Aerosol-Generating Materials

Abstract

The present invention provides an aerosol-generating material comprising an aerosol-forming agent material, a binder comprising tartaric acid, and a filler. The present invention also provides an aerosol-generating composition comprising the aerosol-generating material, a consumable 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

[Technical Field]

[0001] The present invention relates to aerosol generation. In particular, the present invention relates to aerosol-forming materials, aerosol-forming compositions, consumables, non-combustion aerosol delivery systems, methods of generating aerosols, and methods of forming aerosol-forming materials.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles emit inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These may be referred to as non-combustion smoking articles, aerosol-generating assemblies, or non-combustion aerosol delivery systems.

[0003] One example of such a product is a heating device that releases a compound by heating, but not burning, a solid aerosolizable material. The solid aerosolizable material may optionally contain tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products (THPs). A variety of different configurations are known for volatilizing at least one component of a solid aerosolizable material.

[0004] Another example is an e-cigarette / tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices contain a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further contains a solid aerosolizable material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce an inhalation vehicle. Overview

[0005] In one aspect, (i) an aerosol former material; (ii) a binder comprising tartaric acid, and (iii) Filler An aerosol-forming material is provided, comprising:

[0006] In another aspect, an aerosol-forming composition is provided that includes the aerosol-forming material described herein. Also provided are consumables for use in non-combustion aerosol delivery devices that include the aerosol-forming compositions described herein. Also provided is a non-combustion aerosol delivery system comprising a consumable product as described herein and a non-combustion aerosol delivery device. Also provided is a method of generating an aerosol using the non-combustion aerosol delivery system described herein, comprising heating an aerosol-forming material to a temperature of less than 350°C.

[0007] In another aspect, (a) providing a slurry comprising an aerosol former material, a first binder comprising tartaric acid, a filler, and a solvent; (b) forming a layer of slurry; (c) drying the slurry to form an aerosol-generating material; A method of making an aerosol-forming material is provided, comprising:

[0008] To the extent that they are combinable, features described herein in the context of one embodiment of the invention are expressly disclosed in combination with any and all embodiments. Further features and advantages of the present invention will become apparent from the following description, given by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0009] [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 side view of an example of an 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 a non-combustion aerosol delivery system. [Figure 6] 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. Detailed Description

[0010] The aerosol-forming materials / compositions described herein are materials / compositions that are capable of generating an aerosol when energized, for example, by heating, irradiation, or in any other manner.

[0011] The aerosol-generating material may be an "amorphous solid." In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material may be non-fibrous or fibrous. For example, the aerosol-generating material may be substantially non-fibrous. In some embodiments, the aerosol-generating material may be a dry gel. The aerosol-generating material is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material), or the retained fluid may be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0012] In some embodiments, the aerosol-forming composition may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% aerosol-forming material. In some cases, the aerosol-forming composition consists of the aerosol-forming material. In other cases, the aerosol-forming composition comprises about 40 to about 60 wt% aerosol-forming material. The remainder of the composition may be formed from other components described below, such as tobacco material.

[0013] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, less than 12 wt%, or less than 10 wt% water, calculated on a wet weight basis (WWB).

[0014] In some embodiments, the aerosol-forming material may contain less than about 20 wt.% water, e.g., less than about 15 wt.%, less than 12 wt.%, or less than 10 wt.%, calculated on a wet weight basis (WWB). For example, the aerosol-forming material may contain about 1-15 wt.% water, e.g., 3-12 wt.% water (WWB).

[0015] In some embodiments, the aerosol-forming material is at least about 2 cm 3 / g, 2.5cm 3 / g, 3cm 3 / g, or 4cm 3 In some embodiments, the fill value is about 6 cm 3 / g or less, 5.5cm 3 / g or less than 5cm 3 / g.

[0016] In some embodiments, the aerosol-forming material is applied to a volume of about 2 cm 3 / g ~ approx. 6cm 3 / g, approx. 2.5cm 3 / g ~ approx. 5.5cm 3 / g, or approximately 3 cm 3 / g ~ approx. 5cm 3 / g.

[0017] In some embodiments, the aerosol-forming material is applied to a volume of about 4 cm 3 / g ~ approx. 6cm 3 / g, approx. 4.5cm 3 / g ~ approx. 5.5cm 3 / g, or approximately 4.5 cm 3 / g ~ approx. 5cm 3 / g.

[0018] The packing value is measured by placing a known weight of material in a cylinder of known dimensions. This 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.

[0019] More specifically, the fill value of the aerosol-forming material of the present invention can be determined by the following procedure: A 20 g sample of the material is deposited into a 60 mm diameter cylinder of a hydrometer, and the material is then compressed with a 2.90 ± 0.03 kg piston for 30 seconds. The height of the piston in the hydrometer is measured. The fill value of the sample is calculated according to the following formula:

[0020] The volume that a material occupies when compressed is determined using Equation 1.

number

number

[0021] The inventors have surprisingly found that the aerosol-forming materials of the present invention have higher loading values ​​than aerosol-forming materials that do not contain tartaric acid.

[0022] By using a material with a higher fill value as an aerosol-generating material, it may be possible to provide articles and consumables with a lower overall weight than conventional articles. Reducing the overall weight can provide many advantages, such as reduced transportation costs, as well as reduced material costs and / or taxes. Furthermore, reducing the weight of an article can also have a positive impact on the environment, as less energy may be required to transport the article. Furthermore, consumers may prefer to carry and use lighter articles. This material can also be used as a tobacco-free aerosol-generating substrate.

[0023] In some embodiments, the aerosol-generating material has a tensile strength of about 0.5 N / 15 mm, 1 N / 15 mm, 2 N / 15 mm, or 5 N / 15 mm to about 16 N / 15 mm, 14 N / 15 mm, 12 N / 15 mm, or 10 N / 15 mm. In some embodiments, the tensile strength of the aerosol-generating material is within the range of about 0.5 N / 15 mm to about 16 N / 15 mm, about 1 N / 15 mm to about 14 N / 15 mm, about 2 N / 15 mm to about 12 N / 15 mm, or about 5 N / 15 mm to about 10 N / 15 mm.

[0024] Tensile strength is measured using a Stable Microsystems Texture Analyser device. A sample of the sheet material is cut to dimensions of 15 mm wide by 140 mm long. 25 mm of each end of the sample is folded over, resulting in a sample with a total length of 90 mm and a central section of 40 mm single layer thickness.

[0025] A sample of the prepared material is clamped between two gripping clamp plates, which are moved 5 mm apart by the Texture Analyser armature with a measured force. The Texture Analyser device lifts one clamp plate and measures and records the lifting force over the distance traveled. Software associated with the device sets the test parameters, records the forces obtained, and then exports the data as needed.

[0026] The tensile strength of a material is measured using Equation 3.

number

[0027] In some embodiments, the aerosol-forming material has a viscosity of less than about 0.3N, less than about 0.25N, less than about 0.2N, less than about 0.1N, or less than about 0.05N.

[0028] Adhesion is measured using a Texture Analyser device. Samples are cut from the sheet material to a size scale of 7 cm x 7 cm. The sheet material sample is fixed onto an aluminum plate. The Texture Analyser device then lowers the probe into the sheet for 5 seconds while applying a force of 4.5 N, then raises it, thereby measuring and recording the applied force. Software associated with the device sets the test parameters, records the force obtained, and then exports the data as needed.

