Aerosol-generating tobacco substrate

Abstract

An aerosol-generating substrate for use in an aerosol-generating article, the aerosol-generating substrate comprising: a) a first solid composition (a) comprising tobacco or a derivative thereof, a humectant, a first gelling agent, and a first binder; and b) a second solid composition (b) comprising a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler, wherein the first solid composition (a) is granular, and the second solid composition (b) is present as a separate phase on and / or within composition (a).

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating substrate. The present invention also relates to an aerosol-generating article comprising the aerosol-generating substrate, and an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device. The present invention also relates to methods of using and making the aerosol-generating substrate, and methods of generating inhalable aerosols using the aerosol-generating substrate. [Background technology]

[0002] Electronic cigarettes (e-cigarettes) are a widespread alternative to traditional cigarettes. Many e-cigarettes (or similar devices, such as e-pipes) generate aerosols by heating a liquid containing flavoring agents, an aerosol-forming agent, and optionally, nicotine. However, these e-cigarettes and similar devices can provide a non-uniform smoking profile and can lack the characteristic flavor of tobacco. Therefore, such devices are not an ideal replacement for traditional combustible tobacco products.

[0003] Alternatively, a variety of devices and systems are available that heat (rather than burn) a tobacco-containing aerosol-generating substrate to release an aerosol (i.e., vapor) for inhalation by the consumer. These devices and systems are sometimes referred to as "heat-and-burn" and provide a tobacco-based vapor by heating the tobacco-containing substrate.

[0004] To further improve the taste versatility of known aerosol-generating substrates used in heat-and-burn products, it is desirable to add flavors. Flavors are typically added by applying a liquid flavor concentrate (e.g., using a spray nozzle) during primary tobacco processing in a tobacco factory or by online flavor addition. In addition, the aerosol-generating substrate may need to be further heated to be molded, which can degrade and / or evaporate the flavor. Furthermore, there is a risk of liquid flavor leakage during the molding process.

[0005] Alternatively, the fragrance can be sprayed onto the substrate after molding. This application method also requires additional equipment and is problematic because the fragrance is simply deposited on the surface and not properly transferred into the substrate. If the fragrance is simply deposited on the substrate surface, it may come into direct contact with the heater, which can result in an uneven vapor profile and negatively affect the vaping experience.

[0006] Therefore, there is a need to provide useful aerosol-forming substrates with improved flavorings that reduce flavor loss and / or deterioration, for example, during processing, and which, when used in aerosol-generating systems such as heat-and-burn devices, improve the consumer's vaping experience.

[0007] One object of the present invention is, among other things, to provide an aerosol-forming substrate that addresses at least one shortcoming of the prior art, whether identified herein or elsewhere, or to provide an alternative to existing aerosol-forming substrates. Summary of the Invention

[0008] According to aspects of the present invention, there are provided an aerosol-generating substrate, a method for making an aerosol-generating substrate, an aerosol-generating article comprising the aerosol-generating substrate, an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device, the use of the aerosol-generating substrate in an aerosol-generating system, and a method for generating an inhalable aerosol using an aerosol-generating system.

[0009] According to a first aspect of the present invention, there is provided an aerosol-generating substrate for use in an aerosol-generating article, the aerosol-generating substrate comprising: a) a first solid composition (a) comprising tobacco or a derivative thereof, a humectant, a first gelling agent, and a first binder; b) a second solid composition (b) comprising a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler; Including, The first solid composition (a) is particulate and the second solid composition (b) is present as a separate phase on and / or within composition (a).

[0010] According to a second aspect of the present invention, there is provided an aerosol-generating article for use in an aerosol-generating device, the aerosol-generating article comprising an upstream segment located at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-generating substrate according to the first aspect, and a downstream segment located at the downstream end of the aerosol-generating article.

[0011] According to a third aspect of the present invention there is provided the use of a second solid composition (b) in an aerosol-generating substrate according to the first aspect to enhance the stability of the flavouring agent in the aerosol-generating substrate and / or delay the release of the flavouring agent from the aerosol-generating substrate.

[0012] According to a fourth aspect of the present invention, there is provided an aerosol generating system comprising an aerosol-generating article according to the second aspect and an aerosol generating device including a heated chamber for receiving the aerosol-generating article in use.

