Aerosol-Generating Materials

Abstract

1. An aerosol-generating material comprising a sheet or chopped sheet of aerosolizable material comprising non-tobacco plant material, an aerosol former material, a binder, and an active agent, wherein the sheet or chopped sheet has a thickness of at least about 100 μm and a weight of about 100 g / m 2 ~about 250g / m 2 [0003] Described herein are aerosol-forming materials, methods for preparing the aerosol-forming materials, and devices and systems including the aerosol-forming materials, each having an areal density of 1000 .mu.m or less.

Description

[Technical Field]

[0001] The present disclosure relates to aerosol-forming materials, methods for making aerosol-forming materials, and articles including aerosol-forming materials for use in non-combustion aerosol delivery devices. [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, there is provided an aerosol-generating material comprising a sheet or chopped sheet of aerosolizable material comprising non-tobacco plant material, an aerosol former material, a binder, and an active substance, the sheet or chopped sheet having a thickness of at least about 100 μm and a weight of about 100 g / m 2 ~about 250g / m 2 An aerosol-generating material is described having an areal density of

[0004] According to a second aspect, a method for preparing an aerosol-generating material includes combining non-tobacco plant material, an aerosol-forming agent, an active agent, 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 to a thickness of about 100 μm and a weight of about 100 g / m. 2 ~about 250g / m 2 and forming a sheet of aerosolizable material having an areal density of

[0005] According to a third aspect, the use of an aerosol-forming material according to the first aspect in a delivery system, such as a non-combustion aerosol delivery system, is described.

[0006] According to a fourth aspect, an aerosol-generating rod is described, comprising an aerosol-generating material according to the first aspect.

[0007] According to a fifth aspect, a delivery system is described comprising an aerosol-generating material according to the first aspect or an aerosol-generating rod according to the fourth aspect.

[0008] According to a sixth aspect, an aerosol-forming material is described which is obtained or obtainable from a method according to the second aspect.

[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. [Figure 2] 1 is a cross-sectional side view of an article for use with a non-combustion aerosol delivery device. 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 the aerosol contributes to the user's experience and satisfaction. One attribute that contributes to the user's experience and satisfaction is the nicotine content in the aerosol. Another attribute that contributes to the user's experience and satisfaction is the perceived harshness of the aerosol. Therefore, it is important to control the nicotine content and harshness of the aerosol.

[0014] In some instances, aerosol-forming materials have been found to produce aerosols with perceived harshness that is too high for consumers.

[0015] For example, the inventors have noted that aerosol-forming materials containing pure nicotine, e.g., 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 lower perceived harshness. It has been found that aerosol-forming materials containing nicotine and an organic acid produce aerosols with harshness that is perceived as desirable. The addition of an organic acid in the presence of free-base nicotine reduced the perceived harshness to a desirable level.

[0016] In another example, aerosol-forming materials including nicotine salts have been found to produce aerosols with a pleasant perceived harshness.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0023] 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).

[0024] In some embodiments, the non-combustion aerosol delivery system is a tobacco heating system, also known as a non-combustion heating system.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device during use.

[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 one embodiment, an aerosol-generating material includes a sheet or chopped sheet of aerosolizable material comprising non-tobacco plant material, an aerosol former material, a binder, and an active agent, wherein the sheet or chopped sheet has a thickness of at least about 100 μm and a mass of at least about 100 g / m 2 ~about 250g / m 2 There is an aerosol-generating material having an areal density of

[0034] In some embodiments, the substance to be delivered comprises 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.

[0035] The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0036] In some embodiments, the active substance is a legally permitted recreational drug.

[0037] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0038] 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.

[0039] 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.

[0040] In some embodiments, the aerosol-forming material comprises CBD or a derivative thereof.

[0041] 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).

[0042] 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.

[0043] 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.

[0044] An aerosol is a suspension of liquid, solid, or both particles in a gas.

[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] The sheet or chopped sheet of aerosolizable material has a thickness of at least about 100 μm. The sheet or chopped sheet may have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0064] The thickness of the sheet or shredded sheet may vary between the first and second surfaces. In some embodiments, the individual strips or pieces of aerosolizable material have a minimum thickness of about 100 μm across the area of ​​the strip or piece. In some cases, the individual strips or pieces of aerosolizable material have a minimum thickness of about 0.05 mm or about 0.1 mm across the area of ​​the strip or piece. In some cases, the individual strips, strands, or pieces of aerosolizable material have a maximum thickness of about 1.0 mm across the area of ​​the strip, strand, or piece. In some cases, the individual strips or pieces of aerosolizable material have a maximum thickness of about 0.5 mm or about 0.3 mm across the area of ​​the strip or piece.

[0065] The thickness of the sheet may be determined using ISO 534:2011 "Paper and Board - Determination of Thickness".

[0066] Approximately 100g / m 2 ~about 250g / m 2 It is hypothesized that sheets or shredded sheets having a thickness of at least about 100 μm, along with an areal density of at least about 100 μm, are less likely to tear, break, or otherwise deform during the manufacture of the sheets or shredded sheets. A thickness of at least about 100 μm can have a positive effect on the overall structural integrity and strength of the sheets or shredded sheets. For example, sheets or shredded sheets having a thickness of at least about 100 μm can have good tensile strength and therefore be relatively easy to process.