[0029] Tack is a material property of adhesiveness / stickiness. Tack is the force required to overcome the attractive force between the surface of a product and a reference material, in this case a metal probe attached to a Texture Analyser device that the product comes into contact with.

[0030] In some embodiments, the aerosol-forming material has a density of about 0.2 g / cm 3 ~Approx. 1.0g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~about 0.8g / cm 3 It has a density of

[0031] Binder The aerosol-forming material includes a binder that includes tartaric acid. The term "gelling agent" may also be used herein in place of "binder."

[0032] The aerosol-forming material includes tartaric acid, which may increase the loading value of the aerosol-forming material. The use of tartaric acid as a binder may also help to reduce the stickiness of the surface of the aerosol-generating material, and therefore may facilitate processing and / or handling of the aerosol-generating material (e.g., during its manufacture and / or subsequent processing). The use of tartaric acid may also improve the tensile strength of the aerosol-forming material.

[0033] In some embodiments, the aerosol-forming material comprises from about 1%, 1.5%, or 2% to about 10%, 9%, 8%, or 7% tartaric acid by weight. For example, in some embodiments, the aerosol-forming material comprises from about 1 to about 10%, about 1.5 to about 8%, or about 2 to about 7% tartaric acid by weight.

[0034] Additional binders Along with tartaric acid, the aerosol-forming material may further include one or more additional binders other than tartaric acid.

[0035] In some embodiments, the additional binder comprises a hydrocolloid.

[0036] In some embodiments, the aerosol-forming material comprises one or more compounds selected from alginate, pectin, starch or a derivative thereof, such as hydroxypropyl starch or sodium carboxymethyl starch, cellulose or a derivative thereof, such as hydroxypropylmethylcellulose, pullulan, carrageenan, polysaccharide binders such as agar and agarose, gelatin, gums such as locust bean gum, xanthan gum, guar gum and acacia gum, silica or silicone compounds such as PDMS and sodium silicate, clays such as kaolin, and polyvinyl alcohol.

[0037] In some embodiments, the additional binder comprises one or more polysaccharide binders, hi some embodiments, the polysaccharide binder is selected from alginate, pectin, and cellulose or derivatives thereof.

[0038] Examples of cellulose-based binders (also referred to herein as cellulose derivatives) 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 cellulose or its derivatives are selected from 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).

[0039] In some embodiments, the additional binder comprises hydroxypropyl methylcellulose. In some embodiments, the additional binder comprises one or more gums selected from locust bean gum, xanthan gum, guar gum, and acacia gum. In some embodiments, the additional binder comprises locust bean gum. In some embodiments, additional binders include locust bean gum and hydroxypropyl methylcellulose.

[0040] In some embodiments, the aerosol-forming material comprises from about 1%, 2%, 3%, or 4% to about 15%, 13%, or 11% by weight of the additional binder on a dry weight basis of the aerosol-forming material. In some embodiments, the aerosol-forming material comprises a total of about 1 to about 15% by weight, e.g., about 2 to about 13% by weight, or about 4 to about 11% by weight of the additional binder.

[0041] In some embodiments, the only binder is tartaric acid.

[0042] Aerosol-forming materials The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material includes one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0043] In some embodiments, the aerosol former material comprises one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols such as glycerol monoacetate, diacetate, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0044] In certain embodiments, the aerosol former material comprises glycerol in combination with propylene glycol. In certain embodiments, the aerosol former material comprises glycerol.

[0045] The aerosol-forming material may comprise from about 1 wt% to about 60 wt% of the aerosol-forming material. In some embodiments, the aerosol-forming material may comprise from about 1 wt%, 10 wt%, 20 wt%, 30 wt%, or 40 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, or 40 wt% of the aerosol-forming material. In certain embodiments, the aerosol-forming material comprises from about 10 wt% to about 60 wt%, or from about 20 wt% to about 55 wt% of the aerosol-forming material.

[0046] In some embodiments, the aerosol-forming material comprises about 20 to about 40 wt %, or about 25 to about 35 wt %, for example about 30 wt %, of the aerosol former material. In some embodiments, the aerosol-forming material comprises about 40 to about 60 wt %, or about 45 to about 55 wt %, for example about 50 wt %, of the aerosol former material.

[0047] Filler The aerosol-forming material includes a bulking agent. The use of a bulking agent can help reduce the viscosity of the aerosol-forming material, for example, when high levels of aerosol-former material are present.

[0048] In some embodiments, the aerosol-forming material comprises a total amount of filler of about 1 to about 80 wt% of the aerosol-forming material on a dry weight basis, for example, in some embodiments, the aerosol-forming material comprises about 30 to about 70 wt% filler, or about 40 to about 60 wt% filler.

[0049] In some embodiments, the filler comprises (or is) 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 sorbents such as molecular sieves.

[0050] In some embodiments, the filler comprises (or is) one or more organic filler materials such as wood pulp, tobacco pulp, hemp fiber, cellulose and cellulose derivatives, such as microcrystalline cellulose and / or nanocrystalline cellulose.

[0051] As is well understood by those skilled in the art, microcrystalline cellulose can be formed by depolymerizing cellulose through a chemical process (e.g., using acid or enzymes). One exemplary method for forming microcrystalline cellulose involves acid hydrolysis of cellulose using an acid such as HCl. The cellulose produced after this treatment is crystalline (i.e., no amorphous regions remain). Suitable methods and conditions for forming microcrystalline cellulose are well known in the art.

[0052] In some embodiments, the aerosol-forming material is free of inorganic fillers. In some embodiments, the aerosol-forming composition is free of inorganic fillers. In some embodiments, the aerosol-forming material does not include calcium carbonate, such as chalk. In some embodiments, the aerosol-forming composition does not include calcium carbonate, such as chalk.

[0053] In certain embodiments, the aerosol-generating material includes a filler, and the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, tobacco pulp, hemp fiber, cellulose, or a cellulose derivative. In some embodiments, the fibrous organic filler material may be wood pulp, hemp fiber, cellulose, or a cellulose derivative. In certain embodiments, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the aerosol-generating material sheet is wrapped around a rod of aerosolizable material.

[0054] In certain embodiments, the filler comprises microcrystalline cellulose and / or wood pulp.

[0055] Any active substance The aerosol-forming material or composition may include an active agent.

[0056] In some cases, the aerosol-forming material may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 65 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of the active substance.

[0057] In some cases, the active substance is nicotine. In some cases, the aerosol-forming material may contain from about 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% to about 20 wt%, 18 wt%, 15 wt%, 12 wt%, or 10 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may contain about 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0058] As used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be of natural origin or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

[0059] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0060] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0061] In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0062] The active substance may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol). The active substance may include cannabidiol (CBD). Active substances may include nicotine and cannabidiol (CBD). Active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0063] As described herein, an active substance may comprise or be derived from one or more botanical substances or their components, derivatives, or extracts. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may comprise a synthetically derived active compound naturally present in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, raspberry, Bender, 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, kahlua, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0064] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0065] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, wherein the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0066] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0067] In some embodiments, the aerosol-forming material does not contain tobacco fiber. In some embodiments, the aerosol-forming material does not contain tobacco material. In some embodiments, the aerosol-forming material is substantially free of tobacco material. In some embodiments, the aerosol-forming material does not contain an active agent.