[0013] According to a fifth embodiment of the present invention, there is provided a method of producing an aerosol-generating substrate according to the first aspect, the method comprising contacting a first solid composition (a) with a second solid composition (b), placing the contacted compositions in a mould and applying heat and / or pressure to form the substrate.

[0014] According to a sixth aspect of the present invention there is provided a method of generating an inhalable aerosol, the method comprising: (i) providing an aerosol generating system according to the fourth aspect; (ii) forming an inhalable aerosol by applying heat to the aerosol-generating article; Includes.

[0015] Other features of the invention will be apparent from the dependent claims and from the following description.

[0016] The features described in relation to the second, third, fourth, fifth and sixth aspects may have any of the preferred features and advantages described in relation to the first aspect. [Means for solving the problem]

[0017] Unless otherwise stated, the following terms used in the specification and claims have the meanings set forth below.

[0018] According to a first aspect of the present disclosure, there is provided an aerosol-generating substrate for use in an aerosol-generating article, the aerosol-generating substrate comprising: a) a first solid composition (a) comprising tobacco or a derivative thereof, a humectant, a first gelling agent, and a first binder; b) a second solid composition (b) comprising a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler; Including, The first solid composition (a) is particulate and the second solid composition (b) is present as a separate phase on and / or within composition (a).

[0019] The aerosol-generating substrate of the first aspect of the present invention is suitable for use in an aerosol-generating article. The substrate is capable of forming an inhalable aerosol upon heating to a suitable temperature, such as a temperature in the range of 150°C to 450°C, preferably in the range of 200°C to 400°C, more preferably in the range of 250°C to 350°C, and even more preferably in the range of 290°C to 350°C or in the range of 290°C to 350°C. For example, suitable temperatures are about 230°C, about 250°C, about 270°C, about 290°C, about 300°C, about 310°C, about 330°C, or about 350°C. The inhalable aerosol comprises tobacco or a derivative thereof and a flavoring agent.

[0020] As used herein, the term "aerosol" may include a suspension of vaporizable material as one or more of solid particles, liquid droplets, or gas. The suspension may be present in a gas, including air. Aerosol herein generally refers to / may include a vapor. The aerosol may include one or more components of the aerosol-generating substrate.

[0021] The aerosol-generating substrate of the first aspect of the present invention comprises a first solid composition (a) and a second solid composition (b). The first solid composition is granular, meaning that the first solid composition is comprised of granules. The granular nature of the first solid composition provides breathability and a large surface area for efficient and uniform aerosol generation.

[0022] By "particulate" is meant that the components are present in composition (a) as granules. Typically, the particle size distribution of the particulate components is measured by sieve analysis, with the median particle size (i.e., D50) being 0.2 to 1 mm, e.g., 0.5 to 1 mm or 0.5 to 0.7 mm.

[0023] Granules may be formed by any suitable granulation process, such as wet granulation or dry granulation, in which single, discrete particles, such as powder particles, agglomerate to form larger entities, i.e., granules. Granules are therefore to be physically distinguished from powders.

[0024] The second solid composition (b) is present as a separate phase on and / or within the first solid composition (a). The second solid composition (b) may be present in an amount ranging from 1 to 15 wt. %, preferably from 2 to 12 wt. %, more preferably from 3 to 10 wt. %, and even more preferably from 4 to 8 wt. %, based on the total weight of the first solid composition. Alternatively, the weight ratio of the second solid composition to the first solid composition may be 1:99 to 15:85, for example, 2:98 to 12:88, preferably 3:97 to 10:90, and even more preferably 6:94 to 8:92.

[0025] As used herein, the phrase "separate phases" refers to the presence of a distinct boundary between different chemical compositions. In other words, compositions (a) and (b) exist as separate solid entities in the aerosol-generating substrate. This necessarily results in a heterogeneous mixture in the aerosol-generating substrate. This is advantageous because it allows for control of flavor distribution in the substrate, thereby improving the consumer experience.

[0026] References herein to solid compositions refer to compositions that are in a solid state under normal atmospheric conditions (i.e., at 1 atmosphere pressure and 298 K). Compositions (a) and (b) are both solid compositions, and all references herein to compositions (a) and (b) refer to the solid compositions.

