Aerosol-Generating Materials

Abstract

Described herein are aerosol-generating materials, rods comprising the aerosol-generating materials, articles and devices comprising the aerosol-generating materials, and methods for preparing the aerosol-generating materials, the aerosol-generating materials comprising a first fiber material comprising plant material, a second fiber material, an active substance, and a binder, wherein the first fiber material and the second fiber material are different.

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol-forming material including a fibrous material, and a non-combustion aerosol delivery system including the aerosol-forming material. [Background technology]

[0002] The aerosol-forming material is typically heated, for example, by a non-combustion aerosol delivery system, to form an aerosol that can be inhaled by a consumer. The aerosol-forming material may be made from a variety of different sources, including tobacco and / or non-tobacco materials. Summary of the Invention

[0003] According to a first aspect, an aerosol-generating material is described that includes a first fiber material including plant material, a second fiber material, an active substance, and a binder, wherein the first fiber material and the second fiber material are different.

[0004] According to a second aspect, an aerosol-generating rod is described, comprising an aerosol-generating material according to the first aspect.

[0005] According to a third aspect, a delivery system is described comprising an aerosol-generating material according to the first aspect or an aerosol-generating rod according to the second aspect.

[0006] According to a fourth aspect, a method for preparing an aerosol-generating material is described, comprising combining a first fibrous material comprising plant material, a second fibrous material, an active substance, a binder, and water to form a slurry; processing the slurry to form a sheet of aerosolizable material; and drying the sheet of aerosolizable material, wherein the first fibrous material and the second fibrous material are different.

[0007] According to a fifth aspect, an aerosol-forming material is described which is obtained or obtainable from a method according to the fourth aspect.

[0008] According to a sixth aspect, the use of an aerosol-forming material according to the first aspect in an article or delivery system is described.

[0009] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 shows a flowchart of a method of making an aerosol-forming material. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention relates to aerosol-generating materials. The present invention also relates to methods of making the aerosol-generating materials, uses of the aerosol-generating materials, articles for use in delivery systems, and systems comprising the aerosol-generating materials and devices.

[0012] The aerosol-generating material includes an aerosolizable component. During use, the aerosol-generating material generates an aerosol, e.g., a suspension of droplets or fine particles in a gas. The aerosol includes nicotine and other components generated by the aerosol-generating material. During use, the user inhales the aerosol. Therefore, it is important that the aerosol-generating material generate an aerosol that provides a suitable user experience and satisfaction.

[0013] The composition of aerosol contributes to user experience and satisfaction. One attribute that contributes to user experience and satisfaction is the nicotine content in the aerosol. Another attribute that contributes to user experience and satisfaction is the perceived harshness of the aerosol. Therefore, it is important to control the content of active substance and the harshness of the aerosol.

[0014] Certain actives may produce aerosols with a perceived harshness that is too high for the consumer.

[0015] In some examples, it has been found that aerosol-forming materials containing nicotine and one or more organic acids produce aerosols with a perceived harshness that is desirable. The inventors have noted that aerosol-forming materials containing pure nicotine, such as free-base nicotine, produce aerosols that may be perceived as excessively harsh by certain consumers. Therefore, it may be of interest to produce aerosols with a lower perceived harshness. The addition of an organic acid in the presence of free-base nicotine reduced the perceived harshness to a desirable level.

[0016] In some instances, aerosol-forming materials comprising nicotine and one or more organic acids have been noted to produce aerosols that exhibit a desirable overall flavor profile.

[0017] In another example, aerosol-forming materials including nicotine salts have been found to produce aerosols with a pleasant perceived harshness.

[0018] As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user; Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); Non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; and Aerosol-free delivery systems, such as lozenges, gums, patches, articles containing inhalable powders, and smokeless tobacco products such as snus and snuff, that deliver materials to the user without forming an aerosol Includes.

[0019] According to the present disclosure, a "combustion-based" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0020] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0021] In some embodiments, the present disclosure relates to components for use in combustion aerosol delivery systems, such as aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper.

[0022] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not or are not combusted to facilitate delivery to a user.

[0023] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0024] In some embodiments, the non-combustion aerosol delivery system is a vaporization device or an electronic cigarette, also known as an electronic nicotine delivery system (END).

[0025] In some embodiments, the non-combustion aerosol delivery system is a tobacco heating system, also known as a non-combustion heating system.

[0026] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-forming materials, where one or more aerosol-forming materials can be heated. Each of the aerosol-forming materials can be, for example, in the form of a solid, liquid, or gel. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material can include, for example, a tobacco material or a non-tobacco product.

[0027] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device, also referred to herein as an aerosol generating device, and consumables for use with the non-combustion aerosol delivery system.

[0028] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0029] It is envisioned that in some embodiments, a consumable that itself includes a means for powering an aerosol generating component may itself form a non-combustion aerosol delivery system.

[0030] In some embodiments, the non-combustion aerosol delivery system may include a power source and a controller. The power source may be a power source or a heat-generating power source. In some embodiments, the heat-generating power source comprises a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat-generating power source. In some embodiments, the power source, such as the heat-generating power source, is provided with an article to form the non-combustion aerosol delivery system.

[0031] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0032] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may comprise an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0033] In some embodiments, the substance to be delivered includes an active substance. As used herein, an 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, a dietary supplement, a nootropic, or a psychoactive agent. The active substance may be naturally occurring 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 another botanical substance.

[0034] In some embodiments, the active substance is a legally permitted recreational drug.

[0035] In some embodiments, the active agent comprises nicotine, e.g., a nicotine salt or free base nicotine. In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0036] As discussed herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0037] In some embodiments, the aerosol-generating material comprises a cannabinoid selected from the list consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannbitriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A), and mixtures thereof.

[0038] The active substance may be CBD or a derivative thereof.