[0067] The thickness of the sheet or chopped sheet is also believed to affect the areal density of the sheet or chopped sheet, i.e., increasing the thickness of the sheet or chopped sheet may increase the areal density of the sheet or chopped sheet.

[0068] Conversely, decreasing the thickness of the sheet or chopped sheet may decrease the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, strand, piece, or sheet of aerosolizable material, where areal density is calculated by measuring the surface area and weight of a given strip, strand, piece, or sheet of aerosolizable material.

[0069] The sheet or shredded sheet of aerosol-forming material has a mass of about 100 g / m 2 ~about 250g / 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 2 In 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

[0070] Approximately 100g / m 2 ~about 250g / m 2The 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 so that the aerosolizable material remains in place within the rod, while maintaining a desired weight of material within the rod (e.g., about 300 mg), and delivering acceptable organoleptic properties (e.g., taste and odor) when heated in a non-combustion aerosol delivery device.

[0071] In some embodiments, the aerosolizable material is 160 g / m 2 ~200g / m 2 and a minimum thickness of 200-250 μm, or 160 g / m 2 ~200g / m 2 and a minimum thickness of 210 to 240 μm.

[0072] The flexibility of the sheet or shredded sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. The combination of thickness and areal density of the aerosolizable material described herein is believed to provide a relatively flexible sheet or shredded sheet. When the aerosolizable material is incorporated into an article for use in a non-combustion aerosol delivery device, this flexibility can provide various advantages. For example, the strands or strips can easily deform and bend when an aerosol generator is inserted into the aerosol-generating material, thus facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosolizable material.

[0073] Preferably, the strands or strips or aerosolizable material are uncrimped, which further improves the ease with which the aerosol generator can be inserted into the aerosol-generating material. Without wishing to be bound by theory, it is believed that this is because uncrimped strands or strips of aerosolizable material offer less resistance to insertion of the aerosol generator.

[0074] The inventors have found that the areal density of the sheet or chopped sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second surfaces can be adjusted.

[0075] The average volume density of a sheet or shredded sheet of aerosol-forming material may be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 , about 0.3g / cm 3 , or about 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~Approx. 0.9g / cm 3 is.

[0076] The sheet or shredded sheet may have a tensile strength of at least 4 N / 15 mm. In some embodiments, the sheet or shredded sheet has a tensile strength of up to about 30 N / 15 mm, up to about 20 N / 15 mm, or up to about 15 N / 15 mm.

[0077] The inventors have found that if the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, the sheet or shredded sheet may tear, break, or otherwise deform during manufacture of the sheet or shredded sheet and / or subsequent incorporation into an article for use in a non-combustion aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0078] The sheet or shredded sheet of aerosolizable material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0079] If the burst strength is too low, the sheet or shredded sheet may be relatively brittle. As a result, breakage of the sheet or shredded sheet may occur during the process of producing the aerosolizable material. For example, if the sheet is shredded by a cutting process to form shredded sheets, the sheet may shatter or break into pieces or fragments when cut.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] The fiber material includes non-tobacco plant materials. The non-tobacco plant materials may complement the flavor profile of any aerosol generated. For example, non-tobacco plant materials may be selected that have a relatively neutral flavor profile. 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.

[0084] In some embodiments, the non-tobacco plant fiber material may be referred to as a substrate. Substrates made from non-tobacco materials allow consumers to reduce their use of tobacco-based materials if they so desire. However, consumers may wish to retain the physiological effects provided by nicotine. Therefore, providing a substrate made from non-tobacco plant materials that includes nicotine may be of interest to certain consumers.

[0085] In certain situations, a consumer may desire to experience the effects of an active substance other than nicotine, such as one or more of the active substances listed above.

[0086] In some embodiments, the non-tobacco 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.

[0087] 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.

[0088] 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.

[0089] The inventors have discovered an aerosol generated from an aerosol-generating material comprising a sheet or chopped sheet of aerosolizable material comprising non-tobacco plant material, an aerosol former material, a binder, and a nicotine source, wherein the sheet or chopped sheet has a thickness of at least about 100 μm and a weight of at least about 100 g / m 2 ~about 250g / m 2In particular, the perceived harshness is at a desirable level and comparable to that provided by conventional combustion products.

[0090] 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, and the binder may at least partially coat the surfaces of the first and second fibrous materials.

[0091] 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.

[0092] 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.

[0093] In some embodiments, the aerosol-forming material comprises about 60% to about 95% non-tobacco plant material by weight on a dry basis. For example, about 65% to about 95% by weight on a dry basis, such as about 65% to about 90% by weight, such as about 65% to about 85% by weight, such as about 65% to about 80% by weight, or about 70% to about 80% by weight. In some embodiments, the total non-tobacco plant material content of the aerosol-forming material is about 65% by weight on a dry basis. In some embodiments, the total non-tobacco plant material content of the aerosol-forming material is about 70% by weight on a dry basis. In some embodiments, the total non-tobacco plant material content of the aerosol-forming material is about 75% by weight on a dry basis.