[0027] The inventors have surprisingly found that the use of a second solid composition (b) containing a flavorant as a separate phase on and / or within composition (a) in the aerosol-generating substrate of the present invention allows for the introduction of a flavorant without the drawbacks of the prior art. The second solid composition (b) releases the flavorant into the aerosol (i.e., vapor) upon heating in the device, but is more resistant to the heat used during processing. Furthermore, by combining the second composition with the first composition, further control of the flavorant release profile may be possible by disposing the second solid composition (b) on and / or within the first composition (a) in different forms (e.g., as a thin film and / or as fine flakes) and varying its distribution within the aerosol-releasing substrate.

[0028] The first solid composition (a) comprises tobacco or a derivative thereof, a humectant, a first gelling agent, and a first binder, and the second solid composition (b) comprises a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler.

[0029] The first solid composition (a) and the second solid composition (b) can be prepared by any suitable method known to those skilled in the art. For example, the first composition can be prepared as described in WO 2021 / 094366 and / or WO 2021 / 094365. Preferably, the first solid composition (a) comprises at least: 1) forming a mixture by mixing at least tobacco or a derivative thereof, a first binder, a first gelling agent, and a humectant; 2) forming a granular composition from the mixture; It is prepared by

[0030] The second solid composition (b) may be prepared, for example, as described in EP 2682007 and / or EP 2682008. Suitably, the second solid composition (b) comprises at least 1) forming a mixture by combining at least a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler; 2) spreading the mixture onto a substrate; 3) cooling and drying (e.g., heat drying) the stretched mixture to form a solid composition; 4) Optionally, cutting and / or chopping the dried stretched slurry; It is prepared by

[0031] The first solid composition (a) of the first embodiment comprises tobacco or a derivative thereof.

[0032] Reference to tobacco or a derivative thereof includes any part of any member of the genus Nicotiana, including leaves, flowers, or stems, and reconstituted materials thereof. Preferably, tobacco or a derivative thereof may comprise a blend of at least two different tobaccos and / or their derivatives. The use of a blend allows for taste adjustments to be made to the consumer.

[0033] Tobacco or its derivatives in a suitable form may be shredded and / or ground and may have a particle size (Dv90) of greater than 100 μm or greater than 200 μm, for example greater than 400 μm or 500 μm or greater. Tobacco or its derivatives in a suitable form may have a particle size of less than 1000 μm or less than 900 μm, for example less than 800 μm or less than 700 μm, for example less than 600 μm. Tobacco or its derivatives in a typical form may have a particle size of 100 μm to 1000 μm, for example 400 μm to 700 μm, preferably 500 μm to 600 μm.

[0034] Tobacco or a derivative thereof may be present in the first solid composition in any suitable amount. Preferably, tobacco or a derivative thereof may be present in an amount greater than 5 wt %, preferably greater than 10 wt %, more preferably greater than 20 wt %, based on the total weight of the first solid composition, and / or in an amount less than 70 wt %, preferably less than 60 wt %, more preferably less than 40 wt %, based on the total weight of the first solid composition. Preferably, tobacco or a derivative thereof may be present in an amount of 30 wt % to 55 wt % based on the total weight of the first solid composition. Preferably, tobacco or a derivative thereof may be present in an amount of 30 wt % to 40 wt % based on the total weight of the first solid composition.

[0035] The second solid composition (b) of the first aspect may optionally comprise tobacco or a derivative thereof. Preferably, the second solid composition (b) may be substantially free or completely free of tobacco or a derivative thereof.

[0036] As used herein, the term "substantially free" means that the discussed material is present in the composition, if at all, as an incidental impurity. In other words, the material does not affect the properties of the composition. As used herein, the term "completely free" means that the discussed material is completely absent from the composition.

[0037] The first solid composition (a) of the first embodiment comprises a humectant. As used herein, the term "humectant" refers to a hygroscopic compound that can release an aerosol when heated. In this specification, water is not considered a humectant. The first solid composition (a) can comprise any suitable humectant, and can comprise two or more humectants.