[0068] Flavor In some embodiments, the aerosol-forming material or aerosol-forming composition comprises a flavor.

[0069] In some cases, the aerosol-forming material may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 65 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of flavor.

[0070] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They may be naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tomato, etc.). Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang Orchids, sage, fennel, wasabi, bell peppers, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damien, maji The present invention may include other additives such as cholams, olives, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be mimetic, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0071] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0072] In some embodiments, the flavor may include a sensation elicitor, typically chemically induced, intended to achieve somatic sensations perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0073] Other functional materials In some embodiments, the aerosol-forming material or composition may further include one or more other functional materials, which may include one or more of a pH adjuster, a colorant, a preservative, a stabilizer, and / or an antioxidant.

[0074] The aerosol-generating material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid, and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0075] 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.

[0076] Suitably, 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.

[0077] In embodiments in which the aerosol-forming material includes nicotine, the inclusion of an acid is particularly preferred. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during production.

[0078] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched with other components of the aerosol-generating composition or other components of a consumable product that includes the aerosol-generating material.

[0079] Depending on the desired color of the aerosol-generating material, various coloring agents may be used. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic coloring agents, such as natural or synthetic dyes, food-grade coloring agents, and pharmaceutical-grade coloring agents, may be used. In certain embodiments, the coloring agent is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (such as tobacco material) in the aerosol-generating composition that includes the aerosol-generating material. In some embodiments, the addition of a coloring agent to the aerosol-generating material makes the aerosol-generating material visually indistinguishable from the other components in the aerosol-generating composition.

[0080] The colorant may be incorporated into the aerosol-generating material during its formation (e.g., when forming a slurry containing the materials that form the aerosol-generating material), or the colorant may be applied to the aerosol-generating material after its formation (e.g., by spraying it onto the aerosol-generating material).

[0081] In some embodiments, the aerosol-generating material is formed as a sheet. In some cases, the sheet of aerosol-generating material may be incorporated into a non-combustion aerosol delivery system or consumable in sheet form. The sheet of aerosol-generating material may be incorporated as a flat sheet, a pleated or bundled sheet, a crinkled sheet, or a rolled sheet (i.e., in the form of a tube). In some such cases, the aerosol-generating material of these embodiments may be included in the system / consumable as a sheet, for example, as a sheet wrapped around a rod of aerosolizable material (e.g., tobacco). For example, the sheet of aerosol-generating material may be formed on a paper wrapper that wraps around aerosolizable material such as tobacco. In other cases, the sheet may be shredded and then suitably mixed with aerosolizable material such as cut rag tobacco and incorporated into the assembly.

[0082] In some cases, the aerosol-generating material may be in the form of a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be within a range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm, e.g., 0.1-3 mm or 0.15-3 mm. Materials having a thickness of about 0.2 mm may be particularly suitable. The aerosol-generating material may include two or more layers, and the thicknesses described herein refer to the combined thickness of those layers.

[0083] If the aerosol-generating material is too thick, heating efficiency may be compromised, which will negatively impact power consumption during use. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle; very thin materials may be difficult to cast and may be brittle, which may impair aerosol formation during use.

[0084] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0085] In some embodiments, the aerosol-generating material in sheet form may have sufficient tensile strength so that it can be wound onto or unwound from a bobbin without breaking, ie, the aerosol-generating material in sheet form has a tensile strength of about 250 N / m or greater.

[0086] The aerosol-generating material is 30 g / m 2 ~120g / m 2 In some cases, the aerosol-forming material may have an areal density of about 80 to 120 g / m. 2 , or approximately 70-110g / m 2 , or especially about 90-110 g / m 2 , or suitably about 100 g / m 2 (so that it does not readily separate when mixed with tobacco, such as cut rag tobacco). Such areal densities may be particularly suitable when the aerosol-generating material is included in the consumable / system in sheet form or as shredded sheets (described further herein below).

[0087] Aerosol-forming composition One aspect provides an aerosol-forming composition comprising an aerosol-forming material as defined herein.

[0088] In some embodiments, the aerosol-forming composition further comprises a tobacco material. In these embodiments, the tobacco material does not form part of the aerosol-forming material. That is, the tobacco material is present in the aerosol-forming composition separately from the aerosol-forming material.

[0089] Therefore, as used herein, the term "tobacco material" refers to any material containing tobacco or a derivative. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract.

[0090] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental. The tobacco material may also be tobacco particle "fines" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may include tobacco fiber and may be formed by casting, a Fourdrinier-based papermaking process with the post-addition of tobacco extract, or extrusion.

[0091] In some embodiments, the amount of aerosol former material in the aerosol-forming composition is about 5 to about 30 wt% of the aerosol-forming composition on a dry weight basis. For example, in some embodiments, the aerosol-forming composition includes about 10 to about 20 wt%, or about 13 to about 17 wt% of the aerosol former material. In some embodiments, the aerosol-forming composition includes about 15 wt% of the aerosol former material. This amount includes all aerosol former material present in the aerosol-forming composition, for example, aerosol former material provided in the aerosol-forming material, and any aerosol former material loaded onto the tobacco material.

[0092] While cut rag tobacco blends can typically be used alone in conventional combustion smoking articles such as cigarettes, they have been found to be unsuitable for use in non-combustion aerosol delivery devices. Without wishing to be bound by theory, it is believed that cut rag tobacco blends for use in cigarettes typically cannot be loaded with enough aerosol former material to provide a desirable inhalable aerosol when heated by a non-combustion aerosol delivery device.

[0093] Previous attempts to address this problem have involved replacing some or all of the cut rag tobacco in typical combustible tobacco blends with reconstituted tobacco, such as paper-like reconstituted tobacco. Paper-like reconstituted tobacco typically contains a higher percentage of aerosol-forming material. However, tobacco blends containing a high percentage of paper-like reconstituted tobacco can have undesirable sensory characteristics when heated by a non-combustible aerosol delivery device.

[0094] By providing an aerosol-forming material with a high aerosol-former material content in combination with a tobacco material, it is possible to generate an acceptable aerosol without requiring the presence of large amounts of reconstituted tobacco (thereby reducing the undesirable sensory characteristics associated with reconstituted tobacco).

[0095] In some embodiments, the tobacco material comprises or consists of flax tobacco (such as cut rag tobacco) that provides desirable sensory characteristics.

[0096] In some embodiments, the tobacco material comprises reconstituted tobacco in an amount less than about 50 wt%, 30 wt%, 10 wt%, 5 wt%, or 1 wt% of the tobacco material by dry weight. In some embodiments, the tobacco material is substantially free of reconstituted tobacco.

[0097] The tobacco material can be present in any form, but is typically shredded (e.g., cut into narrow strips). Suitably, the shredded tobacco material can be blended with the aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and aerosol-forming material throughout the aerosol-forming composition.