[0039] As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, husks, shells, etc. Alternatively, the material may include synthetically derived active compounds that are naturally present in the botanical material. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary botanicals include eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, 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, lavender, and the like. The active ingredient in the composition may be citric acid, citric acid, citric acid (citric acid), ...The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Egyptian mint (Mentha niliaca), Mentha piperita, Cologne mint (Mentha piperita citrata cv), Candy mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Kentucky Colonel mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), Green mint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0040] 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 eucalyptus, cocoa, and hemp.

[0041] 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 star anise, rooibos, mint, and fennel.

[0042] An aerosol is a suspension of liquid, solid, or both particles in a gas.

[0043] In some embodiments, the fiber material comprises rooibos.

[0044] In some embodiments, the plant material comprises rooibos.

[0045] In some embodiments, the substance to be delivered comprises a flavor.

[0046] 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.Flavors and flavorings include naturally occurring flavor 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, 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 tea 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, damiento, maize The present invention may also include other additives such as joram, olive, 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 charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The flavors and flavorings may be imitation, synthetic, or natural ingredients, or blends thereof. The flavors and flavorings may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0047] 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, such as terpenes.

[0048] In some embodiments, the flavor may include a sensation elicitor intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, aroma or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucolyptol, WS-3.

[0049] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises berry fruit, citrus, and / or tropical fruit flavor components. In some embodiments, the flavor may comprise cucumber, blueberry, citrus, pineapple, strawberry, and / or red berry.

[0050] In some embodiments, flavors added to the aerosol-forming material may be selected to enhance the underlying aroma characteristics of the aerosol-forming material. For example, as described herein, it may be preferable for the fiber material to be free of tobacco material. Instead, a plant material may be selected as the primary component of the fiber material. In such examples, the plant material may produce a particularly neutral aroma profile; for example, it is noted that if rooibos, fennel, star anise, and / or mint are utilized in the aerosol-forming material, the resulting aerosol will be relatively neutral in aroma. When one or more of rooibos, fennel, star anise, and / or mint are used, the aroma produced may be enhanced when paired with flavors such as menthol, spearmint, peppermint, berry fruit, citrus fruit, and / or tropical fruit, or any combination of these flavors.

[0051] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material may be in solid, liquid, or semi-solid (such as a gel) form, for example, which may or may not contain active substances and / or flavorings.

[0052] The aerosol-forming materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0053] The aerosol-generating material may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, gathered to form a gathered sheet, or chopped to form a chopped sheet. The chopped sheet may comprise one or more strands or strips of aerosol-generating material.

[0054] The sheet or shredded sheet includes a first surface and a second surface opposite the first surface. The first and second surfaces have matching dimensions. The first and second surfaces of the sheet or shredded sheet may have any shape. For example, the first and second surfaces may be square, rectangular, oval, or circular. Irregular shapes are also contemplated.

[0055] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth), or may be uneven or irregular. For example, the first and / or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second surfaces are relatively rough.

[0056] The smoothness of the first and second surfaces may be affected by many factors, such as the areal density of the sheet or shredded sheet, the nature of the components that make up the aerosolizable material, or whether the surface of the material has been manipulated, for example, embossed, scored, or otherwise modified to impart a pattern or texture.

[0057] The areas of the first and second surfaces are defined by a first dimension (e.g., width) and a second dimension (e.g., length), respectively. The first and second dimensional measurements may have a ratio of 1:1 or greater than 1:1, and thus the sheet or shredded sheet may have an "aspect ratio" of 1:1 or greater than 1:1. As used herein, the term "aspect ratio" is the ratio of the first dimensional measurement of the first or second surface to the second dimensional measurement of the first or second surface. A "1:1 aspect ratio" means that the first dimensional measurement (e.g., width) and the second dimensional measurement (e.g., length) are identical. An "aspect ratio greater than 1:1" means that the first dimensional measurement (e.g., width) and the second dimensional measurement (e.g., length) are different. In some embodiments, the first and second surfaces of the sheet or shredded sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, or more.

[0058] The shredded sheet may comprise one or more strands or strips of aerosolizable material. In some embodiments, the shredded sheet comprises multiple (e.g., two or more) strands or strips of aerosolizable material. The strands or strips of aerosolizable material may have an aspect ratio of 1:1. In one embodiment, the strands or strips of aerosolizable material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosolizable material have an aspect ratio of about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio of the strands or strips is greater than 1:1, the strands or strips comprise a longitudinal dimension or length extending between a first end of the strand or strip and a second end of the strand or strip.

[0059] When a shredded sheet includes multiple strands or strips of material, the dimensions of each strand or strip may vary among different strands or strips. For example, a shredded sheet may include a first collection of strands or strips and a second collection of strands or strips, where the dimensions of the strands or strips in the first collection are different from the dimensions of the strands or strips in the second collection. In other words, the multiple strands or strips may include a first collection of strands or strips having a first aspect ratio and a second collection of strands or strips having a second aspect ratio that is different from the first aspect ratio.

[0060] The first dimension or cut width of the strand or strip of aerosolizable material is between 0.9 mm and 1.5 mm. If the strand or strip of aerosolizable material has a cut width less than 0.9 mm and is incorporated into an article for use in a non-combustion aerosol delivery system, the pressure drop across the article may be increased to a level that makes the article unsuitable for use in a non-combustion aerosol delivery device. However, if the strand or strip has a cut width greater than 2 mm (e.g., greater than 2 mm), it may be difficult to insert the strand or strip of aerosolizable material into the article during manufacture of the article. In a preferred embodiment, the cut width of the strand or strip of aerosolizable material is between about 1 mm and 1.5 mm.

[0061] The strands or strips of material are formed by shredding a sheet of aerosolizable material. The sheet of aerosolizable material may be cut widthwise, for example, by a cross-cut shredding method, to define a cut length of the strands or strips of aerosolizable material in addition to the cut width. The cut length of the shredded aerosolizable material is preferably at least 5 mm, e.g., at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolizable material may be less than 60 mm, less than 50 mm, or less than 40 mm.