[0038] Examples of suitable humectants include, but are not limited to, glycerol, propylene glycol, ethanol, isopropanol, butanol and its derivatives (e.g., butanol isomers), sebacic acid esters (e.g., di-2-ethylhexyl sebacate), and / or mixtures thereof. Preferably, the humectant may comprise a combination of two or more humectants. Preferably, the first solid composition (a) of the first aspect may comprise a humectant selected from glycerol, propylene glycol, ethanol, and / or mixtures thereof. Preferably, the first solid composition (a) of the first aspect may comprise a humectant selected from glycerol or propylene glycol and / or mixtures thereof. Preferably, the first solid composition (a) of the first aspect may comprise a humectant comprising a mixture of glycerol and propylene glycol. When the moisturizer comprises a mixture of glycerol and propylene glycol, the glycerol and propylene glycol may be present in a weight ratio of 80:20 to 20:80 or 80:20 to 20:80, preferably 70:30 to 30:70 or 70:30 to 30:70. Typically, the amount of glycerol present may be greater than the amount of propylene glycol.

[0039] The humectant may be present in the first solid composition (a) in any suitable amount, such as in an amount of 5% to 70% by weight, preferably 10% to 60% by weight, more preferably 15% to 50% by weight, for example 25% to 45% by weight, for example 35% to 45% by weight, based on the total weight of the first solid composition.

[0040] The first and second compositions of the first aspect each independently comprise a gelling agent (referred to as a "first gelling agent" and a "second gelling agent," respectively). As used herein, the term "gelling agent" refers to a compound that imparts viscoelastic properties to a substrate, i.e., produces a non-flowable gel. The first and second solid compositions may comprise any suitable gelling agent and may include two or more gelling agents. The first and second solid compositions may comprise the same or different gelling agents.

[0041] Suitable gelling agents include non-protein-containing polysaccharides. Typically, the first and second gelling agents of the first aspect can be independently selected from gellan gum, gum arabic, agar, gelatin, pectin, carrageenan, locust bean gum, alginate, lecithin, starch, modified starch derivatives, guar gum, tamarind gum, xanthan gum, tara gum, konjac glucomannan, cassia gum, and psyllium seed gum, and / or mixtures thereof. Preferably, the first and second gelling agents can be independently selected from gellan gum, lecithin, agar, and / or mixtures thereof. More preferably, the first and second gelling agents can be independently selected from gellan gum, agar, and / or mixtures thereof. An example of a suitable commercially available gelling agent is gellan gum Roeper 700f (manufactured by CE Roeper GmbH).

[0042] The first gelling agent may be present in the first solid composition (a) in any suitable amount, such as less than 35 wt.%, e.g., less than 30 wt.%, less than 25 wt.%, less than 20 wt.%, less than 15 wt.%, less than 12 wt.%, or less than 8 wt.%, and / or more than 1 wt.%, e.g., more than 4 wt.%, based on the total weight of the first solid composition. For example, the first gelling agent may be present in the first solid composition (a) in an amount of 1 wt.% to 35 wt.%, preferably 4 wt.% to 30 wt.%, based on the total weight of the first solid composition.

[0043] The second gelling agent may be present in the second solid composition (b) in any suitable amount, such as less than 35 wt.%, e.g., less than 30 wt.%, less than 25 wt.%, less than 20 wt.%, less than 15 wt.%, less than 12 wt.%, or less than 8 wt.%, and / or more than 1 wt.%, e.g., more than 4 wt.%, based on the total weight of the second solid composition. For example, the second gelling agent may be present in the second solid composition (b) in an amount of 1 wt.% to 35 wt.%, preferably 4 wt.% to 30 wt.%, based on the total weight of the first solid composition.

[0044] The first composition of the first aspect includes a binder (referred to as a "first binder"). The second composition of the first aspect may independently include a binder (referred to as a "second binder"). As used herein, the term "binder" refers to a compound used to increase the viscosity of a substrate while maintaining flowability. The first solid composition and the second solid composition may include any suitable binder, and may each include two or more binders. The first solid composition and the second solid composition may include the same or different binders.

[0045] Suitable binders include cellulose derivatives (e.g., hydroxyalkylated cellulose, carboxyalkyl cellulose), modified starch, and xanthan gum. Typically, the first binder and the second binder of the first aspect can be independently selected from carboxymethyl cellulose, hydroxypropyl cellulose, modified starch, agar, gellan gum, xanthan gum, and / or mixtures thereof. Preferably, the first binder and the second binder can be independently selected from carboxymethyl cellulose, hydroxypropyl cellulose, and / or mixtures thereof. A preferred first binder of the first aspect is purified carboxymethyl cellulose, such as Ceroga 4550 C or CEKOL® 2000 (available from CE Roeper GmbH).