[0098] In some embodiments, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. It is possible to use a relatively large amount of leaf tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. Leaf tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises leaf tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In particular examples, the tobacco material comprises shredded tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0099] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0100] The tobacco material may typically be present in the aerosol-forming composition in an amount of about 50-95 wt%, or about 60-95 wt%, or about 70-90 wt%, or about 80-90 wt% of the aerosol-forming composition.

[0101] In some embodiments, the aerosol-forming material is present in the aerosol-generating composition in an amount of about 5-40 wt%, 5-30 wt%, 5-25 wt%, or 10-25 wt%, or 10-20 wt%. Surprisingly, by configuring the aerosol-generating material to have a relatively high aerosol former material content, a relatively small amount of aerosol-generating material (e.g., about 10-20 wt%) can be used in the aerosol-generating composition while still being used with a non-combustion aerosol delivery system to achieve a desirable aerosol.

[0102] In some embodiments, the aerosol-forming composition consists of, or consists essentially of, an aerosol-forming material and a tobacco material.

[0103] In some embodiments, the tobacco material itself contains the aerosol former material. Typically, the tobacco material contains shredded tobacco, and the aerosol former material is loaded into the tobacco strips. In examples, the tobacco material contains the aerosol former material in an amount of about 1-10 wt %, for example about 3-6 wt %, of the tobacco material. The aerosol former materials defined above with respect to the aerosol-generating material are also suitable for use in tobacco materials.

[0104] The aerosol-forming material may be present in the aerosol-forming composition in any suitable form. In an example, the aerosol-forming material is present in sheet form. In an example, the aerosol-forming material is present as a shredded sheet (e.g., the aerosol-forming composition includes small pieces of aerosol-forming material). In an example, the aerosol-forming material is present as a shredded sheet and blended with shredded tobacco material and / or shredded tobacco material, e.g., the aerosol-forming material and the tobacco material are in a similar form. Preferably, providing both the aerosol-forming material and the tobacco material as small pieces / shredded pieces allows for an aerosol-forming composition blend having a uniform distribution of the aerosol-forming material and the tobacco material throughout the aerosol-forming composition.

[0105] In an example, the aerosol-forming material has an areal density that is about 90-110% of the areal density of any tobacco material in the aerosol-forming composition. That is, the aerosol-forming material and the tobacco material have similar areal densities. Configuring the aerosol-forming material and the tobacco material to have similar areal densities allows for better blending of the aerosol-forming material and the tobacco material, typically when provided as shredded sheets. For example, aerosol-forming material in the form of shredded sheets and cut rag tobacco having similar areal densities can be blended to provide a more homogeneous aerosol-forming composition (e.g., better distribution of each component throughout the aerosol-forming composition).

[0106] Shredded tobacco (such as cut rag tobacco) typically has a cut width, expressed as cuts per inch (CPI), which refers to the width of the tobacco shreds. In some instances where the tobacco material is shredded (e.g., when the tobacco material comprises cut rag tobacco) and the aerosol-generating material is a shredded sheet, the cut width of the aerosol-generating material is approximately 90-110% of the cut width of the cut rag tobacco. That is, the aerosol-generating material and the tobacco material have similar cut widths or shred widths. Configuring the aerosol-generating material and the tobacco material to have similar cut widths allows for better blending of the aerosol-generating material and the tobacco material. For example, a shredded aerosol-generating material sheet and cut rag tobacco having similar cut widths can be blended to provide a more homogeneous aerosol-generating composition (e.g., better distribution of each component throughout the aerosol-generating composition). The tobacco material can have a length of 1-4 cm.

[0107] Carrier The aerosol-generating composition may include a carrier on which the aerosol-generating material is provided. The carrier functions as a support for forming the layer of aerosol-generating material, facilitating manufacturing. The carrier may also provide tensile strength to the layer of aerosol-generating material, facilitating handling.

[0108] In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or a combination thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the carrier itself is a laminated structure containing layers of materials selected from the aforementioned list. In some cases, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with a flavor or tobacco extract.

[0109] In some cases, the carrier may be magnetic. This feature may be used to secure the carrier to a non-combustion aerosol delivery device during use or to generate a particular aerosol-generating material shape. In some cases, the aerosol-generating composition may include one or more magnets that can be used to secure the material to an induction heater during use.

[0110] In some cases, the carrier may be substantially or entirely impermeable to gases and / or aerosols. This prevents aerosols or gases from passing through the carrier layer, thereby controlling the flow and ensuring that the flow is delivered to the user. This can also be used to prevent condensation or other deposition of gases / aerosols during use, for example, on the surface of a heater provided in the aerosol generating assembly. This may improve consumption efficiency and hygiene.

[0111] In some cases, the surface of the carrier that contacts the aerosol-generating material may be porous. For example, in one case, the carrier comprises paper. Porous carriers such as paper have been found to be particularly suitable. A porous (e.g., paper) layer contacts a layer of the aerosol-generating material, forming a strong bond. The aerosol-generating material may be formed by drying a slurry; without being limited by theory, it is believed that the slurry partially impregnates the porous carrier (e.g., paper), resulting in the carrier being partially bonded within the aerosol-generating material. This results in a strong bond between the aerosol-generating material and the carrier.

[0112] In some embodiments, the aerosol-forming material may be laminated to a carrier such as a paper sheet. In some embodiments, when the aerosol-forming material is formed from a slurry as described herein, a layer of the slurry may be formed on a carrier, such as a paper sheet.

[0113] Additionally, surface roughness can contribute to the strength of the bond between the aerosol-generating material and the carrier. The paper roughness (of the surface abutting the carrier) may suitably be in the range of 50 to 1000 Bekk seconds, suitably 50 to 150 Bekk seconds, suitably 100 Bekk seconds (measured at air pressure intervals of 50.66 to 48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface; air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a certain amount of air to penetrate between these surfaces is the "Bekk smoothness.")

[0114] Conversely, the surface of the carrier facing away from the aerosol-generating material may be positioned in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is positioned with a rougher side abutting the aerosol-generating material and a smoother side facing away from the aerosol-generating material.

[0115] In certain cases, the carrier may be a paper-backed foil. The paper layer abuts the aerosol-generating material, and the properties discussed in the previous paragraph are provided by this abutment. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also help conduct heat to the aerosol-generating material.

[0116] In other cases, the foil layer of a paper-backed foil abuts the aerosol-generating material, and the foil is substantially impermeable, thereby preventing water provided to the aerosol-generating material from being absorbed by the paper, which could weaken the structural integrity of the paper.

[0117] In some cases, the carrier is formed from or includes a metal foil, such as aluminum foil. The metal carrier may allow for better conduction of thermal energy to the aerosol-generating material. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the carrier includes a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, e.g., about 1 μm to about 10 μm, suitably about 5 μm.

[0118] In some cases, the carrier may have a thickness of from about 0.010 mm to about 2.0 mm, suitably from about 0.015 mm, 0.02 mm, 0.05 mm or 0.1 mm to about 1.5 mm, 1.0 mm or 0.5 mm.

[0119] consumables In another aspect of the present disclosure, there is provided a consumable for use in a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating composition, the aerosol-generating composition comprising an aerosol-generating material as defined herein.

[0120] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating composition and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure. The consumables may be used with any suitable non-combustion aerosol delivery device.