[0094] In some embodiments, the aerosol-forming material further comprises a fibrous material, such as wood fiber / wood pulp. In some embodiments, the aerosol-forming material comprises the fibrous material in an amount of about 5% to about 30% by weight on a dry basis. For example, the fibrous material may be present in an amount of about 5% to about 25% by weight on a dry basis, such as about 5% to about 20% by weight, or about 5% to about 15% by weight.

[0095] In some embodiments, the non-tobacco plant material and the fiber material are different. When the first fiber material and the second fiber material are different, the properties of the aerosol-generating material, such as the aerosol generated, may be altered. For example, two different fiber materials may be combined that complement each other and provide a particularly pleasant / pleasant aerosol for the consumer.

[0096] In some embodiments, the aerosol-forming material includes non-tobacco plant materials and fiber materials, which may be collectively referred to as fillers. In some embodiments, the aerosol-forming material includes a total filler content of about 60% to about 95% by weight on a dry weight basis. For example, the aerosol-forming material may include a total filler content of about 65% to about 95% by weight on a dry weight basis, 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 filler content of the aerosol-forming material is about 65% by weight on a dry weight basis. In some embodiments, the total filler content of the aerosol-forming material is about 70% by weight on a dry weight basis. In some embodiments, the total filler content of the aerosol-forming material is about 75% by weight on a dry weight basis.

[0097] As used herein, wood fiber and wood pulp may be used to describe cellulose materials derived from cellulose materials that have little or no noticeable flavor. For example, the wood fiber and wood pulp may be similar in nature to the wood fiber / wood pulp used to make paper. The wood fiber and wood pulp may be obtained from a non-tobacco-based source.

[0098] In some embodiments, the fiber material comprises a non-tobacco plant material. In some embodiments, the aerosol-generating material comprises two different non-tobacco plant materials. In some embodiments, the aerosol-generating material comprises three or more different non-tobacco plant materials. When the aerosol-generating material comprises two or more plant materials, the aerosol may be modified to a greater extent. In particular, when multiple different plant materials are utilized, each will produce a unique aroma. Therefore, by selecting appropriate plant materials that complement each other, a desirable aerosol may be generated.

[0099] In some embodiments, the ratio of non-tobacco plant material to fiber material may be about 20:1 to about 2:1. For example, the ratio of non-tobacco plant material to 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 non-tobacco plant material to fiber material may be about 4:1. In some embodiments, the ratio of non-tobacco plant material to fiber material may be about 5:1. In some embodiments, the ratio of non-tobacco plant material to fiber material may be about 6:1. The aerosol produced may be particularly favorable when the ratio of non-tobacco plant material to fiber material is about 20:1 to about 2:1. Furthermore, plant material is 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 material with wood fiber / wood pulp to produce an aerosol containing aroma compounds from plant material may be desirable, but is more cost-effectively produced than fiber material containing 100% plant material. The addition of wood fiber / wood pulp at the above ratios has been found to have little or no effect on the sensory properties of the aerosol.

[0100] In some embodiments, the relative amount of plant material compared to wood fiber / wood pulp may be increased, thus increasing the amount of aroma compounds derived from the plant material in the aerosol. Alternatively, the amount of plant material in the fiber material may be reduced to produce an aerosol with fewer aroma compounds. When the aerosol contains fewer aroma compounds, any additional flavors added to the aerosol-generating material may be more pronounced and perceived to a greater extent by the user. Alternatively, producing an aerosol with fewer aroma compounds may enable the use of particularly subtle flavors, such as flavors derived from berry fruits, tropical fruits, and citrus fruits.

[0101] 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.

[0102] 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). It is understood 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 acid-containing aerosol-forming materials described herein produce aerosols with appropriate nicotine content and perceived harshness.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] In some embodiments, the aerosol-forming material comprises 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 amount of acid relative to the moles of nicotine (i.e., moles of acid).

[0108] In some embodiments, the aerosol-forming material includes an amount of acid (i.e., moles of acid) relative to moles of nicotine, such as free base nicotine, in an amount of acid ranging from about 50% to about 250% relative to moles of nicotine, such as free base nicotine, e.g., from about 50% to about 200%, e.g., from about 75% to about 175%, e.g., from about 75% to about 150%, e.g., from 100% to about 150%, e.g., from about 100% to about 125%.

[0109] Those skilled in the art will readily appreciate that the amount of acid that can 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, from about 0.5 to about 2.5 moles, e.g., from about 0.5 to about 2.0 moles, e.g., from about 0.75 to about 1.75 moles, e.g., from about 0.75 to about 1.50 moles, e.g., from about 1.0 to about 1.50 moles, e.g., from about 1.0 to about 1.25 moles, of the amount of acid relative to a mole of nicotine, such as free base nicotine.

[0110] In some embodiments, the aerosol-forming material comprises an extract derived from botanical material.

[0111] The aerosol-generating material includes an aerosol former / aerosol-forming agent material. The total amount of aerosol former may be about 5% to about 35% by weight on a dry weight basis. In some embodiments, the total amount of aerosol former is about 10% to about 30% by weight on a dry weight basis. In some embodiments, the total amount of aerosol former 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 former material is about 20% by weight on a dry weight basis. In some embodiments, the total amount of aerosol former material is about 25% by weight on a dry weight basis.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] In some embodiments, the ratio of aerosol-forming agent to bulking agent 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 bulking agent is within this range, the aerosol-forming material exhibits favorable storage characteristics and produces favorable aerosols.

