aerosol-generating material in the form of one or more non-linear strands

Abstract

The present invention provides an aerosol-generating material in the form of one or more non-linear strands. The aerosol-generating material includes an aerosol-generating agent, a crosslinked binder, optionally one or more fillers, and optionally an active material and / or a flavoring agent and / or an acid. The present invention also provides an aerosol-generating composition including the aerosol-generating material, a consumable product for use in a non-combustion aerosol delivery system, and a non-combustion aerosol delivery system. The present invention also provides a method for producing the aerosol-generating material.

Description

Detailed Description of the Invention

[0001] [Technical field] The present invention relates to an aerosol-forming material, an aerosol-forming composition comprising the aerosol-forming material, a consumable for use in a non-combustion aerosol delivery system, the consumable comprising the aerosol-forming composition, and a non-combustion aerosol delivery system. The present invention also relates to a method for producing the aerosol-forming material and the aerosol-forming material obtainable by the method of the present invention.

[0002] [background] Smoking consumables, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Alternatives to these types of consumables release compounds from a substrate material by heating without combustion, thereby emitting an inhalable aerosol or vapor. These are sometimes referred to as non-combustion smoking consumables or aerosol-generating assemblies.

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

[0004] Another example is a hybrid device, which includes a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol, and further includes a solid aerosol-forming material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium.

[0005] [overview] According to a first aspect of the present invention, there is provided an aerosol-generating material in the form of one or more non-linear strands, the aerosol-generating material comprising: an aerosol generating agent; a cross-linked binder; optionally one or more fillers; Optionally, an active material and / or a flavoring and / or an acid Includes:

[0006] According to a further aspect of the present invention, there is provided an aerosol-forming material in the form of one or more non-linear strands, the aerosol-forming material comprising: an aerosol generating agent; a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof; optionally one or more fillers; Optionally, an active material and / or a flavoring and / or an acid Includes:

[0007] In another aspect, an aerosol-forming composition is provided that includes an aerosol-forming material of the present invention.

[0008] According to a further aspect of the present invention, there is provided a method of forming an aerosol-generating material in the form of a non-linear strand, the method comprising: (a) forming a mixture comprising a solvent, an aerosol-forming agent, a crosslinkable binder, optionally a filler, and optionally an active material and / or a flavoring agent and / or an acid; (b) injecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; Includes:

[0009] According to a further aspect of the present invention, there is provided a method of forming an aerosol-generating material in the form of a non-linear strand, the method comprising: (a) forming a mixture comprising a solvent, an aerosol-forming agent, a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof, optionally a filler, and optionally an active material and / or a flavoring and / or an acid; (b) injecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; Includes:

[0010] According to a further aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol delivery system, the consumable comprising an aerosol-forming composition as defined herein.

[0011] According to a further aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising a consumable as defined herein and a non-combustion aerosol delivery device comprising an aerosol generation device configured (or arranged) to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0012] According to a further aspect of the present invention, there is provided the use of an aerosol generating composition as defined herein in a consumable for use in a non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0013] According to a further aspect of the present invention, there is provided the use of an aerosol-forming material or an aerosol-forming composition as defined herein for generating an aerosol.

[0014] According to a further aspect, the present invention provides an aerosol-forming material obtainable or obtained by the method of the present invention.

[0015] According to a further aspect of the present invention, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system described herein. The method includes heating an aerosol-generating material. In some embodiments, the method includes heating the aerosol-generating material to a temperature of 350°C or less. In some embodiments, the method includes heating the aerosol-generating material to a temperature of about 220°C to about 280°C.

[0016] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which description is given by way of example only with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a cross-sectional view of an example of an aerosol product. [Figure 2] FIG. 2 is a perspective view of the article of FIG. 1. [Figure 3] 1 is a cross-sectional elevation view of an example aerosol product. FIG. [Figure 4] FIG. 4 is a perspective view of the article of FIG. 3. [Figure 5] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 6] FIG. 1 is a cross-sectional view of an example of an aerosol generation assembly. [Figure 7] FIG. 1 is a perspective view of an example of an aerosol generation assembly. [Figure 8] 1 is a schematic diagram illustrating an aerosol-forming material of the present invention. [Figure 9] FIG. 9 is a schematic cross-sectional view of the aerosol-generating material of FIG. 8. [Figure 10] 1 is a schematic diagram illustrating an aerosol-forming material of the present invention. [Figure 11]1 is a photograph of an aerosol-forming material of the present invention (left) and an equivalent aerosol-forming material in the form of shredded sheets (right). [Figure 12] 1 is a photograph of an aerosol-forming material of the present invention. [Figure 13] 1 is a photograph of a series of strands of the present invention. [Figure 14] 1 is a microscope image of a single strand specimen of the present invention.

[0018] [Detailed explanation] The aerosol-forming materials / compositions described herein are materials / compositions capable of generating an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-forming composition includes an aerosol-forming material. The aerosol-forming material may be a dry gel. The aerosol-forming material may be a solid material capable of retaining some fluid, e.g., a liquid, therein. In some embodiments, the aerosol-forming composition may comprise, for example, about 50%, 60%, or 70% by weight of the aerosol-forming material to about 90%, 95%, or 100% by weight of the aerosol-forming material. In some examples, the aerosol-forming composition consists of the aerosol-forming material. In other examples, the aerosol-forming composition comprises about 40% to about 60% by weight of the aerosol-forming material. The remainder of the composition may be formed from other components, such as tobacco material, as described below.

[0019] As described hereinabove, the present invention provides an aerosol-generating material in the form of one or more non-linear strands, the aerosol-generating material comprising: an aerosol generating agent; Cross-linked binder and Includes.

[0020] The present invention also provides an aerosol-forming material in the form of one or more non-linear strands, the aerosol-forming material comprising: an aerosol-generating agent, and a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as acyl gellan gum), and combinations thereof; Includes.

[0021] The aerosol-forming material may also optionally include one or more fillers, active materials and / or flavorings and / or acids.

[0022] The aerosol-generating material is in the form of non-linear strands, which may alternatively be described as non-linear gel fibers. That is, the aerosol-generating material is in the form of strands or gel fibers, with each strand or fiber being non-linear along its length. The strands or fibers may alternatively be described as curled, noodle-like, or twisted. Thus, each strand may be considered to resemble a noodle in shape, while multiple strands or gel fibers collectively may resemble a collection of noodles in shape, where the individual strands may randomly overlap and connect with one another. As used herein, the term "non-linear strand" is also intended to encompass alternative terms described herein, such as "non-linear gel fiber," "curled strand," "curled gel fiber," "noodle-like strand," "noodle-like gel fiber," "twisted strand," etc.

[0023] Schematic examples of nonlinear strands of the present invention are shown in solid lines in Figures 8 and 10, but it will be appreciated that these figures show two-dimensional representations of three-dimensional structures. In reality, each strand is three-dimensional and may be nonlinear in three dimensions as well. By "nonlinear" in three dimensions, it is meant that the strands of the present invention are nonlinear in the x, y, and z directions. A spring or coil is an example of a shape that is nonlinear in the x, y, and z directions. In contrast, other strands may be nonlinear in two dimensions (e.g., the x and y directions) but linear or flat in a third dimension (e.g., the z direction).

[0024] Each non-linear strand may have a diameter of about 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, or 0.5 mm to about 3 mm, 2.5 mm, 2 mm, 1.5 mm, 1.1 mm, 0.8 mm, 0.6 mm, or 0.5 mm. In some embodiments, each non-linear strand has a diameter of about 0.05 mm to about 3 mm, about 0.3 to about 2.5 mm, about 0.5 to about 1.5 mm, or about 0.7 to about 1.1 mm. In some embodiments, each non-linear strand has a diameter of about 0.1 to about 2 mm, about 0.1 to about 1.0 mm, or about 0.2 to about 0.4 mm. Diameter, also referred to as width, is defined as the longest diameter of the cross section of the strand.

[0025] Each non-linear strand may have a circular or substantially circular cross-section, the cross-section being the shape that would appear if one were to cut the strand straight through at a point perpendicular to its length. An example of a strand with a circular cross-section is shown in Figure 9, which cross-section is taken at the dotted line in the schematic representation of a strand of the invention shown in Figure 8.

[0026] However, as described below, the shape of the strands is determined by the method by which they are made, and therefore, one skilled in the art will recognize that strands having other cross-sectional shapes (e.g., rectangular, substantially rectangular, triangular, or substantially triangular) can also be made.

[0027] In some embodiments, the non-linear strands of the present invention are homogeneous across their cross-section, i.e., in some embodiments, the strands have a homogeneous composition.

[0028] Each non-linear strand may have a thickness of about 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, or 0.5 mm to about 3 mm, 2.5 mm, 2 mm, 1.5 mm, 1.1 mm, 0.8 mm, 0.6 mm, or 0.5 mm. In some embodiments, each non-linear strand has a thickness of about 0.05 mm to about 3 mm, about 0.3 to about 2.5 mm, about 0.5 to about 1.5 mm, or about 0.7 to about 1.1 mm. In some embodiments, each non-linear strand has a thickness of about 0.1 to about 2.0 mm, about 0.1 to about 1.0 mm, or about 0.2 to about 0.4 mm. As used herein, the term "thickness" refers to the cross-sectional dimension perpendicular to the diameter or width.

[0029] When the cross section of a non-linear strand is circular, the diameter to thickness ratio of the non-linear strand is 1. Each non-linear strand may have a diameter to thickness ratio of about 1:2 to about 2:1, such as about 3:2 to about 2:3, for example about 1:1.

[0030] Each non-linear strand may have a total length (also referred to herein as gross length) of about 8 mm, 10 mm, 15 mm, 20 mm, or 30 mm to about 200 mm, 100 mm, 75 mm, or 50 mm. The total length or gross length of each strand also refers herein to the unwound length, and is defined as the theoretical length if the strand were extended straight. For example, the total length of the strand shown in FIG. 10 is the gross length of the strand, i.e., the length if the solid black line were straightened.

[0031] In some embodiments, each non-linear strand has a total length of about 10 mm to about 200 mm, such as about 20 mm to about 100 mm, or about 30 mm to about 50 mm.

[0032] Each non-linear strand may have a free length of about 3 mm, 5 mm, 8 mm, or 11 mm to about 25 mm, 22 mm, 20 mm, or 18 mm. The term "free length," as used herein, is intended to mean the shortest (straight) length between the farthest ends of a strand in its natural non-linear (or curled) state (e.g., the distance in "straight line" between the ends of the strand). This is also referred to herein as the rolled length. For example, in FIG. 10, the free or rolled length of the strand is shown by a dashed line. Non-linear strands having free lengths outside the ranges disclosed herein can be more easily bundled together than non-linear strands having free lengths defined herein.

[0033] In some embodiments, each non-linear strand has a free or wound length of about 2 mm to about 35 mm, e.g., about 3 mm to about 25 mm, about 6 mm to about 23 mm, about 8 mm to about 22 mm, or about 11 mm to about 20 mm.

[0034] The total or unwound length is greater than the free or coiled length. In some embodiments, the ratio between the total length and the free length of each non-linear strand (i.e., the total length divided by the free length) is at least about 1.2, e.g., at least about 1.3, at least about 1.5, or at least about 2. In some embodiments, the ratio between the total length and the free length of each non-linear strand is less than about 10, less than about 8, or less than about 6. In some embodiments, the ratio between the total length and the free length of each non-linear strand is from about 1.2 to about 10, e.g., from about 1.5 to about 5, or from about 2 to about 5.

[0035] In some embodiments, the aspect ratio of the non-linear strands (ie, total length divided by diameter) ranges from about 5 to about 200, such as from about 10 to about 100, or from about 20 to about 50.

[0036] In some embodiments, the tensile strength of each strand ranges from about 0.1 N, 0.2 N, 0.3 N, or 0.4 N to about 3.0 N, 2.0 N, 1.5 N, or 1.0 N. In some embodiments, the tensile strength of each strand ranges from about 0.1 N to about 3.0 N, about 0.2 N to about 2.0 N, or about 0.3 N to about 1.0 N.

