 2.0 g of guar is then added to the mixture, which is then homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a sheet of homogenized tobacco material containing graphite particles and placed on a metal tray, allowed to gel, and dried at 65°C in a static oven. A flavor material is obtained containing a layer of gellan gum / alginate matrix that entraps the menthol formulation immobilized on the graphite-containing homogenized tobacco material.

[0206] Preparation G - Aerosol-generating articles containing flavoring materials produced according to Preparation A An amount of flavor material produced according to Preparation A, making up an overall content of 5 mg of menthol, was added to a rod of a commercially available aerosol-generating article (HEET® by Philip Morris Products SA).

[0207] Comparative Preparation A - A flavoring material comprising a menthol formulation entrapped within a gellan gum polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material). 100 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 in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g 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 that does not contain graphite particles and is placed on a metal tray, allowed to gel, and dried in a static oven at 65°C. A flavor material is obtained that contains a layer of gellan gum matrix that entraps the immobilized menthol formulation on the graphite-free homogenized tobacco material.

[0208] Comparative Preparation B - A flavor material comprising a menthol formulation entrapped within a gellan gum-guar polysaccharide matrix supported on a carrier sheet material (homogenized tobacco material) 100 g of water is heated to approximately 60°C, and 1.0 g of gellan gum is added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range of 80-85°C and held at this temperature for 5 minutes. The mixture is then cooled to a temperature in the range of 70-75°C, and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavor-containing mixture is homogenized for 3 minutes. 2.0 g of guar is then added to the mixture, which is then homogenized again for another 3 minutes. The resulting aqueous composition is then cast onto a sheet of particle-free homogenized tobacco material placed on a metal tray, allowed to gel, and dried at 65°C in a static oven. A flavor material is obtained comprising a layer of gellan gum / guar matrix entrapping the immobilized menthol formulation on the graphite-free homogenized tobacco material.

[0209] Comparative Preparation C - Aerosol-generating article containing flavoring material produced according to Preparation A An amount of flavor material produced according to Comparative Preparation A, making up an overall content of 5 mg of menthol, was added to a rod of a commercially available aerosol-generating article (HEET® by Philip Morris Products SA).

[0210] Morphological characterization 2 shows a scanning electron microscope (SEM) image of flavorant 50 produced according to Preparation E 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 trap 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 containing graphite particles, which supports matrix 52. SEM techniques do not allow the graphite particles to be distinguished from the remainder of the carrier sheet material.

[0211] FIG. 3 shows an SEM image of a flavoring material 150 produced according to Preparation A embedded in wax. The image shows that the flavoring material's internal structure comprises a matrix 52 with a plurality of small pockets 54 adapted to trap flavor compositions, the pockets 54 being dispersed throughout the matrix 52. The regions are relatively evenly dispersed throughout the material and relatively consistent in size. In contrast to the flavoring material 50 of FIG. 2, flavoring material 150 does not include a carrier sheet material supporting the matrix, and the carbon particles are embedded within the matrix structure. SEM techniques do not allow for the graphite particles to be distinguished from the remainder of the matrix structure.

[0212] thermogravimetric analysis The flavor release profile of flavoring materials produced according to the above formulations may be analyzed by thermogravimetric analysis (TGA). TGA testing is performed using a thermogravimetric machine coupled to a mass spectrometer or similar TGA instrument. In the analysis, the flavoring material is heated from 25°C to 400°C in an inert nitrogen atmosphere, increasing the temperature at a rate of 15°C per minute and with an airflow of 60 ml per minute. As the temperature increases, the release of menthol is assessed by detecting the menthol molecule via specific ions representing menthol.

[0213] Data collected to perform TGA tests on flavorants according to the present invention can be compared to data collected to perform equivalent TGA tests on the flavorant formulation alone (e.g., pure menthol). One such comparison may provide some information about the release mechanism and kinetics, which may be useful for fine-tuning the flavorant release profile when the flavorant is incorporated into an aerosol-generating article.

[0214] When heated in the thermogravimetric analysis described, pure menthol was released unimodally between 50°C and 166°C, with a maximum at approximately 138°C.

[0215] In contrast, the flavor material produced according to Formulation E was found to provide a multi-modal release of menthol when heated in the described thermogravimetric analysis. A first fraction of menthol (about 57 percent) was released between 62°C and 239°C, with a maximum at about 194°C. A second fraction of menthol (about 24 percent) was released between 240°C and 305°C, with a maximum at about 252°C. A third fraction of menthol (about 19 percent) was released between 305°C and 387°C, with a maximum at about 344°C.