[0118] In some embodiments, the ratio of aerosol-forming agent to non-tobacco plant material is from about 1:6 to about 1:2, such as from about 1:5 to about 1:2, for example, from about 1:3 to about 1:2.

[0119] In some embodiments, the ratio of aerosol-forming agent to 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.

[0120] In some embodiments, the aerosol-forming material comprises particles of non-tobacco plant material. Alternatively, the aerosol-forming material may be described as comprising particulate non-tobacco plant material. Each particle of non-tobacco plant 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 particulate non-tobacco plant material may be measured using scanning electron microscopy (SEM).

[0121] The maximum dimension of each particle of the non-tobacco plant material may be up to about 250 μm, hi some embodiments, the maximum dimension of each particle 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.

[0122] The population of particles of non-tobacco plant material may have a particular target particle size distribution. The population of particles of fibrous material may have a particular target particle size distribution. The population of particles of non-tobacco plant material and fibrous material, i.e., filler, may have a particular target particle size distribution. Particle size distribution 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.

[0123] In some embodiments, the population of particles of the non-tobacco plant material and fiber material, i.e., filler, may have a particle size distribution (D90) of at least about 100 μm, hi some embodiments, the population of particles of the filler 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, e.g., at least about 150 μm.

[0124] In some embodiments, the population of particles of the filler, i.e., non-tobacco plant material and fiber 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 filler 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.

[0125] In some embodiments, the population of filler particles may have a particle size distribution (D10) of about 25 μm to about 75 μm. In some embodiments, the population of filler particles 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.

[0126] In some embodiments, the population of particles of filler, ie, non-tobacco plant material and fiber 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.

[0127] In some embodiments, a population of filler particles 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 filler particles 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.

[0128] 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.

[0129] The particle size of the non-tobacco plant material and fiber material can also affect the roughness of the sheet or shredded sheet of aerosol-forming material.

[0130] 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.

[0131] The sheet or shredded sheet may also include water. The sheet or shredded sheet of aerosolizable material may include water in an amount of less than about 15%, less than about 10%, or less than about 5% by weight of the aerosolizable material. In some embodiments, the aerosolizable material includes water in an amount of about 0% to about 15%, or about 5% to about 15% by weight of the aerosolizable material.

[0132] The sheet or chopped sheet of aerosolizable material may contain water and aerosol former material in a total amount of less than about 30% by weight of the sheet or chopped sheet of aerosolizable material, or less than about 25% by weight of the sheet or chopped sheet of aerosolizable material. It is believed that incorporating water and aerosol former material into the sheet or chopped sheet of aerosolizable material in an amount less than about 30% by weight of the sheet or chopped sheet of aerosolizable material may advantageously reduce the stickiness of the sheet. This may improve the ease with which the aerosolizable material can be handled during processing. For example, it may be easier to roll the sheet of aerosolizable material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness may also reduce the tendency of strands or strips of chopped material to clump together or stick to each other, thus further improving processing efficiency and final product quality.

[0133] In some cases, the total content of actives and / or flavors may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavors may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0134] In some cases, the total content of nicotine source and flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of active substance and / or flavor may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0135] The inventors have surprisingly found that aerosol-generating material in sheet form is beneficial when shredded at a single sheet thickness, as opposed to conventional tobacco cutting processes in which several sheets of lamina material are fed into the shredding equipment simultaneously. Feeding multiple thicknesses of aerosol-generating material into the shredding equipment in a single pass tends to result in uneven distribution of material in the final aerosol-generating material because the multiple thicknesses of sheet material tend to adhere to each other and form clumps.

[0136] 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.

[0137] FIG. 2 is a cross-sectional side view of an article 1 for use in an aerosol delivery system.

[0138] Article 1 comprises a mouthpiece 2 and an aerosol-generating section connected to mouthpiece 2. In this example, the aerosol-generating section comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material 3. In other examples, the aerosol-generating section may comprise a cavity for receiving the source of aerosol-generating material.

[0139] The aerosol-generating material includes multiple strands or strips of aerosol-generating material as described herein. For example, the aerosol-generating material may include multiple strands or strips of aerosolizable material, as described herein, and optionally multiple strands or strips of an amorphous solid. In some embodiments, the aerosol-generating material consists of multiple strands or strips of aerosolizable material.

[0140] In this example, a cylindrical rod of aerosol-forming material 3 includes multiple strands and / or strips of aerosol-forming material and is surrounded by a wrapping material 10. The wrapping material 10 may be a moisture-impermeable wrapping material.

[0141] In this example, the rod of aerosol-forming material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-forming material 3 may have any suitable circumference, for example, from about 20 mm to about 26 mm.

[0142] Article 1 is configured for use in a non-combustion aerosol delivery device that includes an aerosol generator for insertion into an aerosol-generation section. In this example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator within a rod of aerosol-generating material.