[0037] The tensile strength of the non-linear strands of the present invention can be determined by measuring the tensile force required to break the strand. A suitable test procedure is set forth in ISO 527-3:1995. As used herein, tensile strength is essentially the force required to break the strand and is expressed as force per strand in Newtons. The force required to break the strand can be determined using a suitable instrument, such as an Instron tensile tester, Model 68TM-5. Prior to measuring the tensile strength, the sample should be conditioned for at least 48 hours at 22°C ± 1°C and (60 ± 2)% relative humidity (RH). The atmospheric pressure should be within the range of 96 kPa ± 10 kPa.

[0038] In some embodiments, the unwound length, coiled length, aspect ratio, and / or tensile strength value for each strand can be calculated as an average of measurements taken on multiple strands, e.g., values ​​can be calculated as an average of measurements taken on about 5 to about 100 strands, e.g., about 20 to about 70 strands, e.g., 50 strands.

[0039] In some embodiments, the aerosol-forming material is at least about 2 cm 3 / g, 2.5cm 3 / g, 3cm 3 / g, 3.5cm 3 / g, 4cm 3 / g, 4.5cm 3 / g, or 5cm 3 In some embodiments, the fill value is about 6 cm / g. 3 / g, 6.5cm 3 / g, 7cm3 / g, 7.5cm 3 / g, 8cm 3 / g, 8.5cm 3 / g, 9cm 3 / g, 9.5cm 3 / g, or 10cm 3 In some embodiments, the aerosol-forming material has a viscosity of less than about 2 cm / g. 3 / g ~ approx. 7.5cm 3 / g, approx. 3cm 3 / g ~ approx. 7cm 3 / g, approx. 3.5cm 3 / g ~ approx. 6cm 3 / g, or approximately 4 cm 3 / g ~ approx. 6cm 3 In another embodiment, the aerosol-forming material has a loading value of about 3 cm / g. 3 / g ~ approx. 10cm 3 / g, approx. 4cm 3 / g ~ approx. 9.5cm 3 / g, approx. 4.5cm 3 / g ~ approx. 9cm 3 / g, or approximately 5 cm 3 / g ~ approx. 9cm 3 / g.

[0040] The packing value is measured by placing a known weight of material in a cylinder of known dimensions. The material is subjected to pressure from a weighted piston for 30 seconds. The residual height of the compressed sample is measured and converted to volume. The packing value is then calculated as the volume of the material relative to the mass.

[0041] More specifically, the packing value of the non-linear strands of the present invention can be determined by the following procedure: A 20 g sample of material is placed in a 60 mm diameter cylinder of a density meter, and then the material is compressed with a 2.90±0.03 kg piston for 30 seconds. The height of the piston of the density meter is measured. The packing value of the sample is calculated according to the following formula:

[0042] The volume that a material occupies when compressed is determined using Equation 1:

number

[0043] The fill value is then determined using the measured volume and mass of the material according to Equation 2:

number

[0044] Filling values ​​are also in cm 3 It is sometimes expressed in units of / 10g, and 1cm 3 / g is 10cm 3 / 10g.

[0045] The inventors have found that the aerosol-generating material of the present invention has a higher filling value than aerosol-generating material containing the same ingredients but formed as a flat sheet (e.g., by casting), a rolled sheet (e.g., by rolling up a flat sheet), or a shredded sheet (e.g., by shredding a flat sheet). Filling value (also referred to herein as fill value) is a measure of the volume that a given mass of material occupies when a given pressure is applied. In other words, filling value is a measure of a material's ability to occupy a particular volume.

[0046] By using materials with higher loading values ​​as aerosol-generating materials, it may be possible to provide articles and consumables with a lower overall weight than conventional articles. Reducing the overall weight can provide numerous benefits, such as reduced shipping costs and reduced material costs and / or taxes. Furthermore, reducing the weight of an article can also have a positive effect on the environment, as less energy may be required to transport the article. Furthermore, consumers may prefer to carry and use lightweight articles. The materials may also be used as non-tobacco-containing aerosol-generating substrates.

[0047] Because the packing efficiency of aerosol-generating material in the form of non-linear strands is lower than that of conventional aerosol-generating materials, which may be in the form of flat sheets, rolled sheets, or chopped sheets, the materials of the present invention have a higher filling value than conventional aerosol-generating materials. That is, when a container having a given volume is filled with the material of the present invention, the percentage of the container occupied by the material is lower than that of conventional aerosol-generating materials, which may be in the form of flat sheets, rolled sheets, or chopped sheets. In other words, a container containing the material of the present invention has a higher volume of void or empty space. Therefore, less aerosol-generating material is required to fill the container.

[0048] It is therefore advantageous that materials having similar chemical compositions to conventional aerosol-generating materials, but in the forms described herein, can be formulated such that they have higher loading values.

[0049] FIG. 11 shows images of aerosol-forming material in the form of strands of the present invention (left) compared to a similar material formed as a flat sheet and then chopped (right) of the same weight.

[0050] FIG. 12 shows a photograph of an aerosol-forming material of the present invention in the form of multiple non-linear strands.

[0051] The aerosol-generating material may contain from about 1%, 3%, 5%, 10%, 15%, or 20% by weight to about 80%, 60%, 50%, 40%, or 30% by weight of the aerosol-generating agent (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-generating material contains 1-80%, 5-60%, or 10-50% by weight of the aerosol-generating agent (all calculated on a dry weight basis). In other embodiments, the aerosol-generating material contains 10-45%, 20-40%, or 30-40% by weight of the aerosol-generating agent (all calculated on a dry weight basis). In other embodiments, the aerosol-generating material contains 10-45%, 10-40%, or 15-30% by weight of the aerosol-generating agent (all calculated on a dry weight basis). These amounts represent the total amount of aerosol-generating agent(s) in the aerosol-generating material.

[0052] In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some examples, the aerosol generating agent comprises, consists essentially of, or consists of glycerol.

[0053] The aerosol-forming material may include about 1%, 5%, 6%, 7%, 10%, or 15% by weight to about 20%, 25%, 30%, 40%, 50%, or 60% by weight of the crosslinked binder (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-60%, 5-50%, 6-40%, 7-20%, or 15-25% by weight of the binder (on a dry weight basis). These amounts represent the total amount of binder(s) in the aerosol-forming material.

[0054] The crosslinked binder may comprise or consist of a non-cellulosic binder. Examples of non-cellulosic binders that may be used include, but are not limited to, alginate, pectin, carrageenan (e.g., iota carrageenan), gellan gum (e.g., high acyl gellan gum), and combinations thereof.

[0055] In some embodiments, the binder comprises alginate and / or pectin.

[0056] In some embodiments, the binder comprises alginate and / or pectin and / or iota carrageenan.

[0057] In some embodiments, the binder comprises alginate and / or iota carrageenan.

[0058] In some embodiments, the binder comprises, consists essentially of, or consists of alginate and pectin.

[0059] In some embodiments, the binder comprises, consists essentially of, or consists of alginate and iota-carrageenan.

[0060] In some embodiments, the binder does not include an alginate.

[0061] In some embodiments, the binder comprises, consists essentially of, or consists of iota carrageenan.

[0062] The aerosol-forming material may be substantially free of cellulosic binders. By "substantially free," it is meant that the material contains less than 1% by weight, e.g., less than 0.5% by weight, of related components (on a dry weight basis). In some embodiments, the aerosol-forming material does not contain a cellulosic binder.

[0063] The aerosol-forming material may be substantially free of carboxymethylcellulose (CMC). In some embodiments, the aerosol-forming material is CMC-free.

[0064] In some embodiments, the binder comprises an alginate, and the alginate is present in the aerosol-forming material in an amount of 5-50%, 8-40%, 10-30%, or 15-25% by weight of the aerosol-forming material (calculated on a dry weight basis). In some embodiments, the alginate is the only binder present in the aerosol-forming material. In other embodiments, the binder comprises an alginate and at least one additional non-cellulosic binder, such as pectin.

[0065] In some embodiments, the aerosol-forming material comprises multiple binders. In some embodiments, the aerosol-forming material comprises a crosslinked binder and a non-crosslinked binder. When present, the non-crosslinked binder may be a cellulosic binder. Examples of cellulosic binders that may be used include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulosic binder is selected from hydroxyethyl cellulose, hydroxypropyl cellulose, and / or carboxymethyl cellulose. In some embodiments, the cellulosic binder comprises carboxymethyl cellulose (CMC). In some embodiments, the cellulosic binder is carboxymethyl cellulose (CMC).

[0066] In some embodiments, the aerosol-forming material is provided in the form of one or more non-linear strands. The aerosol-forming material includes an aerosol-generating agent and a binder selected from the group consisting of alginate, pectin, carrageenan (e.g., iota carrageenan), gellan gum (e.g., high acyl gellan gum), and combinations thereof. In this material, the total amount of binder may be the same as the amount described above for the crosslinked binder. For example, the aerosol-forming material of this embodiment may include 1 to 60 wt. %, 5 to 50 wt. %, 6 to 40 wt. %, 7 to 20 wt. %, or 15 to 25 wt. % of the binder (on a dry weight basis).

[0067] All aspects of the invention described herein are applicable to any aerosol-forming material of the invention.

[0068] In some embodiments, the aerosol-forming material includes a cross-linking agent. In some instances, the cross-linking agent includes calcium ions. In some embodiments, the cross-linking agent includes calcium lactate, calcium formate, and / or calcium acetate. In some embodiments, the cross-linking agent includes calcium lactate. In some instances, the aerosol-forming material includes calcium cross-linked alginate. The cross-linking agent may also be described as a solidifying agent.

[0069] The aerosol-forming material may include from about 0.5%, 1%, 3%, or 5% to about 10%, 9%, 8%, or 7% by weight of cross-linking agent (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-10%, 3-8%, or 5-7% by weight of cross-linking agent (on a dry weight basis). These amounts represent the total amount of cross-linking agent(s) in the aerosol-forming material.

[0070] The aerosol-forming material may comprise from about 1%, 10%, or 20% to about 80%, 60%, or 50% by weight of flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise 1-80%, 10-60%, or 20-50% by weight of flavoring. These amounts represent the total amount of flavoring(s) in the aerosol-forming material, if flavoring is present.

[0071] As used herein, the terms "flavoring" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, maize, etc.). Ngo, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sea Shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai citric acid, citric acid, citric acid, citric acid salts ...They may contain sugars, maltodextrins, cellulose, cellulose gums, cellulose acetates, cellulose syrups, cellulose gums, cellulose acetates, cellulose gum ...

[0072] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint, hi some embodiments, the flavoring comprises, consists essentially of, or consists of menthol.

[0073] In some embodiments, the flavoring agent is a water-soluble flavoring agent.

[0074] The flavoring may be incorporated during the formation of the aerosol-forming material (e.g., when forming a slurry with the materials that form the aerosol-forming material), or the flavoring may be applied to the aerosol-forming material after its formation (e.g., by spraying the flavoring onto the aerosol-forming material after it has dried).

[0075] In some embodiments, the aerosol-forming material comprises from about 1%, 5%, 10%, 18%, or 20% to about 80%, 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight of filler (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise 1-60%, 1-50%, 5-45%, 10-40%, 18-35%, or 20-30% by weight of filler (all calculated on a dry weight basis). In other embodiments, the aerosol-forming material may comprise 10-80%, 20-70%, 30-65%, or 40-65% by weight of filler (all calculated on a dry weight basis). These amounts represent the total amount of filler(s) in the aerosol-forming material.

[0076] In some embodiments, the aerosol-forming material contains less than 70% by weight of filler, e.g., less than 60%, less than 50%, less than 30%, less than 20%, or less than 10% by weight of filler, hi some embodiments, the aerosol-forming material is substantially free of filler or completely free of filler.

[0077] The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). The filler may also include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., ground cellulose). In certain examples, the aerosol-generating material contains less than 10% by weight, less than 5% by weight, less than 1% by weight, or no calcium carbonate, such as chalk. Because calcium carbonate has a high density, it may be desirable to avoid including large amounts of calcium carbonate in the material (e.g., more than 10% by weight, more than 25% by weight, or more than 50% by weight). Therefore, including large amounts of calcium carbonate may result in a high density and / or a low filler value and / or slow aerosol release.

[0078] In certain embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative, such as methylcellulose (MCC), nanocrystalline cellulose, and / or comminuted cellulose. Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol-forming material may increase the tensile strength of the material.