[0216] The release of a first fraction of menthol up to slightly below 200°C may suggest that a portion of the menthol formulation is solubilized or relatively weakly immobilized within the flavoring material. On the other hand, the release of a second fraction of menthol up to about 250°C (a temperature associated with gellan gum thermal decomposition) may support the assumption that a significant portion of the menthol formulation is entrapped within the matrix structure and has some stronger interaction with the gellan gum within the matrix structure. The release of a third fraction of menthol at even higher temperatures may suggest that the menthol formulation interacts differently with the guar within the matrix structure.

[0217] The same TGA test was performed on a flavor material prepared according to Preparation D. This flavor material was found to provide a bimodal release of menthol. A first, small fraction of menthol (about 9 percent) was released between about 68 degrees Celsius and about 148 degrees Celsius, with a maximum at approximately 1.25 degrees Celsius. A second, much more significant fraction of menthol (about 91 percent) was released between 230 degrees Celsius and 245 degrees Celsius, with a maximum at approximately 242 degrees Celsius.

[0218] The release of a first fraction of menthol at approximately 130 degrees Celsius may indicate that a small portion of the menthol preparation contained in the flavoring material is not immobilized, whereas a larger portion of the menthol preparation contained in the flavoring material released at higher temperatures may indicate a stronger interaction with gellan gum, which results in effective immobilization.

[0219] A comparison of the menthol release profiles of flavoring materials prepared according to Preparation E and Preparation D demonstrates that adjusting the composition of the polysaccharide matrix, for example, using gellan gum alone or in combination with another polysaccharide, can be useful for fine-tuning flavor delivery when the flavoring material is incorporated into an aerosol-generating article. Specifically, it may be possible to control at what temperature flavor release begins and around what temperature flavor release is maximized. In addition, flavoring materials with different flavor release profiles, such as those prepared according to Preparation E and Preparation D, may be combined in a single aerosol-generating article to provide consumers with an even wider range of flavor delivery options.

[0220] The same TGA test was performed on a flavorant prepared according to Comparative Preparation B, which differed from a flavorant prepared according to Preparation E only in that the carrier sheet of homogenized tobacco material did not contain graphite particles. Similar to the flavorant prepared according to Preparation E, the flavorant produced according to Comparative Preparation B was found to provide a multi-modal release of menthol when heated in the described thermogravimetric analysis. A first fraction of menthol (about 41 percent) was released in a lower temperature range, followed by a second fraction (about 34 percent) and a third fraction (about 25 percent) of menthol in a higher temperature interval.

[0221] A comparison of the menthol release profiles between Preparation E and Comparative Preparation B suggests that the inclusion of carbon particles in the flavorant tends to enhance the thermal release of menthol at lower temperatures. Specifically, a shift of approximately 5 degrees Celsius toward lower temperatures is observed, with a maximum associated with the release of the first fraction of menthol being observed at approximately 199 degrees Celsius for the flavorant produced according to Comparative Preparation B.

[0222] Additional tests performed under isothermal conditions confirmed that flavor materials produced according to Formulation E released significantly more menthol than flavor deliveries produced according to Comparative Formulation B, especially at lower temperatures. At 150°C, flavor materials produced according to Formulation E released approximately 1.73 times more menthol than flavor deliveries produced according to Comparative Formulation B. At 180°C, flavor materials produced according to Formulation E released approximately 1.5 times more menthol than flavor deliveries produced according to Comparative Formulation B. This appears to confirm that the presence of carbon particles results in a more effective heat delivery, likely because the carbon particles enhance heat transfer by conduction and promote a more uniform temperature distribution throughout the flavor material. As a result, a larger portion of the menthol is conditioned to be released from the flavor material more rapidly.

[0223] The same TGA testing described above was performed on a flavorant prepared according to Comparative Preparation A, which differs only from a flavorant prepared according to Preparation D in that graphite particles are not included in the convenient delivery material. Similar to the flavorant prepared according to Preparation D, the flavorant produced according to Comparative Preparation A was found to provide a bimodal release of menthol when heated in the described thermogravimetric analysis.

[0224] The menthol release profile of Formulation D was compared to that of Comparative Formulation A by plotting the cumulative amount of menthol released by each flavorant side by side. The results of this comparison suggest that the inclusion of carbon particles in the flavorant tends to enhance the thermal release of menthol. Specifically, a shift toward lower temperatures of about 5 degrees Celsius or more was observed for the flavorant produced according to Formulation D. For example, 40 percent of the menthol contained in the flavorant produced according to Formulation D was released when the flavorant reached 240 degrees Celsius, while only the flavorant produced according to Comparative Formulation A reached the same 40 percent release threshold at 245 degrees Celsius. Similarly, 60 percent of the menthol contained in the flavorant produced according to Formulation D was released when the flavorant reached 243 degrees Celsius, while only the flavorant produced according to Comparative Formulation A reached the same 40 percent release threshold at about 249 degrees Celsius.