[0062] In some embodiments, multiple strands or strips of aerosolizable material are provided, wherein at least one of the multiple strands or strips of aerosolizable material has a length greater than about 10 mm. At least one of the multiple strands or strips of aerosolizable material may alternatively or additionally have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the multiple strands or strips of aerosolizable material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0063] A consumable is an article containing or consisting of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0064] The susceptor is a material that can be heated by penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the varying magnetic field into the conductive material causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration of the varying magnetic field into the magnetic material 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.

[0065] An aerosol generator is a heater that can interact with an aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator can generate an aerosol from the aerosol-generating material without applying heat. For example, the aerosol generator can be capable of generating an aerosol from the aerosol-generating material without applying heat to the aerosol-generating material, such as by one or more of vibrational, mechanical, pressurized, or electrostatic means.

[0066] In some embodiments, the fiber material includes a plant material. A fiber material including a plant material may complement the flavor profile of any aerosol generated. For example, a plant material having a relatively neutral flavor profile may be selected. A neutral flavor profile may be described as a flavor profile that contains few strong flavors and / or a flavor profile that easily accommodates a top flavor load without significantly affecting the perception of the top flavor. For example, a fiber material containing reconstituted tobacco material may be described as producing an aerosol with a relatively neutral flavor profile. It may be advantageous to be able to produce an aerosol with a neutral flavor profile similar to reconstituted tobacco, but without using tobacco material.

[0067] In some embodiments, the fibrous material may be referred to as a substrate. It may be preferable for the substrate to be made from a non-tobacco material so that consumers may reduce their use of tobacco-based materials. However, consumers may wish to retain the physiological effects provided by nicotine. Therefore, providing a substrate made from a non-tobacco plant material that includes nicotine may be of interest to certain consumers.

[0068] In some embodiments, the aerosol-generating material includes a first fiber material including a plant material, a second fiber material, an active agent, and a binder, the first fiber material and the second fiber material being different. In certain situations, a consumer may desire to experience the effects of an active agent other than nicotine, such as one or more of the active agents listed above.

[0069] In some embodiments, the plant material may be any non-tobacco plant material. For example, the material may be derived from a species that is a member of the Asteracae family, the Fabaceae family, the Myrtaceae family, the Apiaceae family, Camellia taliensis, the Solanaceae family, the Brassicaceae family, the Caricaceae family, the Asclepiadaceae family, the Equisetaceae family, the Oleaceae family, the Lamiaceae family, and the tisanes. For example, the non-tobacco plant material may be selected from Matricaria species such as chamomile, Pimpinella anisum species such as anise, Foeniculum vulgare species such as fennel, Aspalathus linearis species such as jasmine, lavender, clove, eucalyptus, and rooibos.

[0070] In some embodiments, the non-tobacco plant material is selected from plant materials containing desirable aroma characteristics for use in non-combustion aerosol delivery systems. For example, the non-tobacco plant material may contain relatively few aroma compounds compared to traditional tobacco materials. Thus, the aerosol generated from the non-tobacco plant material may have a different profile of volatile compounds compared to the aerosol generated from tobacco materials. The non-tobacco plant material may deliver an aerosol that is considered desirable by consumers of tobacco-based delivery systems. In some embodiments, the non-tobacco plant material, when heated, may produce an aerosol with a sensory experience comparable to that provided by traditional combustion products, such as cigarettes. In some embodiments, the non-tobacco plant material is selected from seed-producing plants that do not develop persistent woody tissue and are often valued for their medical or sensory properties. In some embodiments, it may be preferable to provide an aerosol-generating material for use in non-combustion aerosol delivery systems that does not include any tobacco plant material.

[0071] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. 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, tobacco lamina, and / or reconstituted tobacco.

[0072] The inventors have identified particularly advantageous aerosols produced from an aerosol-forming material comprising a first fiber material comprising a plant-based material, a second fiber material, a nicotine source, and a binder, wherein the first and second fiber materials are different, particularly those that provide a desirable level of perceived harshness that is comparable to that provided by conventional combustion products.

[0073] The aerosol-generating material includes a binder configured to bind components of the aerosol-generating material together, for example, to form a sheet or shredded sheets. The binder may at least partially coat the surfaces of the first and second fibrous materials. Alternatively, the binder may hold the first and second fibrous materials together in a matrix.

[0074] The binder may be selected from one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0075] The binder may be present in an amount of about 1 to about 20% by weight of the sheet or chopped sheet, or in an amount of 1 to about 10% by weight of the sheet or chopped sheet of aerosolizable material. For example, the binder may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet or chopped sheet of aerosolizable material.

[0076] In some embodiments, the aerosol-generating material comprises a total fiber content of about 30% to about 95% by weight on a dry basis. For example, the total fiber content may be about 35% to about 95% by weight on a dry basis, e.g., about 40% to about 95% by weight, e.g., about 45% to about 95% by weight, e.g., about 50% to about 95% by weight, e.g., about 55% to about 95% by weight, e.g., about 60% to about 95% by weight, e.g., about 65% to about 95% by weight, e.g., about 65% to about 90% by weight, e.g., about 65% to about 85% by weight, e.g., about 65% to about 80% by weight, e.g., about 70% to about 80% by weight. In some embodiments, the total fiber content of the aerosol-generating material is about 65% by weight on a dry basis. In some embodiments, the total fiber content of the aerosol-generating material is about 70% by weight on a dry basis. In some embodiments, the total fibrous content of the aerosol-forming material is about 75% by weight on a dry basis.

[0077] In some embodiments, the fiber material comprises a first and a second fiber material. In some embodiments, the first fiber material is different from the second fiber material. When the first fiber material is different from the second fiber material, the properties of the aerosol-generating material, such as the generated aerosol, may be modified. For example, two different fiber materials may be combined that complement each other and provide a particularly pleasant / pleasant aerosol for the consumer.

[0078] In some embodiments, the first fiber material comprises a plant material, and the second fiber material comprises wood fiber / wood pulp. As used herein, wood fiber and wood pulp can be used to describe cellulose materials derived from cellulose materials that have little or no noticeable aroma. For example, the wood fiber and wood pulp can be similar in nature to the wood fiber / wood pulp used to make paper. The wood fiber and wood pulp can be obtained from a non-tobacco-based source.