[0079] In some instances, the filler comprises wood pulp, MCC, and / or ground cellulose.

[0080] In some instances, the filler includes (or is) wood pulp.

[0081] In some instances, the filler comprises maltodextrin or microcrystalline cellulose (MCC).As those skilled in the art will appreciate, microcrystalline cellulose can be formed by depolymerizing cellulose through a chemical process (for example, using acid or enzymes).One example of a method for forming microcrystalline cellulose comprises the acid hydrolysis of cellulose, using an acid such as HCl.The cellulose produced after this process is crystalline (i.e., no amorphous regions remain).Suitable methods and conditions for forming microcrystalline cellulose are well known in the art.

[0082] In some examples, the filler is about 2 g / cm 3 Less than, for example, about 0.5 g / cm 3 Less than or about 0.3 g / cm 3 has a density of less than

[0083] The aerosol-forming material may have any suitable water content, for example, from 1% to 15% by weight. Preferably, the water content of the aerosol-forming material may be from about 5%, 7%, or 9% to about 15%, 13%, 11%, 9%, or 8% by weight (wet weight basis) (WWB). In some embodiments, the aerosol-forming material has a water content of less than about 9% by weight (WWB), for example, less than about 8% by weight (WWB). The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0084] The components of the aerosol-forming material, such as the amount of aerosol-forming agent (eg, glycerol) and flavoring (eg, menthol), can be determined by gas chromatography using a flame ionization detector (GC-FID).

[0085] The aerosol-forming material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-forming material. The presence of a colorant in the aerosol-forming material can improve the visual appearance of the aerosol-forming material and the aerosol-forming composition. By adding a colorant to the aerosol-forming material, the aerosol-forming material can be color-matched to other components of the aerosol-forming composition or other components of the article containing the aerosol-forming material.

[0086] Various colorants may be used depending on the desired color of the aerosol-forming material. The color of the aerosol-forming material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants, may be used. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-forming material. In such embodiments, the color of the aerosol-forming material may be similar to the color of other components (e.g., tobacco material) in the aerosol-forming composition that includes the aerosol-forming material. In some embodiments, the addition of a colorant to the aerosol-forming material renders the aerosol-forming material visually indistinguishable from other components in the aerosol-forming composition.

[0087] The colorant may be incorporated into the aerosol-forming material during its formation (e.g., when forming a slurry with the materials that form the aerosol-forming material), or the colorant may be applied to the aerosol-forming material after its formation (e.g., by spraying the colorant onto the aerosol-forming material).

[0088] In some embodiments, colorants may not be necessary since (brown) wood pulp is present as a filler.

[0089] In some embodiments, the aerosol-forming composition further comprises an active agent, i.e., the aerosol-forming composition comprises an aerosol-forming material and an active agent. For example, in some examples, the aerosol-forming composition further comprises tobacco material and / or nicotine. In some examples, the aerosol-forming composition may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some examples, the aerosol-forming composition may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active agent. In some examples, the aerosol-forming composition may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming composition may comprise from 10 to 50%, 15 to 40%, or 20 to 35% by weight of tobacco material. In some examples, the aerosol-forming composition may comprise from about 1%, 2%, 3%, or 4% by weight to about 20%, 18%, 15%, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the aerosol-forming composition may comprise from 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0090] In some examples, the aerosol-forming material may include a botanical extract. The aerosol-forming material may include from about 1%, 3%, 5%, 10%, 15%, 20%, 30%, 35%, or 40% to about 30%, 35%, 40%, 50%, 60%, 65%, or 70% by weight of the botanical extract (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material includes 1-70%, 5-60%, or 10-50% by weight of the botanical extract (all calculated on a dry weight basis). In other embodiments, the aerosol-forming material may include 10-40%, 10-35%, or 15-30% by weight of the botanical extract (all calculated on a dry weight basis). In other embodiments, the aerosol-forming material may contain 10-70%, 20-65%, or 40-60% by weight of the botanical extract (all calculated on a dry weight basis), where these amounts represent the total amount of the botanical extract(s) in the aerosol-forming material.

[0091] The botanical extract may include or consist of a botanical extract that naturally contains metal (e.g., calcium or magnesium) ions (i.e., the ions are present without being added). In some embodiments, the botanical extract naturally contains calcium ions. The botanical extract may also be described as a plant extract.

[0092] As used herein, the term "botanical extract" includes, but is not limited to, extracts of any material derived from a plant, including leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the botanical extract may contain active compounds naturally occurring in the plant material or synthetically obtained. Examples of botanical materials include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: common mint (Mentha arventis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cardifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0093] In some embodiments, the botanical extract comprises tobacco extract. In some embodiments, the botanical extract consists essentially of or consists of tobacco extract. That is, in some embodiments, the botanical extract is tobacco extract.

[0094] In some embodiments, the aerosol-forming material comprises particulate plant material. The aerosol-forming material may comprise from about 1%, 3%, 5%, 10%, 15%, 20%, 30%, 35%, or 40% to about 30%, 35%, 40%, 50%, 60%, 65%, or 70% by weight of the particulate plant material (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 1-70%, 5-60%, 10-50%, or 30-40% by weight of the particulate plant material (all calculated on a dry weight basis).

[0095] In some embodiments, the particulate botanical matter includes or is particulate tobacco material. In some embodiments, the aerosol-forming material includes an additional active material other than a botanical extract. In some embodiments, the active material includes nicotine. In some embodiments, the active material includes caffeine, melatonin, or vitamin B12.

[0096] In some embodiments, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0097] Cannabinoids are a class of natural or synthetic compounds that act on intracellular cannabinoid receptors (i.e., CB1 and CB2) that inhibit neurotransmitter release in the brain. Cannabinoids may be found naturally in plants such as cannabis (phytocannabinoids), from animals (endocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis species exhibit at least 85 different phytocannabinoids, which are divided into subcategories. These subcategories include cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol, and cannabinodiol, as well as other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0098] In some embodiments, the active agent may include a cannabinoid, such as cannabidiol (CBD).

[0099] In some examples, the aerosol-forming composition includes an active agent such as tobacco extract. In some examples, the aerosol-forming composition may include 5 to 60% by weight (calculated on a dry weight basis) of tobacco extract. In some examples, the aerosol-forming composition may include about 5%, 10%, 15%, 20%, or 25% by weight to about 60%, 50%, 45%, 40%, 35%, or 30% by weight of tobacco extract (calculated on a dry weight basis). For example, the aerosol-forming composition may include 10 to 50%, 15 to 40%, or 20 to 35% by weight of tobacco extract. The tobacco extract may include nicotine at a concentration such that the aerosol-forming composition includes 1%, 1.5%, 2%, or 2.5% by weight to about 10%, 8%, 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some embodiments, the aerosol-forming composition may comprise 1-10% by weight, 2.5-8% by weight, or 2-6% by weight of nicotine. In some instances, no nicotine other than that originating from the tobacco extract may be present in the aerosol-forming composition.

[0100] In some embodiments, an aerosol-forming composition comprises an aerosol-forming material as defined herein and a second aerosol-forming material, which may be tobacco. Thus, in some embodiments, an aerosol-forming composition comprises an aerosol-forming material as defined herein and tobacco.

[0101] In some embodiments, the aerosol-forming material may be shredded and then mixed with tobacco, such as cut rag tobacco. In another embodiment, the aerosol-forming composition may be in the form of a shredded composition, in which the aerosol-forming material and tobacco are both shredded and mixed together. In some embodiments, the aerosol-forming composition may comprise from about 5%, 10%, 15%, or 20% to about 35%, 40%, 45%, or 50% by weight of the aerosol-forming material. For example, the aerosol-forming composition may comprise from about 10% to about 50%, e.g., from about 20% to about 40% by weight of the aerosol-forming material of the present invention. The remainder of the aerosol-forming composition may comprise tobacco, optionally in combination with flavorings and / or acids.

[0102] The aerosol-forming composition may comprise from about 10 to about 50 weight percent aerosol-forming material and from about 50 to about 90 weight percent tobacco, or from about 20 to about 40 weight percent aerosol-forming material and from about 60 to about 80 weight percent tobacco.

[0103] In some embodiments, the tobacco comprises (or is) dry ice expanded tobacco (DIET). In some embodiments, the aerosol-forming composition comprises a mixture of the aerosol-forming material of the present invention and a DIET, optionally in combination with other tobaccos (e.g., cut rag tobacco).

[0104] DIET has a very high filling value (generally 7cm 3 DIETs are known to have a high loading value (greater than 1000 kJ / g) and are sometimes used to reduce the weight of articles or consumables used in aerosol delivery systems. However, DIETs are also known to have poor flavor profiles. Thus, the presently claimed aerosol-generating materials may have a high loading value but an improved taste profile, providing an improved alternative to DIETs. It may also be possible to combine DIETs with the aerosol-generating materials of the present invention, thereby reducing the amount of DIET required to achieve a desired loading value.

[0105] In some embodiments, the aerosol-forming composition does not contain tobacco material but does contain nicotine. In some such examples, the aerosol-forming composition may contain from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the aerosol-forming composition may contain from 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0106] The fill value of an aerosol-forming composition can be determined by the fill value of the aerosol-forming material, the fill value of any other materials in the composition (e.g., tobacco), and the relative proportions of the materials in the composition. Thus, the fill value of a composition can be estimated. For example, 3 20% by weight of the aerosol-forming material of the present invention having a loading value of 1 / g, and 5 cm 3 A composition containing 80% by weight tobacco with a loading value of approximately 5.4 cm 3 / g ([7*0.2]+[5*0.8]=5.4).

[0107] In some embodiments, the aerosol-forming composition is at least about 2 cm 3 / g, 2.5cm 3 / g, 3cm 3 / g, 3.5cm 3 / g, 4cm 3 / g, 4.5cm 3 / g, or 5cm 3 In some embodiments, the fill value is about 6 cm / g. 3 / g, 6.5cm 3 / g, 7cm 3 / g, 7.5cm 3 / g, 8cm 3 / g, 8.5cm 3 / g, 9cm 3 / g, 9.5cm 3 / g, or 10cm 3 In some embodiments, the aerosol-forming composition has a volume of less than about 2 cm 3 / g ~ approx. 7.5cm 3 / g, approx. 3cm 3 / g ~ approx. 7cm 3 / g, approx. 3.5cm 3 / g ~ approx. 6cm 3 / g, approx. 4cm 3 / g ~ approx. 6cm 3 / g, or approximately 5 cm 3 / g ~ approx. 6cm 3 / g. In other embodiments, the aerosol-forming composition has a loading value of about 3 cm 3 / g ~ approx. 10cm 3 / g, approx. 4cm 3 / g ~ approx. 9.5cm 3 / g, approx. 4.5cm 3 / g ~ approx. 9cm 3 / g, or approximately 5 cm 3 / g ~ approx. 9cm 3 / g.

[0108] The aerosol-forming material and / or aerosol-forming composition may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0109] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0110] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid and / or pyruvic acid.

[0111] In some embodiments, the acid is selected from lactic acid, benzoic acid, and levulinic acid.

[0112] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming composition includes nicotine. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during production. The presence of an acid can also improve the flavor and effectiveness of the aerosol when nicotine is present. For example, the perceived harshness of nicotine can be reduced by the presence of an acid.

[0113] In some embodiments, the aerosol-forming material is substantially free of tobacco. By "substantially free," it is meant that the material contains less than 1% by weight, e.g., less than 0.5% by weight, of tobacco (on a dry weight basis). In some embodiments, the aerosol-forming material does not contain tobacco. In some embodiments, the aerosol-forming material does not contain tobacco fiber. In certain embodiments, the aerosol-forming material does not contain fibrous material. In this regard, any tobacco present in the slurry used to form the aerosol-forming material may cause premature crosslinking of the binder, making the formation of the non-linear strands of the present invention more difficult. Thus, in some embodiments, the aerosol-forming material is substantially free of tobacco or does not contain tobacco.

[0114] In some embodiments, the aerosol-forming composition does not include tobacco fiber. In certain embodiments, the aerosol-forming composition does not include fibrous material.

[0115] In some embodiments, the aerosol product does not include tobacco fiber. In certain embodiments, the aerosol product does not include fibrous materials.