[0121] A consumable is an article containing or consisting of an aerosol-generating composition, some or all of which is intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating composition storage area, an aerosol-generating composition transfer component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating composition to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0122] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0123] An aerosol modifier is a substance, typically located downstream of the aerosol-generation area, configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0124] The aerosol modifier may be, for example, an additive or a sorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtering material.

[0125] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating composition. In some embodiments, the aerosol generator is a heater configured to provide thermal energy to the aerosol-generating composition to release one or more volatile substances from the aerosol-generating composition and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating composition without heating. For example, the aerosol generator may be configured to provide one or more of vibration, pressure increase, or electrostatic energy to the aerosol-generating composition.

[0126] Non-combustion aerosol delivery system In another aspect of the present disclosure, a non-combustion aerosol delivery system is provided that includes a consumable product as described herein and a non-combustion aerosol delivery device. According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating compositions (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0127] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0128] In some embodiments, the non-combustion aerosol delivery system is an aerosol-forming composition heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0129] In some embodiments, the non-combustion aerosol delivery device is a non-combustion heating device.

[0130] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating compositions, where one or more aerosol-generating compositions may be heated. In some embodiments, the hybrid system comprises an aerosol-generating composition described herein that comprises or consists of an aerosol-generating material and an additional liquid or gel aerosol-generating composition.

[0131] In some embodiments, the non-combustion aerosol delivery device is an e-cigarette hybrid device.

[0132] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0133] In some embodiments, a non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating composition or a heat transfer material proximate the heat-generating power source.

[0134] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0135] A non-combustion aerosol delivery system or device may include a heater configured to heat but not combust the aerosol-forming composition / material. In some cases, the heater may be a thin-film electrical resistive heater. In other cases, the heater may comprise an induction heater or the like. In still other cases, the heater may be a combustion-based heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use.

[0136] In some cases, the heater, when in use, can heat the aerosolizable material to between 120°C and 350°C without combustion. In some cases, the heater, when in use, can heat the aerosolizable material to between 140°C and 250°C without combustion. In some cases, when in use, substantially all of the aerosol-forming material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some cases, the solid is positioned between about 0.017 mm and 2.0 mm, suitably between about 0.1 mm and 1.0 mm, from the heater. These minimum distances may, in some cases, represent the thickness of the carrier supporting the aerosol-forming material. In some cases, the surface of the aerosol-forming material may be in direct contact with the heater.

[0137] In some cases, the heater may be embedded in the aerosol-forming composition / material. In some such cases, the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol-forming composition that is heated by induction.

[0138] The non-combustion aerosol delivery system may further include a cooling element and / or a filter. The cooling element, if present, may act or function to cool the gas or aerosol components. In some cases, the cooling element may act to cool the gas components so that they condense to form the aerosol. The cooling element may also act to move very hot portions of the device away from the user. The filter, if present, may include any suitable filter known in the art, such as a cellulose acetate plug.

[0139] In some cases, the non-combustion aerosol delivery system can be a non-combustion heating system. That is, the non-combustion aerosol delivery system may contain a solid material (but not a liquid aerosolizable material). Non-combustion heating devices are disclosed in WO 2015 / 062983, which is incorporated by reference in its entirety.

[0140] In some cases, the non-combustion aerosol delivery system may comprise an e-cigarette hybrid device. That is, the non-combustion aerosol delivery system may contain a solid aerosolizable material and a liquid aerosolizable material. The separate aerosolizable materials may be heated by separate heaters or by the same heater, and in some cases, the downstream aerosolizable material may be heated by the hot aerosol generated from the upstream aerosolizable material. An e-cigarette hybrid device is disclosed in International Publication No. 2016 / 135331, the entire contents of which are incorporated by reference.

[0141] The consumable product may alternatively be referred to herein as a cartridge. The consumable product may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some cases, the consumable product may further include a filter and / or a cooling element as previously described. In some cases, the consumable product may be enclosed in a packaging material such as paper.

[0142] The consumable product may further include ventilation apertures. The ventilation apertures may be provided in the sidewalls of the product. In some cases, the ventilation apertures may be provided in the filter and / or cooling element. These apertures may allow cool air to be drawn into the product during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0143] Ventilation enhances the production of visible heated volatiles from the article when the article is heated during use. The heated volatiles become visible through the process of 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 solidification of newly formed droplets from the heated volatiles.

[0144] In some cases, the ratio of the cool air to the sum of the heated volatiles and the cool air, known as the ventilation rate, is at least 15%. A ventilation rate of 15% allows the above-described method to make the heated volatiles visible. The visibility of the heated volatiles allows the user to identify that volatiles are being produced, adding to the sensory experience of the smoking experience.

[0145] In another example, the ventilation rate is 50% to 85% to provide additional cooling of the heated volatile components. In some cases, the ventilation rate can be at least 60% or 65%.

[0146] 1 and 2, there are shown a partial cutaway cross-sectional view and a perspective view of an example of an article consumable 101 ("Article"). 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, described below, and shown in FIGS. 5-7. During use, Article 101 can be removably inserted into the device shown in FIG. 5 at insertion point 20 of Device 1.

[0147] Exemplary article 101 is in the form of a substantially cylindrical rod including a body of aerosol-generating composition 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition includes an aerosol-generating material described herein. In some embodiments, the aerosol-generating composition may be included in sheet form. In some embodiments, the aerosol-generating composition may be included in shredded sheet form. In some embodiments, the aerosol-generating compositions described herein may be incorporated in both sheet form and shredded form.

[0148] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouth end segment 111. The article 101 has a first end 113, also known as the mouth end or proximal end, and a second end 115, also known as the distal end. The body of the aerosol-forming composition 103 is disposed toward the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the body of the aerosol-forming composition 103, between the body of the aerosol-forming composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-forming composition 103 and the filter segment 109. In other examples, there may be a gap between the body of the aerosol-forming composition 103 and the cooling segment 107, and between the body of the aerosol-forming composition 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the mouth end segment 111. Mouth end segment 111 is disposed adjacent filter segment 109 toward proximal end 113 of article 101. In one example, filter segment 109 is in abutting relationship with mouth end segment 111. In one embodiment, 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.

[0149] In one example, the rod of aerosol-forming composition 103 is between 34 mm and 50 mm in length, suitably between 38 mm and 46 mm in length, suitably 42 mm in length.

[0150] In one example, the overall length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

[0151] The axial end of the body of aerosol-forming composition 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 the axial end of the body of aerosol-forming composition 103.

[0152] The body of aerosol-forming composition 103 is joined to filter assembly 105 by an annular tipping paper (not shown), which is disposed approximately around the circumference of filter assembly 105 to surround it and extends partially along the length of the body of aerosol-forming composition 103. In one example, the tipping paper is made from 58 GSM tipping paper. In one example, the tipping paper has a length of 42 mm to 50 mm, suitably 46 mm.

[0153] In one example, cooling segment 107 is an annular tube that is disposed around and defines a cavity within the cooling segment. The cavity provides a chamber for the flow of heated volatile components generated from the body of aerosol-forming composition 103. 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 manufacture and during insertion into device 1 during use of article 101. In one example, the wall thickness of cooling segment 107 is approximately 0.29 mm.