[0079] In some embodiments, the first fiber material comprises a plant material, and the second fiber material comprises a different plant material. When the second fiber material comprises a plant material and the first fiber material, the aerosol may be modified to a greater extent. In particular, when two different plant materials are used, each produces a unique scent. Therefore, by selecting appropriate plant materials that complement each other, a desirable aerosol may be produced.

[0080] In some embodiments, the ratio of the first fiber material to the second fiber material may be about 20:1 to about 2:1. For example, the ratio of the first fiber material to the second fiber material may be about 18:1 to about 2:1, such as about 16:1 to about 2:1, such as about 14:1 to about 2:1, such as about 12:1 to about 2:1, or such as about 10:1 to about 2:1. For example, the ratio may be about 9:1 to about 2:1, such as about 8:1 to about 3:1, such as about 7:1 to about 3:1, such as about 6:1 to about 3:1, or such as about 5:1 to about 3:1. In some embodiments, the ratio of the first fiber material to the second fiber material may be about 4:1. In some embodiments, the ratio of the first fiber material to the second fiber material may be about 5:1. In some embodiments, the ratio of the first fiber material to the second fiber material may be about 6:1. The aerosol produced may be particularly favorable when the ratio of the first fiber material to the second material is about 20:1 to about 2:1. Furthermore, plant-based materials are generally more difficult to obtain and more expensive than wood pulp / wood fiber, which is inexpensive and readily available due to its use in paper production. Therefore, combining plant-based materials with wood fiber / wood pulp to produce an aerosol containing aroma compounds from plant-based materials may be desirable, but more cost-effectively produced than fiber materials containing 100% plant-based materials. It has been found that the addition of wood fiber / wood pulp in the above ratios has little or no effect on the sensory properties of the aerosol, and any effect can be compensated / covered / adjusted by the use of flavors.

[0081] In some embodiments, varying the amount of the first fiber material, e.g., including plant material, and the second fiber material, e.g., including wood fiber / wood pulp, allows the aerosol to be modified / tuned to a specific desired profile. For example, increasing the relative amount of plant material compared to wood fiber / wood pulp may increase the amount of aroma compounds derived from the plant material in the aerosol. Alternatively, decreasing the amount of plant material in the fiber material may produce an aerosol with fewer aroma compounds. If the aerosol contains fewer aroma compounds, any additional flavors added to the aerosol-generating material may be more noticeable and perceived to a greater extent by the user. Alternatively, producing an aerosol with fewer aroma compounds may allow the use of particularly subtle flavors, such as flavors derived from berry fruits, tropical fruits, and citrus fruits.

[0082] The exact amount of organic acid used in the aerosol-generating material may be defined in several ways. For example, the amount of organic acid used may be defined in relation to the aerosol-generating material, e.g., as a weight percentage of the aerosol-generating material. Alternatively, the amount of organic acid may be defined in relation to the nicotine content of the aerosol-generating material, e.g., by reference to the ratio of moles of nicotine to moles of acid.

[0083] Without wishing to be bound by any particular theory, it is understood that when the amount of acid in the aerosol-generating material is as described herein, the aerosol generated by the aerosol-generating material contains a particularly beneficial ratio of nicotine in the gas phase to nicotine in the fine particle / liquid phase (nicotine (gas):nicotine (fine particle / liquid)). That is, the ratio of nicotine (gas):nicotine (fine particle / liquid) in the aerosol generated by the aerosol-generating material of the present invention provides an improved user experience and satisfaction. This is believed to be because the use of the amount of acid defined herein allows for optimal protonation of nicotine (e.g., by altering the ratio of free base nicotine to protonated nicotine). Without wishing to be bound by theory, it is hypothesized that protonation of nicotine in the aerosol-generating material alters the ratio of nicotine (gas):nicotine (fine particle / liquid) by increasing the amount of nicotine present in the fine particle / liquid phase. The aerosol generated by the aerosol-generating material described herein delivers an appropriate amount of nicotine to the user. Furthermore, users report that such aerosol-forming materials are neither too harsh nor harsh enough. Thus, the aerosol-forming materials containing the acids described herein produce aerosols with appropriate nicotine content and perceived harshness. The addition of an acid may further improve the overall flavor profile of the consumable.

[0084] In some embodiments, the acid is selected from the group consisting of levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid. In some embodiments, the acid is a combination of benzoic acid and levulinic acid.

[0085] In particular, it is understood that the total amount of acid defined herein represents the minimum amount of acid necessary to provide an adequate nicotine level and sensory experience: using an amount of acid less than that set forth herein will result in a suboptimal amount of nicotine reaching the user.

[0086] It is further understood that the total amount of acid defined herein represents the maximum amount of acid necessary to provide an adequate nicotine level and sensory experience. Using an amount of acid greater than the amount set forth herein does not result in better performance and is therefore considered wasteful.

[0087] In some embodiments, the aerosol-forming material includes an organic acid. The total amount of the acid is about 0.1% to about 5% by weight of the aerosol-forming material. For example, the total amount of the acid is about 0.1% to about 5% by weight, about 0.5% to about 5% by weight, about 1% to about 5% by weight, about 1.5% to about 5% by weight, about 2% to about 5% by weight, or about 2.5% to about 5% by weight of the aerosol-forming material. For example, the total amount of the acid is about 2.5% to about 5% by weight, about 2.5% to about 4.5% by weight, about 2.5% to about 4% by weight, about 2.5% to about 3.5% by weight, or about 2.5% to about 3% by weight of the aerosol-forming material.

[0088] In some embodiments, the aerosol-forming material includes two or more different organic acids. When the aerosol-forming material includes two or more different organic acids, the total amount of the combined organic acids may be about 0.1% to about 5% by weight of the aerosol-forming material. For example, the total amount of the combined acids may be about 0.5% to about 5%, about 1% to about 5%, about 1% to about 4.5%, about 1% to about 4%, about 1% to about 3.5%, about 1% to about 3%, about 1% to about 2.5%, about 1% to about 2%, about 1% to about 1.75%, or about 1.3% to about 1.6% by weight of the aerosol-forming material.