[0116] The aerosol-forming material may be made from a gel, which may further contain a solvent in an amount of 0.1 to 50% by weight. However, the inclusion of a solvent in which the fragrance can dissolve may reduce gel stability, and the fragrance may leave the gel and crystallize. Therefore, in some examples, the gel does not contain a solvent in which the fragrance can dissolve.

[0117] Aspects of the present invention relate to articles (also referred to herein as consumables). Consumables are articles intended to be consumed in part or in whole during use by a user. Consumables may include or consist of an aerosol-forming composition. Consumables may also include one or more other components, such as a filter or an aerosol-modifying substance. Consumables may include a heating element that generates heat during use to cause aerosol generation from the aerosol-forming composition. The heating element may, for example, include a combustible material or may include a susceptor that can be heated by passing it through a varying magnetic field.

[0118] The articles of the present invention may be provided in any suitable shape. In some instances, the articles are provided as rods (e.g., substantially cylindrical). Articles provided as rods may include an aerosol-forming composition optionally blended with cut tobacco.

[0119] The susceptor is a material that can be heated by passing it through a varying magnetic field, such as an alternating magnetic field. The heating material can be an electrically conductive material, in which case passing it through a varying magnetic field causes induction heating of the heating material. The heating material can be a magnetic material, in which case passing it through a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material can be both electrically conductive and magnetic, in which case the heating material can be heated by both heating mechanisms.

[0120] Induction heating is a process in which an electrically conductive object is heated by passing the object through a varying magnetic field. This process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to each other so that the resulting varying magnetic field generated by the electromagnet passes through the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated in the object, their flow against the object's electrical resistance causes the object to heat. This process is called Joule, Ohmic, or resistive heating.

[0121] In some embodiments, the susceptor is in the form of a closed circuit. When the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is strengthened, resulting in stronger or improved Joule heating.

[0122] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by passing the object through a varying magnetic field. Magnetic materials can be thought of as comprising many atomic-scale magnets, or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align along the field. Thus, when a varying magnetic field, such as an alternating magnetic field generated by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes with the variation in the applied field. This reorientation of the magnetic dipoles causes the generation of heat in the magnetic material.

[0123] When an object is both electrically conductive and magnetic, passing the object through a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can intensify Joule heating.

[0124] In each of the above processes, when heat is generated within the object itself rather than by an external heat source via thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting the appropriate object material and geometry, and the appropriate varying magnetic field strength and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require physical contact between the source of the varying magnetic field and the object, which can allow for greater design freedom and control over the heating profile and reduce costs.

[0125] Aspects of the present invention provide a non-combustion aerosol delivery system comprising an article according to those described herein and a non-combustion aerosol delivery device comprising a heater configured to heat but not combust the aerosol product article. The non-combustion aerosol delivery system may also be referred to as an aerosol generation assembly. The non-combustion aerosol delivery device may also be referred to as an aerosol generation apparatus.

[0126] In some examples, during use, the heater may heat the aerosol-forming material to temperatures up to 350°C, for example, between 120°C and 350°C, without burning the aerosol-forming material. In some examples, the heater may heat the aerosol-forming composition to temperatures between 140°C and 250°C, or between 220°C and 280°C, without burning the aerosol-forming composition. In some examples, during use, substantially the entire aerosol-forming material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some examples, the material is positioned between about 0.010 mm and 2.0 mm, preferably between about 0.02 mm and 1.0 mm, and preferably between 0.1 mm and 0.5 mm, from the heater. In some examples, the surface of the aerosol-forming material may be in direct contact with the heater.

[0127] The heater is configured to heat but not burn the aerosol product, and thus the aerosol-forming composition. In some examples, the heater may be a thin-film electrical resistance heater. In other examples, the heater may comprise an induction heater or other heater. The heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use. The aerosol-generating assembly may include multiple heaters. These heaters may be powered by a battery.

[0128] The aerosol product may further comprise a cooling element and / or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components so that they condense to form the aerosol. The cooling element may also act to keep hot portions of the non-combustion aerosol delivery device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

[0129] In some examples, the aerosol generating assembly may be a heat-not-burn device. That is, the aerosol generating assembly may include a solid aerosol-generating material (but not a liquid aerosol-generating material). In some examples, the aerosol-generating material may include a tobacco material. A heat-not-burn device is disclosed in WO 2015 / 062983 A2, the entirety of which is incorporated herein by reference.

[0130] In some examples, the aerosol generation assembly may be an e-cigarette hybrid device, such as that disclosed in WO 2016 / 135331 A1, the entirety of which is incorporated herein by reference.

[0131] The aerosol product article (sometimes referred to herein as an article, cartridge, or consumable) may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol-generating device. In some examples, the article may further comprise a filter and / or a cooling element (as described above). In some examples, the aerosol product article may be surrounded by a packaging material, such as paper.

[0132] The aerosol product may further include vent holes. These may be located in the sidewalls of the product. In some instances, the vent holes may be located in the filter and / or cooling element. These holes allow cool air to be drawn into the product during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0133] Ventilation promotes the production of visible heated volatiles from the article when the article is heated during use. The heated volatiles are made visible by cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation), and ultimately, the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and coalescence of newly formed droplets from the heated volatiles.

[0134] In some instances, the ratio of cool air to the sum of heated volatiles and cool air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0135] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0136] 1 and 2, there is shown a partially cutaway cross-sectional view and a perspective view of an example aerosol production article 101. Article 101 is adapted for use with a device having a power source and a heater. This embodiment of article 101 is particularly suited for use with device 1 shown in FIGS. 5-7, described below. In use, article 101 can be removably inserted into device 1 at insertion point 20 shown in FIG. 5.

[0137] The example article 101 is in the form of a generally cylindrical rod that includes an aerosol-forming composition body 103 and a rod-shaped filter assembly 105. The aerosol-forming composition includes an aerosol-forming material as described herein.

[0138] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The aerosol-generating composition body 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the aerosol-generating composition body 103, between the aerosol-generating composition body 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating composition body 103 and the filter segment 109. In another example, there may be separations between the aerosol-generating composition body 103 and the cooling segment 107 and between the aerosol-generating composition body 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed at proximal end 113 of article 101 and is adjacent to filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In some embodiments, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0139] In one example, the rod of aerosol-forming composition 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably 42 mm.

[0140] In one example, the overall length of the article 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

[0141] One axial end of aerosol-generating composition body 103 is visible at distal end 115 of article 101. However, in other embodiments, distal end 115 of article 101 may include an end member (not shown) that covers one axial end of aerosol-generating composition body 103.

[0142] The aerosol-generating composition body 103 is joined to the filter assembly 105 by an annular tipping paper (not shown), which is disposed substantially around the filter assembly 105 to surround it and extends partially along the length of the aerosol-generating composition body 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0143] In one example, cooling segment 107 is an annular tube that surrounds and defines a cavity within the cooling segment. This cavity provides a chamber through which heated volatile components generated from aerosol-generating composition body 103 flow. Cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into device 1. In one example, the wall thickness of cooling segment 107 is approximately 0.29 mm.

[0144] The cooling segment 107 provides a physical displacement between the aerosol-forming composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile components entering the first end of the cooling segment 107 and the heated volatile components exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperatures of the aerosol-forming composition 103 when the aerosol-forming composition 103 is heated by the device 1. If no physical displacement is provided between the filter segment 109 and the aerosol-generating composition body 103 and the heating element of the device 1, the temperature-sensitive filter segment 109 may become damaged during use and may no longer be able to effectively perform its required function.

[0145] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, even more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0146] The cooling segment 107 is made from paper, meaning that the cooling segment 107 is constructed from a material that, in use, does not produce compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0147] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 101 during insertion into device 1.

[0148] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0149] In some embodiments, a capsule (not shown) may be provided within filter segment 109. The capsule may be located substantially in the center of filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, if a capsule is present, the capsule may contain a volatile component, such as a flavoring or an aerosol-forming agent.

[0150] The density of the cellulose acetate tow material of filter segment 109 controls the pressure drop across filter segment 109, which in turn controls the resistance to draw of article 101. Therefore, the selection of material for filter segment 109 is important in controlling the resistance to draw of article 101. Additionally, the filter segment performs a filtration function in article 101.

[0151] In one example, filter segment 109 is made from 8Y15 grade filter tow material, which provides filtration for the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0152] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips against the surface of filter segment 109.

[0153] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0154] The mouth end segment 111 is an annular tube that surrounds and defines a cavity within the mouth end segment 111. This cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacturing and insertion into the device 1. In one example, the wall thickness of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0155] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0156] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0157] It should be understood that in one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 positioned within the tube to separate the mouth end segment 111 and the cooling segment 107.

[0158] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0159] 3 and 4, a ventilation region 317 is provided in the article 301 to allow air to flow from the exterior of the article 301 to the interior of the article 301. In one example, the ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of the article 301. The vent holes may be located in the cooling segment 307 to aid in cooling the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of the article 301 in a cross section substantially perpendicular to the longitudinal axis of the article 301.

[0160] In one example, there are 1 to 4 rows of vent holes to provide ventilation to article 301. Each row of vent holes may have 12 to 36 vent holes 317. The diameter of vent holes 317 may be, for example, 100 to 500 μm. In one example, the axial spacing between rows of vent holes 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0161] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

[0162] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The vent holes 317 are located such that the user will not block the vent holes 317 when the article 301 is in use.

[0163] By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be positioned on the exterior of the device 1 when the article 301 is fully inserted into the device 1, as seen in Figures 6 and 7. By positioning the vent holes on the exterior of the device, unheated air can enter the article 301 from outside the device 1 through the vent holes to help cool the article 301.

[0164] The length of cooling segment 307 is such that when item 301 is fully inserted into device 1, cooling segment 307 is partially inserted into device 1. This length of cooling segment 307 serves two functions: first, to provide a physical gap between the heating apparatus and heat-sensitive filter apparatus 309 of device 1; and second, to allow vent hole 317 to be positioned within the cooling segment while also being positioned outside device 1 when item 301 is fully inserted into device 1. As can be seen in FIGS. 6 and 7 , the majority of cooling element 307 is positioned within device 1. However, there is a portion of cooling element 307 that extends outside device 1. This portion of cooling element 307 that extends outside device 1 is where vent hole 317 is located.

[0165] 5-7, an example of a device 1 configured to heat an aerosol-forming composition to volatilize at least one component of the aerosol-forming composition, typically to form an inhalable aerosol, is shown. Device 1 is a heating device that releases compounds by heating, but not burning, the aerosol-forming composition.

[0166] The first end 3 may be referred to herein as the oral or proximal end 3 of the device 1, and the second end 5 may be referred to herein as the distal end 5 of the device 1. The device 1 has an on / off button 7, allowing the entire device 1 to be activated / deactivated as desired by the user.

[0167] The device 1 includes a housing 9 for arranging and protecting various internal components of the device 1. In the illustrated example, the housing 9 includes a unitary sleeve 11 that surrounds the outer edge of the device 1, and the sleeve 11 is capped by a top panel 17 that generally forms the "top" of the device 1 and a bottom panel 19 that generally forms the "bottom" of the device 1. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

[0168] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 1, or may be "permanently" secured to unitary sleeve 11, for example, to prevent a user from accessing the interior of device 1. In one example, panels 17 and 19 are made of a plastic material (including, for example, glass-filled nylon formed by injection molding) and unitary sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0169] The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1, through which a user can insert and remove an item 101, 301 containing an aerosol-generating composition into and from the device 1 during use.

[0170] Housing 9 has disposed therein or secured thereto heating device 23, control circuit 25, and power supply 27. In this example, heating device 23, control circuit 25, and power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuit 25 generally located between heating device 23 and power supply 27, although other arrangements are possible.

[0171] Control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol-forming composition within article 101, 301, as discussed further below.

[0172] Power source 27 may be, for example, a battery, which may be rechargeable or non-rechargeable. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and, under the control of control circuitry 25, provides power when needed to heat the aerosol-forming composition within the article (to volatilize the aerosol-forming material without burning the aerosol-forming composition, as described above).

[0173] An advantage of placing power supply 27 laterally adjacent to heating apparatus 23 is that a physically larger power supply 25 can be used without excessively lengthening the overall device 1. Of course, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore can enable longer battery life for device 1.