[0143] The wrapper 10 surrounding the rod of aerosol-forming material may comprise a cellulosic material having a basis weight greater than about 40 grams per square meter (gsm), e.g., greater than about 30 gsm, preferably greater than about 40 gsm, and more preferably greater than about 50 gsm. The inventors have found that such a basis weight advantageously provides improved stiffness to the rod of aerosol-forming material. In this example, the wrapper 10 comprises a paper wrapper.

[0144] The improved stiffness provided by a packaging material having a basis weight greater than about 30 gsm, greater than about 40 gsm, or greater than about 50 gsm can make the rod of aerosol-generating material 3 more resistant to crumpling or other deformation under forces experienced by the article during use, such as when the article is inserted into a device and / or when a heat generator is inserted into the article. Providing a rod of aerosol-generating material with increased stiffness can be beneficial when multiple strands or strips of aerosol-generating material 3 are aligned within the aerosol-generating section such that the longitudinal dimensions of the multiple strands or strips are aligned parallel to the longitudinal axis, as longitudinally aligned strands or strips of aerosol-generating material may provide less stiffness to the rod of aerosol-generating material than if the strands or strips were not aligned. The improved stiffness of the rod of aerosol-generating material allows the article to withstand increased forces experienced by the article during use.

[0145] In other embodiments, the packaging material 10 optionally includes a barrier coating to render the packaging material substantially moisture-impermeable. For example, a layer of aluminum foil on the packaging material 10 has been found to be particularly effective in promoting aerosol formation within the aerosol-generating material 3. For example, the packaging material can be provided with a layer of aluminum foil having a thickness of about 4 μm to 16 μm, e.g., about 6 μm. Metallic layers or foils other than aluminum can also be used. The total thickness of the packaging material is preferably 20 μm to 90 μm, more preferably 30 μm to 60 μm, to provide a packaging material with adequate structural integrity and heat transfer properties. The tension that can be applied to the packaging material before it breaks can be greater than 3,000 grams of force, e.g., 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force.

[0146] In this example, the wrapping material 10 is also substantially impermeable to air. In an alternative embodiment, the wrapping material 10 preferably has an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low-air permeability wrapping materials, for example, having an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, this is hypothesized to be due to reduced loss of aerosol compounds through the wrapping material 10. The air permeability of the wrapping material 10 can be measured in accordance with ISO 2965:2009 for determining the air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0147] Tipping paper 5 is wrapped over a portion of the rod of aerosol-generating material 3 along the entire length of tipping tip 2, with adhesive on the inner surface of tipping paper 5 to connect tipping tip 2 and rod 3. In this example, tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over rod 3 to provide a secure attachment between tipping tip 2 and rod 3. The tipping paper may have a basis weight greater than 20 gsm, for example greater than 25 gsm, or preferably greater than 30 gsm, for example 37 gsm. It has been found that basis weights in these ranges result in tipping paper that has acceptable tensile strength while also being flexible enough to wrap around article 1 and adhere to itself along the paper's longitudinal lap seam. In this example, the circumference of tipping paper 5 is approximately 23 mm when wrapped around tipping tip 2.

[0148] The mouthpiece 2 includes a cooling section 8, also referred to as a cooling element, positioned immediately downstream and adjacent to a source of aerosol-forming material 3. In this example, the cooling section 8 is in abutting relationship with the source of aerosol-forming material. The mouthpiece 2 also includes, in this example, a body of material 6 downstream of the cooling section 8 and a hollow tubular element 4 downstream of the body of material 6 at the mouthpiece end of the article 1.

[0149] The cooling section 8 comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 8. In this example, the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section may comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is generally cylindrical, although other channel shapes / cross-sections may be used in alternative embodiments. The hollow channel may provide space in which aerosol drawn into the cooling section 8 can expand and cool. In all embodiments, the cooling section is configured to limit the cross-sectional area of ​​the hollow channel(s) to limit the displacement of tobacco into the cooling section during use.

[0150] The moisture-impermeable wrapping material 10 may have lower friction with the aerosol-generating material, resulting in easier longitudinal displacement of the strands and / or strips of aerosol-generating material into the cooling section when an aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that providing a cooling section 8 directly adjacent to the source of aerosol-generating material and including an inner channel having a diameter in this range advantageously reduces longitudinal displacement of the strands and / or strips of aerosol-generating material when an aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that reducing displacement of the aerosol-generating material during use advantageously results in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, thereby resulting in more consistent and easily controllable aerosol generation.

[0151] When the aerosol generator is inserted into the rod of aerosol-generating material 3, the strands and / or strips of aerosol-generating material may be longitudinally displaced into the cooling section. The inventors have found that by providing a cooling section 8 directly adjacent to the source of aerosol-generating material and including an inner channel having a diameter in this range, longitudinal displacement of the strands and / or strips of aerosol-generating material is advantageously reduced when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that reducing the displacement of the aerosol-generating material during use can advantageously result in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, thereby resulting in more consistent and improved aerosol generation.