[0089] In some embodiments, the aerosol-forming material includes an acid or two or more different organic acids, and the total amount of acid is about 50%, about 60%, about 70%, about 80%, about 90%, about 100%, about 110%, about 120%, about 130%, about 140%, about 150%, about 160%, about 170%, about 180%, or about 190% to about 200% of the moles of nicotine (i.e., moles of acid).

[0090] In some embodiments, the aerosol-forming material includes an acid, or two or more different organic acids, in an amount (i.e., moles of acid) relative to moles of nicotine, such as free base nicotine, of about 50% to about 250% relative to moles of nicotine, such as free base nicotine, for example, about 50% to about 200%, such as about 75% to about 175%, such as about 75% to about 150%, such as 100% to about 150%, or such as about 100% to about 125% relative to moles of nicotine, such as free base nicotine.

[0091] Those skilled in the art will readily appreciate that the amount of acid that may be included can be described in many other alternative ways. For example, the aerosol-forming material may include an amount of acid relative to a mole of nicotine, such as free base nicotine, such as about 0.5 to about 2.5 moles, e.g., about 0.5 to about 2.0 moles, e.g., about 0.75 to about 1.75 moles, e.g., about 0.75 to about 1.50 moles, e.g., about 1.0 to about 1.50 moles, e.g., about 1.0 to about 1.25 moles, or two or more different organic acids.

[0092] In some embodiments, the aerosol-forming material comprises an extract derived from botanical material.

[0093] The aerosol-generating material includes an aerosol-forming agent / aerosol-forming agent material. The total amount of aerosol-forming agent may be about 5% to about 35% by weight on a dry weight basis. In some embodiments, the total amount of aerosol-forming agent is about 10% to about 30% by weight on a dry weight basis. In some embodiments, the total amount of aerosol-forming agent is about 10% to about 25% by dry weight, e.g., about 12% to about 2%, e.g., about 15% to about 25%, e.g., about 17% to about 23%, e.g., about 18% to about 22%. In some embodiments, the total amount of aerosol-forming agent material is about 20% by weight on a dry weight basis. In some embodiments, the total amount of aerosol-forming agent material is about 25% by weight on a dry weight basis. In some embodiments, the total amount of aerosol-forming agent is about 17% by weight on a dry weight basis.

[0094] In this context, an "aerosol-forming agent" is an agent or material that facilitates the generation of an aerosol. Aerosol-forming agents may facilitate the generation of an aerosol by facilitating the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, aerosol-forming agents may improve the delivery of flavor from the aerosol-forming material.

[0095] The aerosol former materials have been found to improve the sensory performance of articles for use with aerosol-generating devices that include the aerosol-generating materials by aiding in the transport of compounds, such as flavor compounds, from the fiber material to the consumer. In some embodiments, the aerosol former materials described herein are flavored and / or include a flavor described herein.

[0096] Generally, any suitable aerosol-forming agent may be included in the aerosol-generating materials of the present invention. Suitable aerosol-forming agents include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristates, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate.

[0097] In some embodiments, the aerosol forming agent is selected from the group consisting 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, propylene carbonate, and mixtures thereof.

[0098] In some embodiments, the aerosol forming agent comprises glycerol in an amount of about 10% to about 90% by weight of the aerosol forming agent.

[0099] In some embodiments, the ratio of aerosol-forming agent to total fiber material is about 1:7 to about 1:3, such as about 1:6 to about 1:4, e.g., about 1:5. When the ratio of aerosol-forming agent to fiber material is within this range, the aerosol-forming material exhibits favorable storage characteristics and produces favorable aerosols.

[0100] In some embodiments, the ratio of aerosol-forming agent to first fiber material is about 1:6 to about 1:2, such as about 1:5 to about 1:2, for example, about 1:3 to about 1:2. In some embodiments, the ratio of aerosol-forming agent to first fiber material is about 1:1.

[0101] In some embodiments, the ratio of aerosol-forming agent to second fiber material is about 3:1 to about 1:3, such as about 2:1 to about 1:2, for example, about 1.5:1 to about 1:1.5, In some embodiments, the ratio of aerosol-forming agent to second fiber material is about 1:1.

[0102] In some embodiments, the aerosol-generating material comprises particles of a first fibrous material and a second fibrous material. Alternatively, the aerosol-generating material may be described as comprising a particulate fibrous material. Each particle of the fibrous material may have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from any point on the surface of a particle of fibrous material or on a particle of fibrous material to any other surface point on the same particle or particle surface of the fibrous material. The maximum dimension of a particle of a particulate fibrous material may be measured using scanning electron microscopy (SEM).

[0103] The maximum dimension of each particle of the fibrous material may be up to about 250 μm. In some embodiments, the maximum dimension of each particle of the fibrous material may be up to about 200 μm, such as up to about 150 μm, such as up to about 100 μm, e.g., up to about 75 μm. In some embodiments, the maximum dimension of each particle of the fibrous material may be up to about 1 mm.

[0104] The population of particles of the fibrous material may have a particular target particle size distribution, which may be defined by reference to the D10, D50, and D90 values ​​of the sample, and sieve analysis may be used to determine the particle size distribution of the particles of the fibrous material.

[0105] In some embodiments, the population of particles of the fibrous materials, i.e., the first fibrous material and the second fibrous material, may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the fibrous materials has a particle size distribution (D90) of at least about 110 μm, such as at least about 120 μm, such as at least about 130 μm, such as at least about 140 μm, for example at least about 150 μm.

[0106] In some embodiments, the population of particles of the fibrous material, i.e., the first fibrous material and the second fibrous material, may have a particle size distribution (D90) of at least about 200 μm, such as at least about 300 μm, for example at least about 400 μm, such as at least about 500 μm, for example at least about 600 μm, such as at least about 700 μm, for example at least about 800 μm, such as at least about 900 μm, for example at least about 1000 μm.