[0154] Cooling segment 107 provides a physical displacement between aerosol-generating composition 103 and filter segment 109. The physical displacement provided by cooling segment 107 provides a thermal gradient across the length of cooling segment 107. In one example, cooling segment 107 is configured to provide a temperature difference of at least 40° C. between the heated volatile components entering a first end of cooling segment 107 and the heated volatile components exiting a second end of cooling segment 107. In one example, cooling segment 107 is configured to provide a temperature difference of at least 60° C. between the heated volatile components entering a first end of cooling segment 107 and the heated volatile components exiting a second end of cooling segment 107. This temperature difference across the length of cooling segment 107 protects temperature-sensitive filter segment 109 from the high temperatures of aerosol-generating composition 103 when heated by device 1. If no physical displacement is provided between the filter segment 109 and the body of the aerosol-generating composition 103 and the heating element of the device 1, the temperature-sensitive filter segment 109 may become damaged during use and therefore will not effectively perform its required function.

[0155] 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 particularly between 23 mm and 27 mm, even more particularly between 25 mm and 27 mm, suitably 25 mm.

[0156] The cooling segment 107 is made of paper, meaning that it is constructed of a material that does not produce compounds of concern, such as toxic compounds, when used adjacent to the heater of the device 1. In one example, the cooling segment 107 is fabricated 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.

[0157] In another example, cooling segment 107 is a recess created from rigid plug wrap or tipping paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and during insertion of article 101 into device 1 during use.

[0158] Filter segment 109 may be formed of any filter material sufficient to remove one or more volatile compounds from the heated volatile components of the aerosol-generating composition. In one example, filter segment 109 is made of a monoacetate material, such as cellulose acetate. Along with cooling, filter segment 109 reduces the irritation from the heated volatile components without depleting the amount of the heated volatile components to a level that is unsatisfactory for the user.

[0159] In some embodiments, a capsule (not shown) can be provided within filter segment 109. The capsule can be substantially centrally located within filter segment 109 across the diameter and along the length of filter segment 109. In other cases, it can be offset in one or more dimensions. The capsule can optionally contain a volatile component, such as a flavor or aerosol former material, if present.

[0160] 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 retraction resistance of article 101. Therefore, the selection of material for filter segment 109 is important in controlling the retraction resistance of article 101. Additionally, the filter segment performs a filtration function within article 101.

[0161] In one example, the filter segment 109 is made of 8Y15 grade filter tow material, thereby providing filtration for the heated volatilized material while also reducing the size of condensed aerosol droplets resulting from the heated volatilized material.

[0162] The presence of filter segment 109 provides an insulating effect by providing additional cooling to the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the temperature of the surface of filter segment 109 where the user's lips contact.

[0163] In one example, the filter segment 109 is between 6 mm and 10 mm in length, suitably 8 mm.

[0164] The mouth end segment 111 is an annular tube that is disposed about the mouth end segment 111 and defines a void therein. The void 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 manufacture and during insertion into the device 1 when the article is in use. 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, suitably 8 mm.

[0165] The mouth end segment 111 may be manufactured from a spirally wound paper tube that provides a hollow interior chamber yet maintains critical mechanical rigidity. A 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.

[0166] Mouth end segment 111 serves the function of preventing any liquid condensate that accumulates at the outlet of filter segment 109 from coming into direct contact with the user.

[0167] It should be appreciated 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 disposed within the tube to separate the mouth end segment 111 and the cooling segment 107.

[0168] 3 and 4, there are shown partially cut-away cross-sectional and perspective views of an example of an article 301. The reference numbers shown in Figures 3 and 4 are the same as the reference numbers shown in Figures 1 and 2, but are incremented by 200.

[0169] In the example of article 301 shown in Figures 3 and 4, article 301 is provided with a ventilation region 317 that allows air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation region 317 takes the form of one or more vent holes 317 formed through an outer layer of article 301. The vent holes may be located within cooling segment 307 to aid in cooling of article 301. In one example, ventilation region 317 comprises one or more rows of holes, preferably each row of holes arranged circumferentially around article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

[0170] In one example, there are 1 to 4 rows of ventilation holes to provide ventilation to article 301. Each row of ventilation holes may have 12 to 36 ventilation holes 317. The ventilation holes 317 may have a diameter of, for example, 100 to 500 μm. In one example, the axial spacing between rows of ventilation holes 317 is 0.25 mm to 0.75 mm, suitably 0.5 mm.

[0171] In one example, the vent holes 317 are uniform in size. In another example, the vent holes 317 vary in size. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical perforation of the cooling segment 307, or pre-perforation of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to provide effective cooling to the article 301.

[0172] In one example, the row of vent holes 317 is positioned at least 11 mm from the proximal end 313 of the article, suitably 17 mm to 20 mm from the proximal end 313 of the article 301. The positions of the vent holes 317 are positioned such that the user does not block the vent holes 317 while the article 301 is in use.

[0173] Providing a row of vent holes 17-20 mm from proximal end 313 of article 301 allows vent holes 317 to be located on the exterior of device 1 when article 301 is fully inserted into device 1, as can be seen in Figures 6 and 7. Locating the vent holes on the exterior of the device allows unheated air to enter article 301 from outside device 1 through the vent holes to assist in cooling article 301.

[0174] 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. The length of cooling segment 307 serves two functions: first, to provide a physical gap between the heater arrangement and temperature-sensitive filter arrangement 309 of device 1 when item 301 is fully inserted into device 1; and second, to allow vent hole 317 to be located within the cooling segment while also being located outside of device 1. As can be seen in FIGS. 6 and 7 , the majority of cooling element 307 is located within device 1. However, there is a portion of cooling element 307 that extends from device 1. It is this portion of cooling element 307 in which vent hole 317 is located that extends from device 1.

[0175] 5-7, an example of a device 1 is shown that is configured to heat an aerosol-generating composition to volatilize at least one component of the aerosol-generating composition, typically to form an inhalable aerosol. Device 1 is a heating device that releases compounds by heating, but not burning, the aerosol-generating composition.

[0176] The first end 3 is sometimes referred to herein as the mouth end or proximal end 3 of the device 1, and the second end 5 is sometimes referred to herein as the distal end 5 of the device 1. The device 1 has an on / off button 7 that allows the entire device 1 to be switched on and off as desired by the user.

[0177] Device 1 includes a housing 9 for arranging and protecting various internal components of device 1. In the illustrated example, housing 9 includes a unibody sleeve 11 that surrounds the periphery of device 1, with sleeve 11 capped with a top panel 17 that defines a general "top" of device 1 and a bottom panel 19 that defines a general "bottom" of device 1. In another example, the housing includes a front panel, a back panel, and a pair of opposing side panels in addition to top panel 17 and bottom panel 19.

[0178] Top panel 17 and / or bottom panel 19 may be removably secured to unibody sleeve 11 to allow easy access to the interior of device 1, or may be "permanently" secured to unibody sleeve 11 to, for example, 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 unibody sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0179] 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 article 101, 301 containing an aerosol-generating composition into and from the device 1 during use.

[0180] Housing 9 has disposed therein or secured thereto heater assembly 23, control circuitry 25, and power source 27. In this example, heater assembly 23, control circuitry 25, and power source 27 are laterally adjacent (i.e., adjacent when viewed end-on), with control circuitry 25 located substantially between heater assembly 23 and power source 27, although other arrangements are possible.