[0174] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the article 101, 301 containing the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular around its circumference. In one example, the or each heating element may be a thin-film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramic and aluminum nitride ceramic, as well as silicon nitride ceramic, which may be layered and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), and resistive heating elements formed by resistive electrical windings, etc.

[0175] In one particular example, heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. Heating device 23 is dimensioned such that when article 101, 301 is inserted into device 1, substantially the entire body of article 101, 301, consisting of aerosol-forming composition 103, 303, is inserted into heating device 23.

[0176] The or each heating element may be arranged to heat selected zones (areas) of aerosol-forming material independently, for example sequentially (over time as described above) or together (simultaneously), as desired.

[0177] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps reduce heat passing from the heating device 23 to the exterior of the device 1. This generally reduces heat loss, and therefore helps keep the power requirements of the heating device 23 low. The insulation 31 also helps keep the exterior of the device 1 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low-pressure region between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (e.g., including a suitable foam-type material) in addition to or in place of the double-walled sleeve.

[0178] The housing 9 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23 .

[0179] The device 1 further includes a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 9, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f spaced along the exterior surface of the chamber 35, each fin circumferentially disposed about the exterior surface of the chamber 35. When the item 101, 301 is inserted into the device 1 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the item 101, 301. The gap 36 surrounds the entire periphery of the item 101, 301 over at least a portion of the cooling segment 307.

[0180] The collar 33 includes a plurality of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage with and help secure items 101, 301 inserted within the device 1. Open spaces (not shown) defined by adjacent pairs of the ridges 60 and the items 101, 301 form ventilation paths around the outer surfaces of the items 101, 301. These ventilation paths allow hot steam escaping from the items 101, 301 to exit the device 1 and allow cooling air to flow into the device 1 around the items 101, 301 within the gap 36.

[0181] In operation, article 101, 301 is removably inserted into insertion site 20 of device 1, as shown in Figures 5-7. Referring particularly to Figure 6, in one example, aerosol-generating composition body 103, 303 (which is located at distal end 115, 315 of article 101, 301) is completely contained within heating element 23 of device 1. Proximal end 113, 313 of article 101, 301 extends from device 1 and serves as a mouthpiece assembly for the user.

[0182] During operation, the heating device 23 heats the article 101, 301 to volatilize at least one component of the aerosol-forming composition from the aerosol-forming composition body 103, 303.

[0183] The primary flow path for heated volatile components from the aerosol-generating composition body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating composition body is between 60°C and 250°C, which may exceed acceptable inhalation temperatures for a user. The heated volatile components cool as they travel through the cooling segment 107, 307, and some of the volatile components condense on the interior surface of the cooling segment 107, 307.

[0184] In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0185] Another aspect of the invention provides a method of making an aerosol-forming material in the form of a non-linear strand, such as an aerosol-forming material described herein.

[0186] This method is (a) forming a mixture comprising a solvent, an aerosol-forming agent, a crosslinkable binder, optionally a filler, and optionally an active material and / or a flavoring agent and / or an acid; (b) injecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; may include:

[0187] This method is (a) forming a mixture comprising a solvent, an aerosol-forming agent, a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof, optionally a filler, and optionally an active material and / or a flavoring and / or an acid; (b) injecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; may include:

[0188] Step (a) involves forming a mixture or slurry containing the components of the aerosol-generating material or precursors thereof and a solvent (typically water). Thus, the slurry or mixture formed in step (a) may include a crosslinkable binder (i.e., a precursor to the crosslinked binder present in the material of the present invention), an aerosol-generating agent, and optionally a filler, an active material, and / or a fragrance and / or an acid. The mixture or slurry may contain these components, on a dry weight basis, in any of the proportions indicated herein for the composition of the aerosol-generating material.

[0189] Step (b) involves injecting the mixture through a nozzle. The shape of the nozzle can determine the cross-section of the material formed by the methods of the present invention. In some embodiments, the nozzle has a circular shape. In this example, the cross-section of the final material is circular or substantially circular. As used herein, the term "nozzle" can be used interchangeably with the terms "orifice" or "aperture."

[0190] In some embodiments, the nozzle has a diameter of about 0.05 mm, 0.2 mm, 0.5 mm, 1.5 mm, or 1.5 mm to about 4 mm, 3.0 mm, 2.5 mm, or 1.5 mm. In some embodiments, the nozzle has a diameter of about 0.05 to about 4 mm, about 0.5 to about 4 mm, about 1.0 to about 3.0 mm, or about 1.5 to about 2.5 mm.

[0191] In some embodiments, the nozzle has a diameter of about 0.05 mm, 0.1 mm, 0.2 mm, or 0.3 mm to about 3.0 mm, 2.0 mm, 1.0 mm, or 0.7 mm. In some embodiments, the nozzle has a diameter of about 0.05 to about 3.0 mm, about 0.1 to about 2.0 mm, about 0.2 to about 2.0 mm, or about 0.3 to about 0.7 mm.

[0192] As used herein, the term "injecting" is also intended to encompass the terms "extruding" and "discharging." Thus, in some embodiments, step (b) comprises discharging the mixture through a nozzle. In some embodiments, step (b) comprises extruding the mixture through a nozzle.

[0193] After the mixture is ejected from the nozzle, the mixture has velocity. This velocity may be imparted by gravity, i.e., because the mixture may fall as it is ejected from the nozzle into a medium (e.g., air). Alternatively and / or additionally, velocity may be imparted by the injection process, i.e., because kinetic energy is imparted to the mixture as it is forced through the nozzle. The mixture is generally ejected in the form of a continuous stream or flow of material.

[0194] In some embodiments, the mixture is ejected from a nozzle into a gaseous medium, such as air.

[0195] The mixture can be contacted with the cross-linking agent by injecting the mixture into a medium such as air directly above a solution containing the cross-linking agent, with gravity (optionally together with an applied force to eject the mixture from a nozzle) acting to bring the mixture into contact with the solution.

[0196] Alternatively, the mixture may be contacted with a solution containing a crosslinker by forcefully ejecting the mixture. In this case, the nozzle can be positioned directly above the solution, but also and / or alternatively, it may be positioned to the side of the solution or even below the solution. The angle between the direction of the nozzle (i.e., the direction in which the mixture is initially ejected) and the surface of the solution can be varied. When the nozzle is positioned directly above the solution, this angle is 90°. When the nozzle is immediately to the side of the solution (i.e., parallel to the solution), this angle is 0°. In one embodiment, this angle is 90°. In another embodiment, this angle is less than about 90° and greater than about 0°. In some embodiments, this angle is from about 10° to about 85°, from about 20° to about 80°, or from about 30° to about 75°.

[0197] Thus, in one embodiment, the nozzle is positioned directly above the surface of the solution containing the cross-linking agent, although this may not be necessary if the mixture is extruded from the nozzle in such a way that it does not move directly downward after injection.

[0198] In some embodiments, the nozzle is positioned at a distance of about 0.5 to about 100 cm, e.g., about 1 to about 50 cm, or about 2 to about 20 cm, above the surface of the solution containing the cross-linking agent. Increasing the distance between the nozzle and the surface of the solution can decrease the diameter of the resulting non-linear strands. Thus, by positioning the nozzle at a distance from the surface of the solution that exceeds the ranges disclosed herein, the diameter of the non-linear strands can be significantly reduced compared to the diameter of the nozzle.

[0199] In some embodiments, the volume of solution and the container used to hold the solution containing the crosslinker are selected so that the depth of the solution at the point of impingement is at least about 1 cm, 2 cm, 3 cm, or 5 cm, and can be less than about 50 cm, 30 cm, 20 cm, or 10 cm. In some embodiments, the depth of the solution at the point of impingement is about 1 to about 50 cm, about 2 to about 30 cm, or about 3 to about 10 cm.

[0200] The nozzle may be stationary or may move as the mixture is ejected. For example, the nozzle may move across the surface of the solution containing the cross-linking agent as the mixture is ejected. Alternatively, the nozzle may be stationary, and the solution containing the cross-linking agent may move as the mixture is ejected. Having at least one of the nozzle and / or solution moving during the process can be useful if the entire process is continuous, and this can help prevent individual strands from overlapping.

[0201] In some embodiments, the nozzle may eject the mixture in a series of pulses. For example, step (c) may include pausing ejection of the mixture from the nozzle for a selected time interval. This method may avoid or reduce the need to cut the strand. The length of the strand may be determined by the length of the time interval. Generally, the longer the time interval, the longer the strand.

[0202] Step (c) involves contacting the injection mixture with a solution containing a cross-linking agent, the velocity of the mixture decreasing upon contact with the solution.

[0203] When the material comes into contact with the crosslinking agent, the crosslinkable binder crosslinks, thereby forming a crosslinked binder. Without wishing to be bound by theory, it is believed that when the extruded mixture comes into contact with the solution containing the crosslinking agent, the binder immediately crosslinks. This, combined with the reduced velocity resulting from collision of the mixture with the solution, is believed to result in the formation of the nonlinear strands or gel fibers of the present invention. Thus, the result of step (c) is an aerosol-generating material in the form of nonlinear strands or gel fibers, i.e., an aerosol-generating material as defined herein.

[0204] In some embodiments, a solution containing a cross-linking agent is provided in a container into which the injected mixture falls and / or is extruded. In some embodiments, the solution is sprayed or otherwise applied onto the mixture, and after the solution is injected and the solution is moving at a velocity, contact between the injected mixture and the cross-linking solution results in a desired decrease in the velocity of the injected mixture.

[0205] The crosslinking agent is used in the present method in the form of a solution containing the crosslinking agent. In some embodiments, the solution is an aqueous solution containing water and the crosslinking agent. Generally, the crosslinking agent is present in the solution in excess so that some crosslinking agent remains after the binder is crosslinked. In some embodiments, the concentration of the crosslinking agent in the solution may range from about 0.01 M to about 2.0 M, from about 0.3 M to about 1.5 M, or from about 0.5 M to about 1.0 M.

[0206] Suitable cross-linking agents and amounts thereof are set forth above. For example, the slurry may include sodium alginate, potassium alginate, or ammonium alginate as a binder precursor, and may use a solidifying or cross-linking agent that includes a calcium source (e.g., calcium formate, calcium acetate, or calcium lactate) to form a calcium alginate gel or binder.

[0207] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form gels. Alginates with a high G monomer content more readily form gels upon addition of a calcium source. Thus, in some instances, the gel precursor may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0208] In some embodiments, the solution of step (c) further comprises one or more of a flavoring agent, an active material, an aerosol-forming agent (e.g., glycerol), and a botanical extract. In some embodiments, the flavoring agent is water-soluble.

[0209] When present, each of these components can enter (eg, diffuse into) the non-linear strand or gel fibers of the present invention.

[0210] Thus, the result of step (c) may be an aerosol-forming material comprising one or more of a flavoring agent, an active material, an aerosol-forming agent (eg, glycerol), and a botanical extract.

[0211] The amount of additional ingredients (e.g., botanical extracts) in the resulting non-linear strands can vary depending on the length of time the material is in contact with the solution. Generally, the longer the contact time between the material and the solution, the greater the amount of flavor, active material, aerosol-forming agent (e.g., glycerol), and / or botanical extract in the resulting non-linear strands. Thus, the amount of flavor, active material, aerosol-forming agent (e.g., glycerol), and / or botanical extract in the non-linear strands can be controlled by the contact time between the material and the solution. In some embodiments, the contact time between the material and the solution may be less than about 120 seconds. In some embodiments, the contact time between the material and the solution may range from about 5 seconds to about 120 seconds, from about 10 seconds to about 60 seconds, or from about 10 seconds to about 30 seconds.

[0212] In some embodiments, the solution further comprises a botanical extract in addition to the cross-linking agent. Suitable botanical extracts are listed above. The botanical extract may contain metal (e.g., calcium) ions, which may cause cross-linking of the cross-linkable binder. Therefore, less cross-linking agent may be required. In some embodiments, the concentration of the botanical extract in the solution may range from about 20% to about 90% by weight, from about 25% to about 75% by weight, or from about 30% to about 50% by weight.