[0107] In some embodiments, the population of particles of the fibrous materials, i.e., the first fibrous material and the second fibrous material, may have a particle size distribution (D50) of from about 25 μm to about 125 μm. In some embodiments, the population of particles of the fibrous materials has a particle size distribution (D50) of from about 35 μm to about 115 μm, e.g., from about 45 μm to about 105 μm, e.g., from about 50 μm to about 100 μm.

[0108] In some embodiments, the population of particles of the fibrous materials, i.e., the first fibrous material and the second fibrous material, may have a particle size distribution (D10) of about 25 μm to about 75 μm. In some embodiments, the population of particles of the fibrous materials has a particle size distribution (D10) of about 30 μm to about 70 μm, e.g., about 35 μm to about 65 μm, e.g., about 40 μm to about 60 μm, e.g., about 45 μm to about 50 μm.

[0109] In some embodiments, the population of particles of the fibrous materials, i.e., the first fibrous material and the second fibrous material, may have a particle size distribution D10 of less than 50 μm, a D50 of between 50 μm and 100 μm, and a D90 of between 100 μm and 150 μm.

[0110] In some embodiments, a population of particles of a fibrous material, i.e., a first fibrous material and a second fibrous material, may have a particle size distribution D10 of 50 μm to 100 μm, D50 of 50 μm to 100 μm, and D90 of 50 μm to 100 μm. For example, a population of particles of a fibrous material may have a particle size distribution D10 of 50 μm to 60 μm, D50 of 60 μm to 80 μm, and D90 of 80 μm to 100 μm. If the D10, D50, and D90 are similar, the population distribution may be described as narrow. In other words, such a particle size distribution includes very little variation in particle size.

[0111] The maximum dimension and particle size distribution of particles affect the thickness of any aerosol-forming material produced from the particles. The inventors have found that providing particle size distributions such as those described herein, e.g., having a D90 of at least about 100 μm, or a D50 of about 25 μm to about 125 μm, or a D10 of about 25 μm to about 75 μm, or a D10 of less than 50 μm, a D50 of about 50 μm to about 100 μm, and a D90 of about 100 μm to about 150 μm, or a D10 of about 50 μm to about 60 μm, a D50 of about 60 μm to about 80 μm, and a D90 of about 80 μm to about 100 μm, allows for better mixing and improves interparticle bonding and chemical interactions. Additionally, providing particles within these ranges allows those skilled in the art to more broadly control the thickness of any sheet prepared from the particles.

[0112] The particle size of the particulate fibrous material can also affect the roughness of the sheet or shredded sheet of aerosol-forming material.

[0113] In some embodiments, the aerosol-generating material has a thickness of about 50 μm to about 450 μm. In some embodiments, the aerosol-generating material has a thickness of about 50 μm to about 400 μm, for example, about 75 μm to about 350 μm, for example, about 75 μm to about 300 μm, for example, about 75 μm to about 250 μm, for example, about 75 μm to about 200 μm, for example, about 100 μm to about 200 μm, for example, about 100 μm to about 175 μm, or for example, about 100 μm to about 150 μm.

[0114] In some embodiments, the aerosol-forming material has a water content of about 3% to about 15%. For example, the aerosol-forming material has a water content of about 3% to about 12%, such as about 3% to about 10%, such as about 3% to about 9%, such as about 3% to about 8%, such as about 4% to about 7%, or such as about 5% to about 6%. In some embodiments, the aerosol-forming material has a water content of about 5%.

[0115] In some embodiments, the aerosol-forming material is applied to a volume of about 2 cm 3 / g ~ approx. 10cm 3In some embodiments, the aerosol-forming material has a loading value of about 3 cm 3 / g ~ approx. 8cm 3 / g, for example, the aerosol-forming material may have a loading value of about 4 cm 3 / g ~ approx. 7cm 3 / g, for example, about 4 cm 3 / g ~ approx. 6cm 3 In some embodiments, the aerosol-forming material may have a loading value of about 5 cm / g. 3 / g. The filling value is about 2 cm 3 / g ~ approx. 10cm 3 / g, for example, about 5 cm 3 / g, a consumable product containing an aerosol-generating material can achieve the same hardness using less material, and therefore the total weight of material used to achieve the same / required fill value is less, resulting in cost savings on the product.

[0116] In some embodiments, the aerosol-forming material exhibits a burst strength of about 5 KPa to about 40 KPa. In some embodiments, the aerosol-forming material exhibits a burst strength of about 10 KPa to about 30 KPa. In some embodiments, the aerosol-forming material exhibits a burst strength of about 15 KPa to about 25 KPa, e.g., about 20 KPa to about 25 KPa. In some embodiments, the burst strength is about 20 KPa.

[0117] In one embodiment, the nicotine salt is selected from nicotine benzoate, nicotine citrate, and nicotine lactate, nicotine levulinate, or mixtures thereof.

[0118] According to one aspect of the present disclosure, there is provided a method for producing the aerosol-generating material described herein. The method includes combining a first fibrous material comprising a plant material, a second fibrous material, a nicotine source, a binder, and water to form a slurry. The slurry is then processed to form a sheet of aerosolizable material comprising the first fibrous material, the second fibrous material, the nicotine source, and the binder. The slurry may be processed by forming a layer of the slurry on a surface and then drying the slurry to remove at least a portion of the water and form a sheet of aerosol-generating material.

[0119] Water may be removed by evaporating the water from the slurry at ambient temperature and pressure (e.g., 25°C and 101 kPa). Alternatively, water may be removed by applying heat to the slurry (e.g., by heating to about 25°C) and / or by reducing the atmospheric pressure surrounding the slurry (e.g., to less than 101 kPa). Alternatively, water may be removed by applying heat to the cast sheet by heating the material to about 100°C to about 120°C.

[0120] In some embodiments, the slurry is processed by band casting the slurry.