[0152] The rod of aerosol-generating material 3 and cooling section 8 each have a cross-sectional area measured perpendicular to the longitudinal axis of article 1, as shown by line X-X' in Figure 2. The cooling section is configured so that a maximum percentage of the cross-sectional area of ​​the cooling section consists of hollow interior channels, e.g., less than about 45% of the cross-sectional area, preferably less than 30% of the cross-sectional area, and more preferably less than 25% of the cross-sectional area. In this example, about 18% of the cross-sectional area of ​​the cooling section consists of hollow channels.

[0153] Additionally or alternatively, at least about 4%, or at least about 6%, or at least about 8% of the cross-sectional area of ​​the cooling section may be occupied by the hollow inner channel. In some examples, between 4% and 32% of the cross-sectional area of ​​the cooling section is occupied by the hollow inner channel.

[0154] The cooling section 8 preferably has a radial wall thickness, which can be measured, for example, using a caliper. The wall thickness of the cooling section 8 defines the inner diameter of the cavity enclosed by the walls of the cooling section 8 for a given outer diameter of the cooling section. The cooling section 8 preferably has a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling section 8 has a wall thickness of about 1.5 mm. The inventors have found that providing a cooling section 8 with a wall thickness within this range preferably improves retention of the supply of aerosol-generating material within the aerosol-generating section by reducing longitudinal displacement of the strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article during use.

[0155] Cooling section 8 is formed from filamentary tow. Other structures can be used to form tubular element 8, such as multiple parallel wound layers of paper with butt seams, or spirally wound layers of paper, cardboard tubes, tubes formed using a paper-mache process, molded or extruded plastic tubes, etc. Cooling section 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and while article 1 is in use.

[0156] The filamentary tow material described herein may include cellulose acetate fiber tow. The filamentary tow can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. When the material is cellulose acetate tow, the filamentary tow may be plasticized with a plasticizer suitable for tows, such as triacetin, or the tow may be unplasticized. The tows may have other cross sections, such as "Y" or "X", and may have any suitable specifications, such as fibers with filamentary denier values ​​of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0157] The filamentary tows forming the cooling section 8 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not overly dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the hollow tubular elements 4 have a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filamentary tows forming the cooling section 8 are formed from cellulose acetate and have an 8Y40,000 tow containing 18% plasticizer, such as triacetin.

[0158] The wall material of the cooling section 8 may be relatively non-porous so that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0159] Preferably, the length of the cooling section 8 is less than about 30 mm. More preferably, the length of the cooling section 8 is less than about 25 mm. Even more preferably, the length of the cooling section 8 is less than about 20 mm. Additionally or alternatively, the length of the cooling section 8 is preferably at least about 10 mm. Preferably, the length of the cooling section 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 8 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling section 8 is 19 mm.

[0160] Cooling section 8 is disposed around mouthpiece 2 and defines an air gap within mouthpiece 2, which functions as the cooling section. The air gap provides a chamber through which heated volatile components generated by aerosol-generating material 3 flow. Cooling section 8 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while article 1 is in use. Cooling section 8 provides a physical displacement between aerosol-generating material 3 and body of material 6. The physical displacement provided by cooling section 8 provides a thermal gradient across the length of cooling section 8.

[0161] Preferably, the mouthpiece 2 has a length of 110 mm. 3It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 is formed, for example, within the cooling section 8, and has a cavity with a volume greater than 110 mm 3 Larger, even more preferably 130mm 3 The cavity has a larger internal volume, allowing for further improvement of the aerosol. In some examples, the internal cavity is about 130 mm 3 ~about 230mm 3 , for example, about 134 mm 3 or 227 mm 3 It has a volume of

[0162] Cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of cooling section 8 and the heated volatile components exiting the second downstream end of cooling section 8. Cooling section 8 is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of cooling section 8 and the heated volatile components exiting the second downstream end of cooling section 8. This temperature difference across the length of cooling section 8 protects body 6 of temperature-sensitive material from the high temperatures of aerosol-generating material 3 when heated.

[0163] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 7 is a non-porous plug wrap having an air permeability of, for example, less than 100 Coresta units, for example, less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0164] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the body of material 6 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

[0165] In this example, the body of material 6 is formed from filamentary tow. In this example, the tow used in the body of material 6 has a denier per filament (dpf) of 5 and a total denier of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises approximately 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, a different material can be used to form the body of material 6. For example, rather than tow, the body 6 can be formed from paper, in a manner similar to paper filters known for use in cigarettes. Alternatively, the body 6 can be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a dpf of at least 5. Preferably, to achieve a body 6 of sufficiently uniform material, the tow has a denier per filament of 12 d.pf or less, preferably 11 d.pf or less, even more preferably 10 d.pf or less.

[0166] The total denier of the tow forming the body of material 6 is preferably up to 30,000, more preferably up to 28,000, and even more preferably up to 25,000. These total denier values ​​provide a tow that is a reduced percentage of the cross-sectional area of ​​the tipping 2, resulting in a lower pressure drop across the tipping 2 than tows having higher total denier values. For appropriate hardness of the body of material 6, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is 5 to 12, while the total denier is 10,000 to 25,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although other shapes, such as "X" shaped filaments, having the same dpf and total denier values ​​as provided herein, can be used in other embodiments.