[0181] Control circuitry 25 may include a control device, such as a microprocessor arrangement, constructed and arranged to control the heating of the aerosol-forming composition within article 101, 301, as further described below.

[0182] Power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium-ion batteries, nickel batteries (such as nickel-cadmium batteries), alkaline batteries, and / or the like. Battery 27 is electrically coupled to heater arrangement 23 and, under the control of control circuitry 25, provides power as needed to heat the aerosol-forming composition within the article (to volatilize the aerosol-forming composition without burning it, as described).

[0183] An advantage of locating the power source 27 laterally adjacent to the heater structure 23 is that a physically larger power source 25 can be used without excessively lengthening the overall device 1. As will be appreciated, a physically larger power source 25 generally has a larger capacity (i.e., total electrical energy that it can deliver, often measured in ampere-hours or the like), and therefore may enable a longer battery life for the device 1.

[0184] In one example, the heater element 23 is in the form of a generally hollow cylindrical tube having a hollow internal heating chamber 29 into which, in use, the article 101, 301 containing the aerosol-forming composition is inserted for heating. Various configurations are possible for the heater element 23. For example, the heater element 23 may comprise a single heating element or may be formed from multiple heating elements arranged along the longitudinal axis of the heater element 23. The heating element, or each of the heating elements, may be annular or tubular around its periphery, or at least partially annular or partially tubular. In one example, the heating element, or each of the heating elements, may be a thin-film heater. In another example, the heating element, or each of the heating elements, may be made of a ceramic material. Examples of suitable ceramic materials include alumina, aluminum nitride, and silicon nitride ceramics, which may be layered and sintered. Other heating elements are also possible, including, for example, induction heating elements, infrared heating elements that heat by emitting infrared radiation, or resistive heating elements, formed, for example, by resistive electrical windings.

[0185] In one particular example, the heater element 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heater element 23 is sized so that when the article 101, 301 is inserted into the device 1, substantially the entire body of the aerosol-forming composition 103, 303 of the article 101, 301 is inserted into the heater element 23.

[0186] The heating element, or each of the heating elements, may be positioned so that selected zones of the aerosol-forming composition can be heated independently, as desired, e.g., sequentially (over time, as described above) or together (simultaneously).

[0187] The heater element 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 serves to reduce the passage of heat from the heater element 23 to the exterior of the device 1. This generally reduces heat loss and therefore helps reduce the power requirements of the heater element 23. The insulation 31 also serves to keep the exterior of the device 1 cool during operation of the heater element 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 of the insulation 31 are possible, including using insulating materials in addition to or instead of a double-walled sleeve, including, for example, suitable foam-type materials.

[0188] The housing 9 may further include various internal support structures 37 for supporting all internal components and the heating arrangement 23 .

[0189] Device 1 further includes a collar 33 extending around opening 20 and projecting from the opening into the interior of housing 9, and a generally tubular chamber 35 located between collar 33 and one end of vacuum sleeve 31. Chamber 35 further includes cooling structure 35f, in this example including a plurality of cooling fins 35f spaced along the exterior surface of chamber 35, each circumferentially arranged around the exterior surface of chamber 35. A gap 36 exists between hollow chamber 35 and article 101, 301 over at least a portion of the length of hollow chamber 35 when the article is inserted into device 1. A gap 36 exists circumferentially around article 101, 301 over at least a portion of cooling segment 307.

[0190] The collar 33 includes a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and projecting into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening span of the opening 20 at the location of the ridges 60 is smaller than the opening span of the opening 20 without the ridges 60. The ridges 60 are configured to mate with the articles 101, 301 inserted into the device 1 to help secure the articles within the device 1. Open spaces (not shown) defined by adjacent pairs of ridges 60 and the articles 101, 301 form ventilation paths around the outside of the articles 101, 301. These ventilation paths allow hot steam escaping from the articles 101, 301 to exit the device 1 and allow cooling air to flow into the device 1 and reach around the articles 101, 301 within the gap 36.

[0191] In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 1, as shown in Figures 5-7. Referring particularly to Figure 6, in one example, the body of the aerosol-forming composition 103, 303 disposed toward the distal end 115, 315 of the article 101, 301 is completely contained within the heater arrangement 23 of the device 1. The proximal end 113, 313 of the article 101, 301 extends from the device 1 and serves as the user's mouthpiece assembly.

[0192] During operation, the heater arrangement 23 heats the article 101, 301 to volatilize at least one component of the aerosol-forming composition from the body of the aerosol-forming composition 103, 303.

[0193] The primary flow path for heated volatile components from the body of the aerosol-forming composition 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, through the mouth-end segment 111, 313, and to the user. In one example, the temperature of the heated volatile components generated from the body of the aerosol-forming composition is between 60°C and 250°C, which may exceed an acceptable inhalation temperature for a user. As the heated volatile components travel through the cooling segment 107, 307, they cool, and some volatile components condense on the inner surface of the cooling segment 107, 307.

[0194] 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.

[0195] Method for producing aerosol-generating materials Another aspect of the present invention provides a method of making the aerosol-forming materials described herein, the method comprising: (a) providing a slurry comprising an aerosol former material, a binder comprising tartaric acid, a filler, and a solvent; (b) forming a layer of slurry; (c) drying the slurry to form an aerosol-generating material; may include:

[0196] In some embodiments, the method may further include aerating the slurry before the layer of slurry is formed.

[0197] In some embodiments, when the method includes an aeration step, the aeration step may include mixing the slurry under high shear conditions. However, it has surprisingly been found that by including tartaric acid in the slurry, a foamed aerosol-generating material can be formed without an aeration step. Instead, foam can be formed during the drying step. This can make it easier to form the foamed aerosol-generating material.

[0198] In some embodiments, when the method includes an aerating step, the aerating the slurry may include mixing the slurry under high shear conditions such that providing the slurry is part of aerating the slurry.

[0199] In some embodiments, a gas is bubbled through the slurry prior to the drying step (c).

[0200] The disclosures herein regarding the components of the aerosol-forming material apply equally to the slurry, which may contain these components in any of the proportions given herein for the composition of the aerosol-forming material.

[0201] If the aerosol-generating material includes an additional binder, including alginate and / or pectin, the slurry may further include a hardening agent and / or a hardening agent may be applied to the slurry. In this case, the method may further include hardening the slurry. In some examples, the steps of forming the layer of slurry, hardening the slurry, and / or drying the slurry are performed at least partially simultaneously (e.g., during electrospraying). In some examples, the steps of forming the layer of slurry, hardening the slurry with an optional hardening agent, and drying the slurry are performed sequentially in this order.

[0202] (b) The step of forming the layer of slurry typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by casting the slurry. In some instances, the slurry is applied to a substrate, and a layer can be formed on the substrate.

[0203] In examples, the drying step (c) removes about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt%, to about 80 wt%, 90 wt%, or 95 wt% (wet weight basis, WWB) of the water in the slurry.

[0204] In examples, the drying step (c) reduces the thickness of the cast material by at least 80%, suitably 85% or 87%. For example, if the slurry is cast to a thickness of 2 mm, the resulting dried aerosol-generating material may have a thickness of 0.2 mm.