[0121] After drying, the sheet of aerosolizable material can be cut into strips or strands of aerosolizable material. The strips or strands of aerosolizable material can be collected and formed into an article for use in a non-combustion aerosol delivery system. Suitable methods for cutting a sheet of aerosolizable material and collecting the sheet into an article can be found in WO 2019 / 057796. Optionally, the aerosolizable material can be crimped before being collected and formed into an article.

[0122] FIG. 1 illustrates how an article for use in a non-combustion aerosol delivery system containing aerosol-generating material can be manufactured. A slurry is formed containing first and second fibrous materials, a nicotine source, water, and a binder. Optionally, an aerosol-forming agent is added at this point. A layer of the slurry is formed on a surface. The layer of slurry is allowed to dry on the surface to form a sheet of aerosolizable material. A single-thickness sheet of aerosolizable material is fed to a shredding device. This can be accomplished, for example, by providing a bobbin of sheet material that can be continuously fed to the shredding device. Alternatively, individual portions of the aerosolizable material in sheet form, such as sheets known to those skilled in the art as flags, can be fed to the shredding device. The sheet of aerosolizable material is shredded to form strands or strips of aerosolizable material. Optionally, the aerosolizable material may be subjected to a second cutting step (not shown), such as a cross-cut shredding method, to obtain a predetermined cut length. The strands or strips of aerosolizable material are gathered together to form the aerosol-generating section of the article.

[0123] In some embodiments, the aerosol-forming material is in the form of a sheet or shredded sheet and weighs about 60 g / m 2 ~about 400g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2In some embodiments, the sheet or shredded sheet has an areal density of about 160 g / m 2 , 170g / m 2 , 180g / m 2 , 190g / m 2 , or 200 g / m 2 In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160 g / m 2 has an areal density of

[0124] Approximately 100g / m 2 ~about 250g / m 2 The areal density of about 180 gsm is believed to contribute to the strength and flexibility of the sheet or shredded sheet. Furthermore, the inventors have found that a rod comprising a shredded sheet of aerosolizable material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm can be filled such that the aerosolizable material remains in place within the rod, while maintaining a desired weight of tobacco material within the rod (e.g., about 300 mg) and delivering acceptable organoleptic characteristics (e.g., taste and odor) when heated in a non-combustion aerosol delivery device.

[0125] In one embodiment, the aerosol-generating material is in the form of a rod. The aerosol-generating rod may have a total weight of about 250 mg to about 350 mg. In one embodiment, the aerosol-generating rod may be enclosed in a packaging material having an air permeability of less than 100 Coresta units. The aerosol-generating rod may have a circumference of at least about 19 mm, preferably about 19 mm to about 23 mm or about 21 mm. This may facilitate insertion of the article into the aerosol-generating device.

[0126] As used herein, the term "rod" is used to describe a generally cylindrical element of generally circular, oval, or elliptical cross section.

[0127] For the compositions described herein, when amounts are given in weight percent, this refers to a dry weight basis unless specifically indicated to the contrary. Therefore, any water that may be present in the aerosol-forming material or any of its components is completely ignored for purposes of determining weight percent. The water content of the aerosol-forming materials described herein may vary, for example, from 5% to 15% by weight. The water content of the aerosol-forming materials described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content may be determined by Karl Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, any components other than water are included in the weight of the aerosol-forming material, even if the aerosol-forming material is a component in a liquid phase, such as glycerol or propylene glycol.

[0128] In some embodiments, a system comprises an article described herein, wherein the aerosol-generating device is configured to receive at least a portion of the article including an aerosol-generating material, heat the portion of the article including the aerosol-generating material, and generate an aerosol from the aerosol-generating material.

[0129] In some embodiments, the aerosol-generating material may be disposed in an aerosol-generation section of the article. In use, the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mmH2O. In some embodiments, the aerosol-generation section exhibits a pressure drop across the aerosol-generation section of about 15 to about 30 mmH2O.

[0130] In some embodiments, the article comprises a tipping tip and a cylindrical rod of aerosol-forming material connected directly or indirectly to the tipping tip. A tipping tip wrapper, also referred to herein as tipping paper, is wrapped over a portion of the rod of aerosol-forming material along the entire length of the tipping tip and has adhesive on an inner surface of the tipping paper to connect the tipping tip and the rod.

[0131] In some embodiments, the tipping paper extends 5 mm over the rod of aerosol-generating material, but may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to provide a secure attachment between the tipping tip and the rod. The tipping paper may have a basis weight higher than that of the plug wrap used in the article for use with the aerosol-generating device, for example, 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. It has been found that these basis weight ranges result in tipping paper that has acceptable tensile strength while also being flexible enough to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. The circumference of the tipping paper, once wrapped around the tipping tip, may be approximately 21 mm.

[0132] According to some embodiments, there is provided an article for use in an aerosol delivery system, the article comprising: an aerosol-forming material or substrate; a mouthpiece downstream of the aerosol-forming material; and a wrapping material, the wrapping material comprising a warming agent material, wherein a portion of the mouthpiece wrapping material proximate the downstream end of the mouthpiece contacts a consumer's lips during use.

[0133] The tipping wrap may be positioned to enclose the tipping in a region between the upstream and downstream ends of the tipping. The tipping wrap may be positioned such that when the article is inserted into the heating device, a portion of the tipping wrap is heated to the same or a similar temperature as the aerosol-forming material.

[0134] In some embodiments, the tipping wrapper comprises a warming agent material. The warming agent material may comprise a flavoring agent, as described herein. In some embodiments, the flavoring agent may be licorice, rose oil, vanilla, lemon oil, orange oil, mint flavor, preferably menthol and / or mint oil from any species of the genus Mentha, such as peppermint oil and / or spearmint oil, or lavender, fennel, or anise. In preferred embodiments, the warming agent material comprises a sugar and / or a sugar substitute (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol). Additionally or alternatively, the warming agent material may comprise a material that delivers a cooling, hot, or sour sensation to the consumer during use of the article.