[0167] Regardless of the material used to form the body 6, the pressure drop across the body 6 can be, for example, 0.3 to 5 mmWG per mm of length of the body 6, such as 0.5 to 2 mmWG per mm of length of the body 6. The pressure drop can be, for example, 0.5 to 1 mmWG / mm of length, 1 to 1.5 mmWG / mm of length, or 1.5 to 2 mmWG / mm of length. The total pressure drop across the body 6 can be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body 6 can be about 5, 6, or 7 mmWG.

[0168] As shown in Figure 2, the tipping tip 2 of the article 1 has an upstream end 2a adjacent the rod of aerosol-forming material 3 and a downstream end 2b remote from the rod of aerosol-forming material 3. At the downstream end 2b, the tipping tip 2 has a hollow tubular element 4 formed from filamentary tow. This has been found to significantly reduce the temperature of the exterior surface of the tipping tip 2, preferably at the downstream end 2b of the tipping tip that contacts the consumer's mouth when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the exterior surface of the tipping tip 2, even upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 4 directing the aerosol closer to the center of the tipping tip 2, thus reducing heat transfer from the aerosol to the exterior surface of the tipping tip 2.

[0169] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This may be measured, for example, using a caliper. The wall thickness is suitably greater than 0.9 mm, more preferably 1.0 mm or greater. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably 1.0 mm or greater, at any point around the hollow tubular element 4. In this example, the wall thickness of the hollow tubular element 4 is approximately 1.15 mm.

[0170] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0171] Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, more preferably between 0.4 and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to achieve a good balance between the improved hardness imparted by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filamentary tow forming the element, including any plasticizers incorporated therein. The density may be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, which may be calculated using appropriate measurements of the hollow tubular element 4, for example, obtained using a caliper. If necessary, a microscope may be used to measure appropriate dimensions.

[0172] The filamentary tows forming the hollow tubular element 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a tubular element 4 that is not overly dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tows forming the hollow tubular element 4 have a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments in the tow is "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0173] The filamentary tows forming the hollow tubular elements 4 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not overly dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the hollow tubular elements 4 have a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filamentary tows forming the hollow tubular elements 4 are formed from cellulose acetate, with the tow including 18% plasticizer, such as triacetin.

[0174] The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. A smaller diameter may result in the velocity of the aerosol passing through the mouthpiece 2 and reaching the consumer's mouth being increased more than desired, such that the aerosol becomes excessively warm, for example reaching temperatures above 40°C or above 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is about 3.9 mm.

[0175] The hollow tubular element 4 preferably contains 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) can also be used. More preferably, the tubular element 4 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19% by weight of plasticizer.

[0176] In this example, the first hollow tubular element 4, the body of material 6, and the second hollow tubular element 8 are joined together using a second plug wrap 9 that is wrapped around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units, for example, less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0177] In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article can be provided in any of the formats described herein, for example, having a circumference of 15 mm to 25 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved by using an article with a lower circumference within this range, for example, a circumference less than 23 mm. It has been found that article circumferences greater than 19 mm are particularly effective for achieving improved aerosol upon heating while maintaining a suitable product length. Articles having circumferences of 19 mm to 23 mm, more preferably 20 mm to 22 mm, have been found to achieve a good balance between providing effective aerosol delivery and enabling efficient heating.

[0178] The article has a ventilation level such that approximately 10% of the aerosol is drawn through the article. In alternative embodiments, the article may have a ventilation level such that 1% to 20%, e.g., 1% to 12%, of the aerosol is drawn through the article. These levels of ventilation help to improve the consistency of the aerosol inhaled by the user at the mouth end 2b while assisting the aerosol cooling process. Ventilation is provided directly within the mouth end 2 of the article 1. In this example, ventilation is provided within the cooling section 8, which has been found to be particularly beneficial in assisting the aerosol generation process. Ventilation is provided via perforations 12, in this case formed as a single row of laser perforations, located 13 mm from the mouth end 2b downstream of the mouth end 2. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9, and the cooling section 8. In alternative embodiments, ventilation can be provided elsewhere within the mouth end, for example, in the body of material 6 or the first tubular element 4. Preferably, the article is constructed so that the perforations are located no more than about 28 mm from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In this example, the openings are located about 25 mm from the upstream end of the article.

[0179] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that the longitudinal dimensions of the plurality of strands or strips are aligned parallel to the longitudinal axis of the article. A majority of the strands or strips may be arranged such that the longitudinal dimensions of the strands or strips are aligned parallel to the longitudinal axis of the article. In some embodiments, between about 95% and about 100% of the plurality of strands or strips are arranged such that the longitudinal dimensions of the plurality of strands or strips are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged within the aerosol-generation section of the article such that the longitudinal dimensions of the strands or strips are aligned parallel to the longitudinal axis of the aerosol-generation section.

[0180] The inventors have found that if the majority of the strands or strips are positioned within the aerosol-generation section such that the longitudinal axes of the strands or strips are parallel to the longitudinal axis of the aerosol-generation section of the article, the force required to insert the aerosol generator into the aerosol-generating material may be relatively low, which may mean that the article is easier to use.