[0213] Adding a botanical extract to the mixture in step (a) can result in premature crosslinking of the crosslinkable binder due to the metal (e.g., calcium) ion content of the botanical extract. This can result in undesirable crosslinking of the mixture or slurry during step (a) before it is ejected through a nozzle and contacts the solution in steps (b) and (c). This can prevent the slurry from being ejected through a nozzle, thus preventing the formation of non-linear strands.

[0214] Therefore, when forming a material containing a plant extract, it may be beneficial to form a slurry without the plant extract in step (a) and then inject the slurry into a solution containing the plant extract. This method can also reduce the amount of cross-linkable binder required in the solution.

[0215] In some embodiments, the solution of step (c) further comprises another component of the aerosol-forming material, which may then diffuse into the aerosol-forming material in the same manner as the botanical extract. For example, the solution may further comprise a flavoring, such as a water-soluble flavoring, and / or an active substance in addition to the botanical extract and / or the aerosol-forming agent (e.g., glycerol).

[0216] Alternatively, it may be desirable to include a component of the aerosol-generating material (e.g., an aerosol-generating agent) in solution to prevent diffusion or loss of the component from the material when the material comes into contact with the solution. For example, it may be useful to include the same aerosol-generating agent in solution as in the mixture formed in step (a), optionally at substantially the same or the same concentration. This can prevent or reduce loss of the aerosol-generating agent during the manufacturing process, and particularly when the material comes into contact with the solution in step (c).

[0217] In some embodiments, the aerosol-generating agent is included in a solution. In some embodiments, the same aerosol-generating agent is included in the solution as in the mixture. In some embodiments, the solution contains from about 1%, 3%, 5%, 10%, 15%, or 20% to about 80%, 60%, 50%, 40%, or 30% by weight of the aerosol-generating agent. In some embodiments, the solution contains 10-45%, 20-40%, or 30-40% by weight of the aerosol-generating agent. In other embodiments, the aerosol-generating material contains 10-45%, 10-40%, or 15-30% by weight of the aerosol-generating agent.

[0218] In some embodiments, the solution comprises about 15% or less by weight of the aerosol-generating agent in the mixture, e.g., about 10% or less by weight, about 5% or less by weight, or about 1% or less by weight of the aerosol-generating agent.

[0219] In one embodiment, the concentration of the aerosol-generating agent in the solution is substantially the same as or equal to the concentration of the aerosol-generating agent in the mixture, such that the concentration of the aerosol-generating agent in the final aerosol-generating material is the same as or substantially the same as the concentration of the aerosol-generating agent in the mixture.

[0220] Conversely, if the concentration of the aerosol-generating agent in the solution is lower than that in the mixture, the concentration of the aerosol-generating agent in the final aerosol-generating material will be lower than that in the mixture due to diffusion of the aerosol-generating agent from the material upon contact with the solution. Similarly, if the concentration of the aerosol-generating agent in the solution is higher than that in the mixture, the concentration of the aerosol-generating agent in the final aerosol-generating material will be higher than that in the mixture.

[0221] The method of the present invention comprises: (d) separating the material formed in step (c) (e.g., the cross-linked material in the form of non-linear strands) from a solution containing the cross-linking agent; (e) drying the material; It may further include.

[0222] The step (d) of separating the material from the solution containing the cross-linking agent may comprise manually separating the material from the solution, for example by filtering or sieving.

[0223] The processes described herein may be continuous or batch processes, but are generally continuous processes.

[0224] Drying step (e) may include any suitable drying method, including, but not limited to, infrared (IR) heating, convection heating, air impingement, conduction heating, and microwave heating. Conduction heating may include heating a surface on which the material is disposed. The surface may be, for example, a metal or metal alloy (e.g., stainless steel) band. The surface may be self-heating (e.g., it is the surface of a heater) or indirectly heated. For example, the surface may be heated from below, for example, using steam. In some embodiments, drying step (e) is performed using a belt dryer.

[0225] The drying step (e) may, in some instances, remove from about 50%, 60%, 70%, 80%, or 90% by weight to about 80%, 90%, or 95% by weight of the water in the slurry (WWB).

[0226] Drying may be carried out at a suitable temperature, for example, from room temperature (25°C) to about 200°C, e.g., from about 50°C to about 150°C, or from about 100°C to about 130°C. As one skilled in the art will recognize, higher temperatures can result in faster drying times but may be more energy intensive. In some embodiments, the material is dried for about 30 seconds to about 10 minutes, e.g., from about 1 minute to about 5 minutes, e.g., from about 2 minutes to about 4 minutes.

[0227] The drying step (e) may, in some instances, reduce the average diameter of each of the strands by at least about 20%, such as from about 20% to about 90%, or from about 30% to about 70%.

[0228] During step (e), the material may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent, which is typically water.

[0229] After drying step (e), the aerosol-forming material may have a water content as defined above. In particular, the aerosol-forming material may have a water content of 1% to 15% by weight (wt. wt.). Preferably, the water content of the aerosol-forming material may be about 5%, 7%, or 9% to about 15%, 13%, 11%, 9%, or 8% (wet weight basis) (wt. wt.). In some embodiments, the aerosol-forming material has a water content of less than about 9% by weight (wt. wt.), e.g., less than about 8% by weight (wt. wt.). The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0230] In some cases, the solvent is part of the slurry or mixture and may consist essentially of or consist of water. In some cases, the slurry or mixture may contain about 50%, 60%, 70%, 80%, or 90% by weight (WWB) of solvent.

[0231] In instances where the solvent comprises water, the dry weight content of the slurry may match the dry weight content of the aerosol-forming material. As such, discussions herein regarding solid materials are expressly disclosed in conjunction with the slurry aspects of the invention. In particular, the above aspects and embodiments defining the components and amounts of the aerosol-forming material apply mutatis mutandis to the slurries and methods of the invention.

[0232] The method of the present invention may also include the step of cutting the non-linear strands to a desired free length, which may be performed before or after drying, and the desired free length may be as set forth herein above.

[0233] In some embodiments, the material is cut into a plurality of non-linear strands prior to drying step (e). By cutting the material into a plurality of non-linear strands (each shorter than the initially formed non-linear strand(s)) before drying the material, entanglement of the material can be reduced, which can subsequently facilitate processing and / or incorporating the material into an article. Reducing entanglement of the material can also facilitate forming a homogeneous mixture when the material is blended with tobacco.

[0234] In some embodiments, the non-linear strands may be arranged to form a net or mesh-like structure. In some embodiments, the non-linear strands are bonded or woven together to form a sheet of aerosol-generating material. Such a structure can be formed by arranging the strands in a net or mesh shape (e.g., grid formation) before, during, and / or after drying.

[0235] In a further aspect, the present invention also provides an aerosol-forming material obtainable or obtained by the method of the present invention. The above aspects and embodiments defining the components and amounts thereof of the aerosol-forming material apply mutatis mutandis to this further aspect of the invention.

[0236] According to aspects of the present invention, there is provided a method of generating an aerosol using the non-combustion aerosol delivery system described herein. In some embodiments, the method comprises heating the aerosol-forming material (or aerosol-forming composition) to a temperature of 350°C or less. In some embodiments, the method comprises heating the aerosol-forming material (or aerosol-forming composition) to a temperature of about 220°C to about 280°C. In some embodiments, the method comprises heating at least a portion of the aerosol-forming material (or aerosol-forming composition) to a temperature of about 220°C to about 280°C over a use session.

[0237] As used herein, a "use session" refers to a single period of use of a non-combustion aerosol delivery system by a user. A use session begins when power is first applied to at least one heating unit present in the heating assembly. The device is ready for use after a period of time has elapsed since the start of the use session. A use session ends when power is no longer applied to any of the heating elements of the aerosol delivery device. The end of a use session may coincide with the point at which the smoking article is depleted (the point at which the user considers the total particulate matter yield (mg) per puff to be unacceptably low). A session has a duration of multiple puffs. The session may have a duration of 7 minutes, 6 minutes, 5 minutes, 4 minutes 30 seconds, 4 minutes, or less than 3 minutes 30 seconds. In some embodiments, a use session may have a duration of 2 to 5 minutes, 3 to 4.5 minutes, 3.5 to 4.5 minutes, or preferably 4 minutes. A session may be initiated by the user activating a button or switch on the device, which initiates an increase in temperature of at least one heating element.

[0238] All weight percentages (denoted as wt. %) described herein are calculated on a dry weight basis (DWB) unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights stated on a dry weight basis refer to the entire slurry, aerosol-forming composition, or aerosol-forming material, excluding water, and may include components that are liquids themselves at room temperature and pressure, such as glycerol. Conversely, weight percentages stated on a wet weight basis (WWB) refer to all components, including water.

[0239] For the avoidance of doubt, where the term "comprising" is used herein to define the invention or features of the invention, embodiments are also disclosed in which the invention or features may be defined using the terms "consisting essentially of" or "consisting of" instead of "comprising." Reference to a material "comprising" certain features means that those features are included in, contained in, or retained within the material.

[0240] Any feature described in connection with one aspect of the invention is expressly disclosed in combination with any other aspect described herein.

[0241] Illustrative Embodiments Further embodiments of the present invention are as follows.