[0135] In some embodiments, the warming agent material may include one or more of a pH adjuster, a stabilizer, and / or an antioxidant, which may help to extend the shelf life of the tipping wrapper and, therefore, the article.

[0136] The warming material may be encapsulated in an encapsulating material, for example, the warming material may be provided in the form of microcapsules that are applied to the packaging material.

[0137] The tipping wrapper may have an inner surface and an outer surface, and the warmth material may be present on at least a portion of the inner and / or outer surfaces of the wrapper. For example, the warmth material may be disposed on the outer surface of the tipping wrapper in an area that contacts the consumer's lips during use. By disposing the warmth material on the outer surface of the tipping wrapper, the warmth material may be transferred to the consumer's lips during use. By transferring the warmth material to the consumer's lips during use of the article, the organoleptic properties (e.g., taste) of the aerosol generated by the aerosol-generating substrate may be modified. For example, the warmth material may impart a flavor to the aerosol generated by the aerosol-generating substrate. The warmth material may be at least partially soluble in water so that it can be transferred to the user via the consumer's saliva.

[0138] Suitably, a relatively small amount of the warming material may be required to modify the sensory properties delivered to the consumer during use of the article, although this will depend to some extent on the properties of the warming material, as the minimum amount required to modify the sensory properties will vary between different warming materials. This can have the advantage that the addition of the warming material to the tipping wrap may not significantly increase the overall weight of the article.

[0139] Example 1 An aerosol-forming material having the composition shown in Table 1 was prepared.

[0140] [Table 1]

[0141] The aerosol-generating material was prepared by adding rooibos, wood pulp / wood fiber, glycerol, nicotine, benzoic acid, and guar gum to water to form a slurry, which was then cast into a sheet and dried to form the aerosol-generating material.

[0142] Example 2 Aerosol-forming materials were prepared having the compositions shown in Table 2.

[0143] [Table 2]

[0144] The aerosol-forming material of Example 2 was prepared in a similar manner to the aerosol-forming material of Example 1. That is, rooibos, wood pulp / wood fiber, glycerol, nicotine, benzoic acid, levulinic acid, and guar gum were added to water to form a slurry. The slurry was then cast into a sheet and dried to form the aerosol-forming material.

[0145] 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. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. a first fibrous material comprising a plant material; a second fibrous material; and an active substance; a binder; and 1. An aerosol-forming material comprising: The aerosol-forming material, wherein the first fiber material and the second fiber material are different.

2. 10. The aerosol-forming material of claim 1, wherein the aerosol-forming material is free or substantially free of tobacco material.

3. 3. The aerosol-forming material of claim 1, wherein the plant material is selected from the list consisting of rooibos, star anise, fennel, mint, and combinations thereof.

4. 4. The aerosol-forming material of claim 3, wherein the plant material is rooibos.

5. 4. The aerosol-forming material of claim 3, wherein the botanical material is star anise, fennel, or mint, and combinations thereof.

6. 6. The aerosol-forming material of claim 1, wherein the second fibrous material comprises wood fibre / wood pulp.

7. 7. The aerosol-forming material of claim 1, wherein the ratio of the first fiber material to the second fiber material is from about 20:1 to about 2:

1.

8. 6. The aerosol-forming material of claim 1, wherein the binder is a natural gum binder selected from the list consisting of alginate, pectin, starch, cellulose, natural gum, silica, silicone compound, clay, and polyvinyl alcohol.

9. 9. The aerosol-forming material of claim 1, wherein the binder is selected from the list consisting of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

10. 10. The aerosol-forming material of claim 1, wherein the binder is present in an amount of from about 1% to about 20% by dry weight.

11. The aerosol-forming material of any one of claims 1 to 10, wherein the active substance comprises a nicotine salt.

12. 12. The aerosol-forming material of claim 11, wherein the nicotine salt is selected from the list consisting of nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof.

13. 11. The aerosol-forming material of claim 1, wherein the active substance comprises free base nicotine and an organic acid.

14. 14. The aerosol-forming material of claim 13, wherein the organic acid is selected from the list consisting of lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, 2-methylvaleric acid, and mixtures thereof.

15. 15. The aerosol-forming material of claim 14, wherein the organic acid is present in a ratio of about 0.5 to about 2.5 moles per mole of free base nicotine.

16. 16. The aerosol-forming material of any one of claims 1 to 15, wherein the active substance is a non-nicotine active substance.

17. The aerosol-generating material of any one of claims 1 to 16, further comprising an aerosol former material.

18. 18. The aerosol-generating material of claim 17, wherein the aerosol former material is present in an amount of about 5% to about 35% on a dry weight basis.

19. 19. The aerosol-generating material of claim 17 or 18, wherein the aerosol former material is selected from the list consisting of glycerin, 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.

20. 20. The aerosol-forming material of any one of claims 1 to 19, comprising a total fibrous material content of from about 70% to about 95% by weight on a dry basis.

21. 21. The aerosol-forming material of any one of claims 1 to 20, having a thickness of from about 100 μm to about 450 μm.

22. Approximately 2 cm ３ / g ~ approx. 10cm ３ 22. The aerosol-forming material of claim 1, having a loading value of 0.1g / g.

23. An aerosol-generating rod comprising the aerosol-generating material of any one of claims 1 to 22.

24. A delivery system comprising an aerosol-generating material according to any one of claims 1 to 22 or an aerosol-generating rod according to claim 23.

25. 1. A method for preparing an aerosol-forming material, comprising: combining a first fibrous material comprising plant material, a second fibrous material, an active material, a binder, and water to form a slurry; processing the slurry to form a sheet of aerosolizable material; drying the sheet of aerosolizable material; Including, The method wherein the first and second fibrous materials are different.

26. 26. The method of claim 25, wherein the method includes shredding the sheet to form a shredded sheet comprising a plurality of strips of the aerosolizable material, and / or the step of processing the slurry includes casting the sheet in a band caster.

27. 27. An aerosol-forming material obtained or obtainable from the method of claim 25 or 26.

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