[0181] In some embodiments, the aerosol-forming material is applied to a volume of about 2 cm 3 / g ~ approx. 10cm 3 In 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, consumables containing the aerosol-generating material may be lighter. Thus, the total weight of material used to achieve the same / required fill value is smaller, resulting in cost savings on the product. In addition, using the aerosol-generating materials described herein may also be advantageous because resistance to inhalation is not affected, thus providing a more favorable user experience for consumers.

[0182] In one embodiment, the nicotine salt is selected from nicotine benzoate, nicotine citrate, and nicotine lactate, nicotine levulinate, or mixtures thereof.

[0183] 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.

[0184] 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 casing sheet by heating the material to about 100°C to about 120°C.

[0185] In some embodiments, the slurry is processed by band casting the slurry.

[0186] 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.

[0187] The aerosol-forming material is in the form of a sheet or shredded sheet and has a density of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m2 ~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 2 In 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

[0188] Approximately 100g / m 2 ~about 250g / m 2 It is believed that an areal density of about 180 g / m contributes to the strength and flexibility of the sheet or shredded sheet. 2 It has been found that a rod comprising chopped sheets of aerosolizable material having an areal density of 100-200 μm and a minimum thickness of 220-230 μm can be loaded 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.

[0189] 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.

[0190] As used herein, the term "rod" is used to describe a generally cylindrical element of generally circular, oval, or elliptical cross section.

[0191] 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.

[0192] 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.

[0193] In one embodiment, an article for use in a non-combustion aerosol delivery system is described, the article comprising an aerosol-forming material described herein.

[0194] In some embodiments, the article comprises an aerosol-generating section including the aerosol-generating material described herein. In some embodiments, the aerosol-generating section comprises a packaging material surrounding the aerosol-generating material. In some embodiments, the aerosol-generating material occupies at least about 70% of the volume of the aerosol-generating section.

[0195] 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.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] 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.

[0205] 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. 1. An aerosol-generating material comprising a sheet or chopped sheets of aerosolizable material comprising non-tobacco plant material, an aerosol former material, a binder, and an active substance, said sheet or chopped sheets having a thickness of at least about 100 μm and a weight of about 100 g / m ２ ~Approx. 250g / m ２ an areal density of the aerosol-generating material;

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 or 2, wherein the non-tobacco plant material is selected from the list consisting of rooibos, star anise, fennel, and mint, and combinations thereof.

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

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

6. 6. The aerosol-forming material of claim 1, wherein the sheet or chopped sheet of the aerosolizable material has an average thickness of about 150 μm to about 300 μm.

7. The aerosol-generating material of any one of claims 1 to 6, wherein the chopped sheet of aerosolizable material comprises a plurality of strands or strips of the aerosolizable material.

8. 8. The aerosol-forming material of claim 7, wherein the strands or strips of aerosolizable material have a width of about 0.9 mm to about 2.0 mm.

9. The aerosol-forming material of any one of claims 1 to 8, further comprising a fibrous material.

10. 10. The aerosol-forming material of claim 9, wherein the fibrous material comprises wood fiber / wood pulp.

11. 11. The aerosol-forming material of any one of claims 1 to 10, wherein the sheet or shredded sheet of the aerosolizable material has a burst strength of at least about 75g.

12. 12. The aerosol-forming material of any one of claims 1 to 11, wherein the sheet or chopped sheet of the aerosolizable material has a tensile strength of at least about 4 N / 15 mm.

13. 13. The aerosol-forming material of any one of claims 1 to 12, wherein the binder is selected from the list consisting of alginates, pectins, starches, celluloses, natural gums, silicas, silicone compounds, clays, and polyvinyl alcohols.

14. 14. 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.

15. The aerosol-forming material of any one of claims 1 to 14, wherein the active substance comprises a nicotine source.

16. 16. The aerosol-forming material of claim 15, wherein the nicotine source comprises a nicotine salt.

17. 17. The aerosol-forming material of claim 16, wherein the nicotine salt is selected from the list consisting of nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof.

18. 16. The aerosol-forming material of claim 15, wherein the nicotine source comprises free base nicotine and the aerosol-forming material further comprises an organic acid.

19. 19. The aerosol-forming material of claim 18, 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.

20. 1. A method for preparing an aerosol-forming material, comprising: combining non-tobacco plant material, an aerosol former, an active agent, a binder, and water to form a slurry; processing the slurry to form a sheet of aerosolizable material; The sheet of aerosolizable material is dried to a thickness of about 100 μm and a mass of about 100 g / m ２ ~Approx. 250g / m ２ forming a sheet of aerosolizable material having an areal density of A method comprising:

21. 21. The method of claim 20, further comprising shredding the sheet to form a shredded sheet comprising a plurality of strips of the aerosolizable material.

22. 22. The method of claim 20 or 21, wherein the step of treating the slurry comprises casting the sheet in a band caster.

23. Use of an aerosol-forming material according to any one of claims 1 to 19 in a delivery system, such as a non-combustion aerosol delivery system.

24. An aerosol-generating rod comprising the aerosol-generating material of any one of claims 1 to 19.

25. A delivery system comprising an aerosol-generating material according to any one of claims 1 to 19 or an aerosol-generating rod according to claim 24.

26. 23. An aerosol-forming material obtained or obtainable from a method according to any one of claims 20 to 22.

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