[0242] Embodiment 1. an aerosol generating agent; Cross-linked binder and 1. An aerosol-forming material in the form of one or more non-linear strands, comprising: Embodiment 1a. an aerosol-generating agent, and a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof; 1. An aerosol-generating material in the form of one or more non-linear strands, comprising: Embodiment 2. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a diameter of from about 0.05 mm to about 3 mm. Embodiment 3. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a diameter of between about 0.3 mm and about 2.5 mm. Embodiment 4. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a diameter of about 0.5 to about 1.5 mm. Embodiment 5. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a diameter of about 0.7 to about 1.1 mm. Embodiment 6. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a thickness of from about 0.05 mm to about 3 mm. Embodiment 7. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a thickness of from about 0.3 mm to about 2.5 mm. Embodiment 8. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a thickness of from about 0.5 to about 1.5 mm. Embodiment 9. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a thickness of from about 0.7 to about 1.1 mm. Embodiment 10. The aerosol-forming material of any preceding embodiment, wherein the ratio of diameter to thickness of each of the non-linear strands is from about 1:2 to about 2:1. Embodiment 11. The aerosol-forming material of any preceding embodiment, wherein the ratio of diameter to thickness of each of the non-linear strands is from about 3:2 to about 2:3. Embodiment 12. The aerosol-forming material of any preceding embodiment, wherein the ratio of diameter to thickness of each of the non-linear strands is about 1:1. Embodiment 13. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has an unwound length of between about 8 mm and about 200 mm. Embodiment 13a. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has an unwound length of between about 10 mm and about 200 mm. Embodiment 14. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has an unwound length of between about 20 mm and about 100 mm. Embodiment 15. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has an unwound length of between about 30 mm and about 50 mm. Embodiment 16. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a wound length of between about 2 mm and about 35 mm. Embodiment 17. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a wound length of between about 3 mm and about 25 mm. Embodiment 18. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a wound length of between about 6 mm and about 23 mm. Embodiment 19. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a wound length of between about 8 mm and about 22 mm. Embodiment 20. The aerosol-forming material of any preceding embodiment, wherein each of the non-linear strands has a wound length of between about 11 mm and about 20 mm. Embodiment 21. The aerosol-forming material of any preceding embodiment, wherein the unwound length is greater than the rolled length. Embodiment 22. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is at least about 1.2. Embodiment 23. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is at least about 1.3. Embodiment 24. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is at least about 1.5. Embodiment 25. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is at least about 2.0. Embodiment 25. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is less than about 10. Embodiment 26. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is less than about 8. Embodiment 27. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is less than about 6. Embodiment 28. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is from about 1.2 to about 10. Embodiment 29. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is from about 1.5 to about 5. Embodiment 30. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to wound length of each non-linear strand is from about 2 to about 5. Embodiment 31. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to diameter of each of the non-linear strands is from about 5 to about 200. Embodiment 32. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to diameter of each of the non-linear strands is from about 10 to about 100. Embodiment 33. The aerosol-forming material of any preceding embodiment, wherein the ratio of unwound length to diameter of each of the non-linear strands is from about 20 to about 50. Embodiment 34. The aerosol-forming material of any preceding embodiment, wherein the tensile strength of each strand is in the range of about 0.1 N to about 3.0 N. Embodiment 35. The aerosol-forming material of any preceding embodiment, wherein the tensile strength of each strand is in the range of about 0.2 N to about 2.0 N. Embodiment 36. The aerosol-forming material of any preceding embodiment, wherein the tensile strength of each strand is in the range of about 0.3 N to about 1.0 N. Embodiment 37. Approximately 2 cm 3 / g ~ approx. 7.5cm 3 / g. Embodiment 36. Approximately 3cm 3 / g ~ approx. 7cm 3 / g. Embodiment 36. Approximately 3.5cm 3 / g ~ approx. 6cm 3 / g. Embodiment 37. Approximately 4cm 3 / g ~ approx. 6cm 3 / g. Embodiment 37a. Approximately 3cm 3 / g ~ approx. 10cm 3 / g. Embodiment 37b. Approximately 4cm 3 / g ~ approx. 9.5cm 3 / g. Embodiment 37c. Approximately 4.5cm 3 / g ~ approx. 9cm 3 / g. Embodiment 37d. Approximately 5cm 3 / g ~ approx. 9cm 3 / g. Embodiment 38. The aerosol-forming material of any preceding embodiment, comprising about 1 to about 80% by weight of the aerosol-forming agent. Embodiment 39. The aerosol-forming material of any preceding embodiment, comprising about 5 to about 60% by weight of an aerosol-forming agent. Embodiment 40. The aerosol-forming material of any preceding embodiment, comprising about 10 to about 50% by weight of an aerosol-forming agent. Embodiment 41. The aerosol-forming material of any preceding embodiment, comprising about 10 to about 45% by weight of an aerosol-forming agent. Embodiment 42. The aerosol-forming material of any preceding embodiment, comprising about 20 to about 40% by weight of the aerosol-forming agent. Embodiment 43. The aerosol-forming material of any preceding embodiment, comprising about 30 to about 40% by weight of the aerosol-forming agent. Embodiment 44. The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating agent comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Embodiment 45. The aerosol-generating material of any preceding embodiment, wherein the aerosol-generating agent comprises glycerol. Embodiment 46. The aerosol-forming material of any preceding embodiment, comprising about 1 to about 60% by weight of the binder. Embodiment 47. The aerosol-forming material of any preceding embodiment, comprising about 5 to about 50 weight percent of a binder. Embodiment 48. The aerosol-forming material of any preceding embodiment, comprising about 6 to about 40 weight percent of the binder. Embodiment 49. The aerosol-forming material of any preceding embodiment, comprising about 7 to about 20% by weight of the binder. Embodiment 50. The aerosol-forming material of any preceding embodiment, wherein the binder comprises cross-linked alginate and / or pectin. Embodiment 50a. The aerosol-forming material of any preceding embodiment, wherein the binder comprises alginate and / or pectin and / or iota-carrageenan. Embodiment 50b. The aerosol-forming material of any preceding embodiment, wherein the binder comprises alginate and / or iota-carrageenan. Embodiment 51. The aerosol-forming material of any preceding embodiment, being substantially free of a cellulosic binder. Embodiment 52. The aerosol-forming material of any preceding embodiment, which is substantially free of carboxymethyl cellulose. Embodiment 52a. The aerosol-forming material of any preceding embodiment, comprising a crosslinked binder and a non-crosslinked binder. Embodiment 53. The aerosol-forming material of any preceding embodiment, comprising one or more fillers. Embodiment 53a. The aerosol-forming material of any preceding embodiment, comprising about 1 to about 60% by weight of a filler. Embodiment 54. The aerosol-forming material of any preceding embodiment, comprising about 1 to about 50% by weight of a filler. Embodiment 55. The aerosol-forming material of any preceding embodiment, comprising about 5 to about 45% by weight of a filler. Embodiment 56. The aerosol-forming material of any preceding embodiment, comprising about 10 to about 40% by weight of a filler. Embodiment 57. The aerosol-forming material of any preceding embodiment, comprising about 18 to about 35% by weight of a filler. Embodiment 58. The aerosol-forming material of any preceding embodiment, comprising about 20 to about 30% by weight of a filler. Embodiment 58a. The aerosol-forming material of any preceding embodiment, comprising about 10 to about 80% by weight of a filler. Embodiment 58b. The aerosol-forming material of any preceding embodiment, comprising about 20 to about 70% by weight of a filler. Embodiment 58c. The aerosol-forming material of any preceding embodiment, comprising about 30 to about 65% by weight of a filler. Embodiment 58d. The aerosol-forming material of any preceding embodiment, comprising about 40 to about 65% by weight of a filler. Embodiment 59. The aerosol-forming material of any preceding embodiment, comprising less than about 60% by weight of a filler. Embodiment 60. The aerosol-forming material of any preceding embodiment, comprising less than about 50% by weight of a filler. Embodiment 61. The aerosol-forming material of any preceding embodiment, comprising less than about 30% by weight of a filler. Embodiment 62. The aerosol-forming material of any preceding embodiment, comprising less than about 20% by weight of a filler. Embodiment 63. The aerosol-forming material of any preceding embodiment, comprising less than about 10% by weight of a filler. Embodiment 64. The aerosol-forming material of any preceding embodiment, wherein the filler is a fibrous organic filler material selected from wood pulp, hemp fiber, cellulose, or a cellulose derivative, such as microcrystalline cellulose (MCC), nanocrystalline cellulose, and / or comminuted cellulose. Embodiment 65. The aerosol-forming material of any preceding embodiment, wherein the filler comprises wood pulp, MCC, and / or comminuted cellulose. Embodiment 65a. The aerosol-forming material of any preceding embodiment, having a water content of less than about 9% by weight. Embodiment 65b. The aerosol-forming material of any preceding embodiment, having a water content of less than about 8% by weight. Embodiment 65c. The aerosol-forming material of any preceding embodiment, comprising about 1-70% by weight of particulate plant material. Embodiment 65d. The aerosol-forming material of any preceding embodiment, comprising about 5-60% by weight of particulate plant material. Embodiment 65e. The aerosol-forming material of any preceding embodiment, comprising about 10-50% by weight of particulate plant material. Embodiment 65f. The aerosol-forming material of any preceding embodiment, comprising about 30-40% by weight of particulate plant material. Embodiment 66. The aerosol-forming material of any preceding embodiment, being substantially free of tobacco. Embodiment 67. An aerosol-forming composition comprising the aerosol-forming material of any preceding embodiment. Embodiment 67a. The aerosol-forming composition of embodiment 67, wherein the aerosol-forming material is shredded and mixed with tobacco. Embodiment 67b. The aerosol-forming composition of embodiment 67 or 67a, comprising about 10-50% by weight of aerosol-forming material and about 50-90% by weight of tobacco. Embodiment 67c. The aerosol-forming composition of embodiment 67 or 67a, comprising about 20-40% by weight of aerosol-forming material and about 60-80% by weight of tobacco. Embodiment 67d. The aerosol-forming composition of any of embodiments 67-67c, comprising a mixture of an aerosol-forming material of the present invention and dry ice expanded tobacco (DIET). Embodiment 67e. Approximately 3cm 3 / g ~ approx. 10cm 3 The aerosol-forming composition of any of embodiments 67-67d, having a loading value of 1 / g. Embodiment 67f. Approximately 4cm 3 / g ~ approx. 9.5cm 3 The aerosol-forming composition of any of embodiments 67-67e, having a loading value of 1 / g. Embodiment 67g. Approximately 4.5cm 3 / g ~ approx. 9cm 3 The aerosol-forming composition of any of embodiments 67-67f, having a loading value of 1 / g. Embodiment 67h. Approximately 5cm 3 / g ~ approx. 9cm 3 The aerosol-forming composition of any of embodiments 67-67g, having a loading value of / g. Embodiment 68. The aerosol-forming composition of any of embodiments 67-67h, further comprising one or more additional active agents and / or fragrances, and optionally one or more other functional materials. Embodiment 69. 69. The aerosol-forming composition of embodiment 67 or 68, further comprising one or more other functional materials. Embodiment 70. 70. The aerosol-forming composition of embodiment 68 or 69, wherein the other functional materials comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant. Embodiment 71. 70. The aerosol-forming composition of embodiment 69, wherein the other functional materials comprise one or more fillers. Embodiment 72. The aerosol-forming composition of embodiment 71, wherein the filler is selected from inorganic filler materials, wood pulp, hemp fiber, cellulose, and cellulose derivatives. Embodiment 73. 73. The aerosol-forming composition of any of embodiments 67-72, which does not include calcium carbonate, such as chalk. Embodiment 74. 74. The aerosol-forming composition of any of embodiments 67-73, which does not comprise fibrous materials. Embodiment 75. 75. The aerosol-forming composition of any of embodiments 67-74, which does not contain tobacco fiber. Embodiment 76. 76. The aerosol-forming composition of any of embodiments 67-75, comprising about 50-100% by weight (WWB) of the aerosol-forming material. Embodiment 77. 77. The aerosol-forming composition of any of embodiments 67-76, comprising about 50-95% by weight (WWB) of the aerosol-forming material. Embodiment 78. 78. The aerosol-forming composition of any of embodiments 67-77, comprising about 50-90% by weight (WWB) of the aerosol-forming material. Embodiment 79. 79. The aerosol-forming composition of any of embodiments 67-78, comprising about 60-100% by weight (WWB) of the aerosol-forming material. Embodiment 80. 80. The aerosol-forming composition of any of embodiments 67-79, comprising about 60-95% by weight (WWB) of the aerosol-forming material. Embodiment 81. 81. The aerosol-forming composition of any of embodiments 67-80, comprising about 60-90% by weight (WWB) of the aerosol-forming material. Embodiment 82. 82. The aerosol-forming composition of any of embodiments 67-81, comprising about 70-100% by weight (WWB) of the aerosol-forming material. Embodiment 83. 83. The aerosol-forming composition of any of embodiments 67-82, comprising about 70-95% by weight (WWB) of the aerosol-forming material. Embodiment 84. 84. The aerosol-forming composition of any of embodiments 67-83, comprising about 70-90% by weight (WWB) of the aerosol-forming material. Embodiment 85. 85. The aerosol-forming composition of any of embodiments 67-84, consisting of or consisting essentially of an aerosol-forming material. Embodiment 86. A consumable product for use in a non-combustion aerosol delivery device, comprising the aerosol-forming composition of any of embodiments 67-85. Embodiment 87. A non-combustion aerosol delivery system comprising the consumable of embodiment 86 and a non-combustion aerosol delivery device. Embodiment 88. A consumable for use in the non-combustion aerosol delivery device of embodiment 86 or the non-combustion aerosol delivery system of embodiment 87, wherein the non-combustion aerosol delivery device is a non-combustion heated device. Embodiment 88. 67. A method of making the aerosol-forming material of any of embodiments 1-66, comprising: (a) aerosol generating agents, crosslinkable binders, optionally a filler, optionally an active material and / or a flavoring and / or an acid, and solvent forming a mixture comprising: (b) injecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; A method comprising: Embodiment 89. 89. The method of embodiment 88, wherein the solution of step (c) further comprises one or more of a flavoring agent, an active material, an aerosol generating agent (e.g., glycerol), and a botanical extract. Embodiment 90. 90. The method of embodiment 88 or 89, wherein the solution of step (c) further comprises an aerosol-generating agent (e.g., glycerol), and / or a botanical extract. Embodiment 91. The method of any of embodiments 88-90, wherein the solution of step (c) further comprises the same aerosol-generating agent as is present in the mixture of step (a). Embodiment 92. (d) separating the material formed in step (c) from the solution containing the cross-linking agent. 92. The method of any of embodiments 88-91, further comprising: Embodiment 93. (e) Drying the material 93. The method of embodiment 92, further comprising: Embodiment 94 The method of any one of embodiments 88-93, wherein the solvent is water. Embodiment 95. An aerosol-forming material obtainable by the method of any of Embodiments 88-94.

[0243] [Example] The material was conditioned at 22±1° C. and 60±2% RH for 48 hours.