[0225] thermal stability The thermal stability of flavoring materials according to the present invention under stress conditions may be evaluated by aging the flavoring material at a constant temperature and monitoring its weight loss over time. To this end, samples of the flavoring material cut into regular, uniformly sized pieces were weighed and distributed into a series of open shot glass jars. The samples were aged in a laboratory oven set at 50°C for a period of two weeks. For flavoring materials produced according to Preparation E, a weight loss of approximately 24 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 moisture and glycerol, and are therefore considered satisfactory.

[0226] Flavor delivery evaluation per puff The flavor delivery of an aerosol-generating article incorporating a flavoring material according to the present invention may be evaluated by heating the aerosol-generating article in a compatible commercially available heating device and measuring the menthol delivered at the mouth end of the article with each puff. 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).

[0227] The menthol delivery per puff of the aerosol-generating article made according to Formulation G was compared to the delivered emission per puff of the aerosol-generating article made according to Comparative Formulation C under the same test conditions. It was observed that a greater amount of menthol was released from the Formulation G article with each puff than from the Comparative Formulation C article. Furthermore, the amount of menthol released with the second puff and each successive puff from the Comparative Formulation C article varied from about 0.04 mg / puff to 0.09 mg / puff, while the amount of menthol released with the second puff and each successive puff from the Formulation G article was more consistent, from about 0.09 mg / puff to about 0.11 mg / puff.

[0228] 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 instances, 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, the flavoring material comprising: a polysaccharide matrix structure; 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; greater than 0.1 percent by weight of carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers.

2. 10. The flavoring material of claim 1, further comprising a carrier sheet material, wherein the polysaccharide matrix structure and the flavoring agent formulation are supported by the carrier sheet material, and the carrier sheet material contains the carbon particles.

3. 3. The flavoring material of claim 2, wherein the carrier sheet material is one of a sheet of homogenized tobacco material, a sheet of non-tobacco aerosol-generating material, and a paper wrapper material.

4. A flavor delivery method according to any one of claims 1 to 3, wherein the polysaccharide matrix structure comprises gellan gum and an emulsifier.

5. 5. The flavoring material of claim 4, wherein the polysaccharide matrix structure comprises gellan gum as the only polysaccharide or gellan gum in combination with at least one further polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethylcellulose, and hydroxypropyl methylcellulose, and wherein the gellan gum preferably comprises from 5 percent to 99.9 percent by weight of the flavoring material on a dry weight basis.

6. Formula C n H 2n+2 O n 6. The flavoring material of claim 1, further comprising a polyol having the formula: wherein the polyol is selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol, and / or the polyol comprises from 0.01 weight percent to 20 weight percent of the flavoring material on a dry weight basis.

7. The flavoring material according to any one of claims 1 to 6, wherein the carbon particles are one or more of graphite particles, expanded graphite particles, and graphene particles.

8. 8. The flavoring material according to any one of claims 1 to 7, wherein the carbon particles have a volume average particle size of from 30 micrometers to 150 micrometers.

9. 9. The flavoring material according to claim 1, 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 no more than 25 or 15 times the D10 particle size.

10. 10. The flavoring material according to any one of claims 1 to 9, wherein the carbon particles comprise from 0.01 weight percent to 10 weight percent of the flavoring material on a dry weight basis.

11. 11. The flavoring material of any one of claims 1 to 10, further comprising fiber, preferably said fiber comprising from 0.01 to 10 percent by weight of said flavoring material on a dry weight basis.

12. 1. An aerosol-generating article comprising a flavorant, the flavorant being releasable from the flavorant upon heating of the flavor delivery material, the flavorant comprising: a polysaccharide matrix structure; a flavorant formulation dispersed within the polysaccharide matrix structure, the flavorant formulation being entrapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavorant; 10. An aerosol-generating article, wherein the flavoring material comprises greater than 0.1 percent by weight of carbon particles, the carbon particles having a volume average particle size greater than 10 micrometers.

13. 13. The aerosol-generating article of claim 12, wherein the flavoring material further comprises a carrier sheet material, the polysaccharide matrix structure and the flavoring agent formulation being supported by the carrier sheet material, and the carrier sheet material comprising the carbon particles.

14. 14. An aerosol-generating article as described in claim 12 or 13, comprising: a rod of aerosol-generating substrate; a downstream section of the aerosol-generating substrate provided downstream of the rod and extending to the mouth end of the aerosol-generating article; and optionally an upstream section provided downstream of the rod of the 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 the aerosol-generating substrate, the downstream section, and optionally the upstream section.

15. 14. The aerosol-generating article of claim 13, 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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