[0205] In embodiments, the dry aerosol-forming material forms a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be within a range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm, e.g., 0.05-0.3 mm or 0.15-0.3 mm. Materials having a thickness of about 0.2 mm may be particularly suitable.

[0206] Another aspect of the present invention provides a method (hereinafter referred to as the second method) of making an aerosol-forming composition comprising the aerosol-forming material described herein. The method may include providing an aerosol-forming material and combining the aerosol-forming material and a tobacco material to provide the aerosol-forming composition.

[0207] In some cases, the aerosol-forming composition may include the aerosol former material in an amount of about 5 to about 30 wt % of the aerosol-forming composition on a dry weight basis.

[0208] The second method typically includes providing an aerosol-forming material as described above, providing a tobacco material as described above, and combining the aerosol-forming material and the tobacco material in a ratio such that an aerosol-forming composition is provided having an aerosol-former material content of about 5-30 wt% of the aerosol-forming composition.

[0209] In examples, the aerosol-generating material is provided as a shredded sheet. In particular examples, providing the aerosol-generating material includes shredding the sheet of aerosol-generating material to provide the aerosol-generating material as a shredded sheet. In examples, the tobacco material is shredded, and combining the aerosol-generating material and the tobacco material includes blending the shredded sheet of aerosol-generating material with the shredded tobacco material.

[0210] The slurry itself is an aspect of the present invention. In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry contains about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB). [Example]

[0211] An aerosol-forming material containing tartaric acid and having the composition shown in Table 1 was prepared. Wood pulp was partially refined using water under high shear conditions. A binder and a foaming agent were added, followed by glycerol and cellulose. The mixture was sheared at a high shear rate and cast to a height of 1 mm. The mixture had a solids content of 20% (i.e., dry matter) and a moisture content of 80%.

[0212] Percentage amounts are quoted on a dry weight basis unless otherwise specified.

[0213] [Table 1]

[0214] The packing value, tack and tensile strength of the aerosol-forming materials were measured as described above, and the results are shown in Table 2 below.

[0215] [Table 2]

[0216] As can be seen from Table 2, Examples 1 and 2, which contained tartaric acid, both exhibited higher loading values ​​and lower stickiness than Controls 1 and 2, which did not contain tartaric acid.

[0217] Example 1, which contains tartaric acid and 35% glycerol, has a higher tensile strength than Control 1, which does not contain tartaric acid. However, Example 2, which contains tartaric acid and 50% glycerol, has a lower tensile strength than Control 2.

[0218] All weight percentages (expressed as wt%) set forth herein are calculated on a dry weight basis (DWB) unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis refer to the totality of the extract or slurry or material other than water, and may include components that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages quoted on a wet weight basis (WWB) refer to all components, including water.

[0219] For the avoidance of doubt, where the term "comprises" is used herein in defining the invention or features of the invention, embodiments are also disclosed in which the invention or features may be defined using the terms "consists essentially of" or "consists of" instead of "comprises." Reference to a material "comprising" certain features means that those features are included in, contained within, or retained within the material.

[0220] The above-described embodiments should be understood as illustrative examples of the present invention. It should be understood that any feature described in connection with any one embodiment, aspect, or example may be used alone or in combination with other described features, or may be used in combination with one or more features of any other embodiment, aspect, or example, or any combination of any other embodiment, aspect, or example. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, as defined in the appended claims.

[0221] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. (i) an aerosol former material; (ii) a binder comprising tartaric acid, and (iii) Filler 1. An aerosol-generating material comprising:

2. The aerosol-forming material of claim 1 , further comprising an additional binder.

3. 3. The aerosol-generating material of claim 2, wherein the additional binder comprises one or more compounds selected from alginate, pectin, starch or a derivative thereof, such as hydroxypropyl starch or sodium carboxymethyl starch, cellulose or a derivative thereof, such as hydroxypropyl methylcellulose, pullulan, carrageenan, polysaccharide binders such as agar and agarose, gelatin, gums such as locust bean gum, xanthan gum, guar gum and acacia gum, silica or silicone compounds such as PDMS and sodium silicate, clays such as kaolin, and polyvinyl alcohol.

4. 4. The aerosol-forming material of claim 2 or 3, wherein the additional binder comprises locust bean gum.

5. The aerosol-forming material of any one of claims 2 to 4, wherein the additional binder comprises hydroxypropyl methylcellulose.

6. 3. The aerosol-forming material of claim 2, wherein the additional binder comprises locust bean gum and hydroxypropyl methylcellulose.

7. 7. The aerosol-forming material of claim 2, comprising from about 1 to about 15 wt % of the additional binder.

8. 8. The aerosol-forming material of claim 1, comprising from about 1 to about 10 wt %, for example from about 2 to about 7 wt %, of tartaric acid.

9. At least about 3 cm ３ 9. The aerosol-forming material according to claim 1, having a loading value of 0.1g / g.

10. 10. The aerosol-forming material according to any one of claims 1 to 9, having a tensile strength of at least 2 N / 15 mm.

11. 11. The aerosol-forming material of any one of claims 1 to 10, having a viscosity of less than 0.1 N.

12. Approximately 0.4 to approximately 0.9g / cm ３ 12. The aerosol-forming material of claim 1, having a density of

13. 13. The aerosol-generating material of any one of claims 1 to 12, wherein the aerosol former material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

14. 14. The aerosol-forming material of any one of claims 1 to 13, comprising from about 1 to about 60 wt% of the aerosol former material.

15. 15. The aerosol-forming material of any one of claims 1 to 14, comprising from about 10 to about 60 wt% of the aerosol former material.

16. 16. The aerosol-forming material according to any one of claims 1 to 15, comprising from about 20 to about 40 wt% of the aerosol former material, for example from about 40 to about 60 wt% of the aerosol former material.

17. 17. The aerosol-forming material according to any preceding claim, wherein the filler comprises wood pulp, cellulose and / or a cellulose derivative, such as wood pulp and / or microcrystalline cellulose.

18. 18. The aerosol-forming material of any one of claims 1 to 17, comprising from about 1 to about 80 wt% filler, for example from about 30 to about 70 wt% filler, for example from about 40 to about 60 wt% filler.

19. 19. The aerosol-forming material of any one of claims 1 to 18, which is free of carboxymethylcellulose or alginate, and / or free of active substances, and / or free of tobacco material.

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

21. 21. A consumable product for use in a non-combustion aerosol delivery device comprising the aerosol forming composition of claim 20.

22. 22. A non-combustion aerosol delivery system comprising the consumable of claim 21 and a non-combustion aerosol delivery device, wherein the non-combustion aerosol delivery device comprises an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

23. 23. A method of generating an aerosol using the non-combustion aerosol delivery system of claim 22, comprising heating the aerosol-forming material to a temperature of less than 350°C.

24. (a) (i) an aerosol former material; (ii) a binder comprising tartaric acid; (iii) a filler, and (iv) Solvent providing a slurry comprising: (b) forming a layer of the slurry; (c) drying the slurry to form the aerosol-forming material.

20. A method of forming the aerosol-forming material of any one of claims 1 to 19, comprising:

25. 25. The method of claim 24, wherein the solvent is water.

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