[0244] Example 1 A gel slurry was made in a 10 L Robot Coupe mixer (R 10 VV Robot Coupe). Wood pulp with a 70-80 SR Schopper Riegler was added to water to form a mixture of water and 3% by weight of wood pulp. Alginate was slowly added at a speed of 600 RPM over a period of 5 minutes. Ground cellulose was then slowly added to the slurry mixture over a period of 5 minutes. Following this, glycerol was added, and water was added and mixed over a period of 2 minutes. The final gel slurry was allowed to stand and mixed for an additional 10 minutes before being poured into a beaker. The slurry mixture was then slowly stirred using an overhead mixer. The gel slurry had a solids content of 15% by weight.

[0245] The resulting slurry contained wood pulp (7.5 wt%), alginate algogel 6021 (7.5 wt%), glycerol (50 wt%), and ground cellulose (35 wt%) (all weight percentages on a dry weight basis).

[0246] The gel slurry was pumped using a 2.0 mm circular nozzle and a 620S Watson Marlow peristaltic pump into a 0.06 M calcium formate bath solution. The residence time was 0 min (gel strands in mesh trays were immediately removed), and the gel strands were dried at 70° C. for 3 h.

[0247] Once dry, the strands were divided into four batches: one batch was left uncut (Material 1) and the other three were cut into cut lengths of 1, 2 and 3 cm (Materials 2, 3 and 4, respectively).

[0248] The tensile strength of individual strands selected from the material was measured using an Instron 68TM-5 (TCT_004) tension / compression machine with Bluehill Universal software. Non-linear strands to be tested were visually selected from the bulk sample material at approximately 4-6 cm of rolled length, without clumping with the rest of the sample. The strands were cut from the remaining sample material. An example of a test strand is shown in Figure 13.

[0249] A Keyence VHX-6000 (DMI_001) was used to measure the wound and unwound lengths of the strands. An image of an example strand is shown in Figure 14. A selective sampling technique was applied rather than random sampling. Strands were visually selected to avoid clumping with the rest of the sample. The strands were cut from the rest of the sample.

[0250] The results of the tensile tests, in Newtons (N), and the wound / unwound lengths are summarized in Tables 1-4 below.

[0251] [Table 1]

[0252] [Table 2]

[0253] [Table 3]

[0254] [Table 4]

[0255] Example 2 A series of materials (Materials 5-9) according to Table 5 below were made by forming gel slurries in a 10 L Robot Coupe mixer (R 10 VV Robot Coupe) as follows: Wood pulp with a 70-80 SR Schopper Riegler was added to water to form a mixture of water and 3% by weight wood pulp. Alginate was slowly added at a speed of 600 RPM over a period of 5 minutes. Ground cellulose was then slowly added to the slurry mixture over a period of 5 minutes. Following this, glycerol was added, and water was added and mixed over a period of 2 minutes. The final gel slurry was allowed to stand and mixed for an additional 10 minutes before being poured into a beaker. This slurry mixture was then slowly stirred using an overhead mixer. The gel slurry had a solids content of 15%.

[0256] The resulting slurry contained wood pulp, alginate algogel 6021, glycerol, and ground cellulose, with the percentages of each component shown in Table 5 below.

[0257] The gel slurry was pumped into a 0.06 M calcium formate bath solution using a 620S Watson Marlow peristaltic pump with a 2.0 mm, 1.5 mm, or 0.5 mm diameter circular nozzle. The residence time in the bath solution was 0 min (gel strands in mesh trays were immediately removed), after which the gel strands were dried at 70° C. for 3 h.

[0258] Once dry, the strands of each material were divided into four batches and cut into cut lengths of 1, 2 and 3 cm (one batch was left uncut).

[0259] The fill values ​​of these materials were then measured as described above, and the results are shown in Table 5, where the fill values ​​shown are the average of three replicates for each batch of material.

[0260] [Table 5]

[0261] Loading values ​​were also measured for a known comparative aerosol-forming material containing 50% by weight glycerol, 7% by weight wood pulp, 7% by weight CMC, and 36% by weight ground cellulose. The loading value for this comparative material, which is not in the form of non-linear strands of the present invention, was 2.696 cm 3 / g.

[0262] Example 3 The gel slurry was made in a 10L Robot Coupe mixer (R 10 VV Robot Coupe). The alginate was slowly added to the water at 600 RPM over 5 minutes. Then, the milled cellulose was slowly added to the slurry mixture over 5 minutes. Then, the microcrystalline cellulose (MCC) was slowly added to the slurry mixture over 5 minutes. Following this, glycerol was added, and water was added and mixed over 2 minutes. The final gel slurry was allowed to stand and mixed for an additional 10 minutes before being poured into a beaker. The slurry mixture was then slowly stirred using an overhead mixer.

[0263] The resulting slurry contained alginate algogel 6021 (7.5 wt%), glycerol (20 wt%), milled cellulose (50 wt%), and MCC (22.5 wt%) (all weight percentages on a dry weight basis).

[0264] The gel slurry was pumped using a 0.5 mm circular nozzle and a 620S Watson Marlow peristaltic pump into a 0.06 M calcium formate bath solution. The residence time was 0 min (gel strands in mesh trays were immediately removed), and the gel strands were dried at 70° C. for 3 h.

[0265] A Keyence VHX-6000 (DMI_001) was used to measure the wound and unwound lengths of the strands as described in connection with Example 1. The results are shown in Table 6 below.

[0266] [Table 6]

[0267] Example 4 A slurry containing water, alginate Algogel 6021 (8 wt%), glycerol (20 wt%), milled cellulose (38 wt%), MCC (21 wt%), and carrageenan (13%) (all weight percentages on a dry weight basis) was formed. The slurry had a solids content of 15%.

[0268] The slurry was pumped using a 0.8 mm or 1.0 mm round nozzle into a calcium formate bath solution that also contained 20 wt % glycerol.

[0269] The residence time was 0 minutes (gel strands were removed immediately) and the gel strands were dried in a heat tunnel at 120° C. for 2.5 minutes.

[0270] The loading values ​​of these materials were then measured as explained in the description above, and the results are shown in Table 7.

[0271] [Table 7]

[0272] Example 5 A slurry was formed containing water, alginate Algogel 6021 (8 wt%), glycerol (20 wt%), milled cellulose (38 wt%), MCC (21 wt%), and carrageenan (13%) (all weight percentages on a dry weight basis). The slurry had a 15% solids content.

[0273] The slurry was pumped using a 0.5 mm nozzle (Example 5a) or a 0.6 mm nozzle (Examples 5b, 5c and 5d) into a 0.06 M calcium formate solution that also contained various amounts of glycerol.

[0274] The residence time was 30 seconds and the gel strands were dried in a heat tunnel at 120°C for 3.5 minutes.

[0275] The glycerol content of the final material was measured by gas chromatography using a flame ionization detector (GC-FID). The results are shown below. The glycerol content shown below for Examples 5a, 5b, and 5c is the average of three strands from the same batch.

[0276] [Table 8]

[0277] As can be seen from the above results, by including an aerosol-generating agent (i.e., glycerol) in the crosslinking solution, it was possible to produce materials with desired levels of the aerosol-generating agent. Conversely, when the aerosol-generating agent was not included in the solution, the level of the aerosol-generating agent in the final material was significantly reduced compared to the initial mixture.

Claims

1. an aerosol-forming material in the form of one or more non-linear strands, an aerosol generating agent; a cross-linked binder; optionally one or more fillers; Optionally, an active material and / or a flavoring and / or an acid and an aerosol-generating material comprising:

2. 10. The aerosol-forming material of claim 1, wherein each of the non-linear strands has a diameter of about 0.05 mm to about 3 mm.

3. 3. The aerosol-forming material of claim 1, wherein each of the non-linear strands has a thickness of about 0.05 mm to about 3 mm.

4. 4. The aerosol-forming material of claim 1, wherein the ratio of diameter to thickness of each of the non-linear strands is from about 1:2 to about 2:

1.

5. 5. The aerosol-forming material of claim 1, wherein each of the non-linear strands has an unwound length of about 20 mm to about 100 mm, and / or each of the non-linear strands has a wound length of about 3 mm to about 25 mm, with the unwound length being greater than the wound length.

6. 6. The aerosol-forming material of claim 1, wherein the ratio of unwound length to wound length of each non-linear strand is at least about 1.2, such as from about 1.2 to about 10.

7. 7. The aerosol-forming material of claim 1, wherein each of the non-linear strands has an unwound length-to-diameter ratio of about 5 to about 200.

8. 8. The aerosol-forming material of claim 1, wherein the tensile strength of each strand ranges from about 0.1 N to about 3.0 N.

9. Approximately 3cm ３ / g ~ approx. 10cm ３ 9. The aerosol-forming material according to claim 1, having a loading value of 0.1g / g.

10. about 1 to about 80% by weight of an aerosol-forming agent; about 1 to about 60 weight percent of a crosslinked binder; optionally about 1 to about 60 weight percent of a filler; Optionally, about 1 to about 50% by weight of active material and / or flavoring agent; Including, The aerosol-forming material of any one of claims 1 to 9, wherein these amounts are calculated on a dry weight basis.

11. 11. The aerosol-generating material of claim 1, wherein the aerosol-generating agent comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate, e.g., the aerosol-generating agent comprises glycerol.

12. The aerosol-forming material of any one of claims 1 to 10, wherein the binder comprises cross-linked alginate and / or pectin.

13. 13. The aerosol-forming material of any one of claims 1 to 12, which is substantially free of cellulosic binders and / or substantially free of carboxymethyl cellulose.

14. 14. The aerosol-forming material of any one of claims 1 to 13, wherein the filler is present, preferably the filler comprises wood pulp, MCC, and / or ground cellulose.

15. 15. The aerosol-forming material of claim 14, comprising a filler in an amount of from about 5 to about 60% by weight.

16. 16. The aerosol-forming material of claim 1, further comprising a cross-linking agent, for example, the cross-linking agent comprises calcium ions, for example, the cross-linking agent comprises calcium lactate, calcium acetate, and / or calcium formate.

17. The aerosol-forming material of any one of claims 1 to 16, which is substantially free of tobacco.

18. an aerosol generating agent; a binder selected from the group consisting of alginate, pectin, carrageenan (such as iota carrageenan), gellan gum (such as high acyl gellan gum), and combinations thereof; optionally one or more fillers; Optionally, an active material and / or a flavoring and / or an acid 1. An aerosol-forming material in the form of one or more non-linear strands, comprising:

19. An aerosol-forming composition comprising the aerosol-forming material of any one of claims 1 to 18.

20. 20. The aerosol-forming composition of claim 19, comprising chopped or chopped strands of the aerosol-forming material.

21. 21. The aerosol-forming composition of claim 20, further comprising tobacco.

22. 22. The aerosol-forming composition of claim 21, wherein the tobacco is shredded or cut, e.g., cut rag tobacco.

23. 23. The aerosol-forming composition of any one of claims 19 to 22, comprising from about 10 to about 50% by weight of the aerosol-forming material and from about 50 to about 90% by weight of tobacco.

24. A consumable product for use with a non-combustion type aerosol delivery device, the consumable product comprising the aerosol forming composition of any one of claims 19 to 23.

25. 25. A non-combustion aerosol delivery system comprising the consumable of claim 24 and a non-combustion aerosol delivery device, wherein the non-combustion aerosol delivery device is configured to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

26. 26. The system of claim 25, wherein the non-combustion aerosol delivery device comprises a heater configured to heat but not combust the consumable.

27. Use of an aerosol-forming material according to any one of claims 1 to 18, or use of an aerosol-forming composition according to any one of claims 18 to 23, to generate an aerosol.

28. 18. A method of making the aerosol-forming material of any one of claims 1 to 17, comprising the steps of: (a) aerosol generating agents, crosslinkable binders, optionally a filler, optionally an active material and / or a flavoring and / or an acid, and solvent forming a mixture comprising: (b) ejecting the mixture through a nozzle such that the mixture moves at a velocity; (c) contacting the injected mixture with a solution containing a cross-linking agent, wherein the velocity of the mixture decreases upon contact with the solution; A method comprising:

29. 30. The method of claim 28, wherein the solution further comprises an aerosol generating agent.

30. 30. The method of claim 28 or claim 29, further comprising: (d) separating the material formed in step (c) from the solution containing the cross-linking agent; and (e) drying the material, optionally further comprising cutting the material into a plurality of non-linear strands before drying.

31. An aerosol-forming material obtainable by the method of any one of claims 28 to 30.

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