[0046] The first binder may be present in the first solid composition (a) in any suitable amount, such as less than 35 wt%, for example less than 30 wt%, less than 25 wt%, less than 20 wt%, or less than 15 wt%, and / or more than 1 wt%, for example more than 5 wt%, or more than 10 wt%, based on the total weight of the first solid composition. For example, the first binder may be present in the first solid composition (a) in an amount of 1 wt% to 35 wt%, preferably 5 wt% to 30 wt%, based on the total weight of the first solid composition.

[0047] If the second solid composition (b) comprises a second binder, the second binder may be present in any suitable amount, such as less than 35 wt.%, e.g., less than 30 wt.%, less than 25 wt.%, less than 20 wt.%, or less than 15 wt.%, and / or more than 1 wt.%, e.g., more than 5 wt.% or more than 10 wt.%, based on the total weight of the second solid composition. For example, if present, the second gelling agent may be present in the second solid composition (b) in an amount of 1 wt.% to 35 wt.%, preferably 4 wt.% to 30 wt.%, based on the total weight of the first solid composition.

[0048] The second solid composition (b) of the first embodiment comprises a flavoring agent. As used herein, the term "flavoring agent" refers to a compound (or mixture of compounds) that provides flavor, i.e., provides flavor to the aerosol generated from the aerosol-generating substrate. "Flavoring agent" may alternatively be referred to as flavor or flavoring.

[0049] Examples of suitable flavoring agents include, but are not limited to, menthol, natural and / or artificial botanical flavors, sugars, animal flavors, other flavoring agents known for use in conventional products or e-cigarettes, and / or mixtures thereof. Suitable examples of flavoring agents include cinnamon, sage, chamomile, kudzu (Pueraria lobata), sweet tea (Hydrangeae dulcis folium), clove, lavender, cardamom, clove, nutmeg, bergamot, geranium, honey essence, rose oil, lemon, orange, cinnamon bark, caraway, jasmine, ginger, coriander, vanilla extract, spearmint, peppermint, cassia, coffee, celery, cascarilla, sandalwood, cocoa, ylang-ylang, fennel, anise, licorice, carob (St. John's Examples of flavoring agents include, but are not limited to, coconut oil, citric acid ...

[0050] The flavoring agent in the second solid composition (b) can be present in any suitable amount, and the amount can be determined according to the desired flavor profile. For example, the flavoring agent in the second solid composition (b) can be present in an amount of 2 to 80 wt % based on the total weight of the second solid composition. The flavoring agent can be present in the second solid composition (b) in an amount less than 35 wt %, for example less than 30 wt %, preferably less than 25 wt % or less than 20 wt %. Alternatively, the flavoring agent can be present in the second solid composition (b) in an amount greater than 40 wt %, for example greater than 45 wt %, preferably greater than 50 wt % or greater than 55 wt %. A high or low content of flavoring agent in the second composition can have different advantages. For example, a high content of flavoring agent can achieve a strong and consistent flavor. A low content of flavoring agent can achieve a delicate flavoring.

[0051] The second solid composition (b) may further comprise a stimulant. As used herein, the term "stimulant" refers to a compound (or mixture of compounds) that provides a sensory effect but does not provide a flavor, i.e., that provides a sensory effect (but does not provide a flavor) to the aerosol generated from the granular composition. An example of a sensory effect may be a cooling sensation.

[0052] Examples of suitable stimulants include, but are not limited to, caffeine, cooling agents, or TRPM8 agonists selected from carboxamide or cyclohexanecarboxamide derivatives.

[0053] The first solid composition (a) of the first aspect may contain water. For example, the first solid composition (a) may contain less than 20 wt. %, for example, less than 10 wt. % water based on the total weight of the first solid composition. The first solid composition (a) may contain more than 1 wt. %, for example, more than 2 wt. % water based on the total weight of the first solid composition. For example, the first solid composition may contain 3 to 9 wt. %, for example, 3 to 6 wt. % water. Preferably, no drying step is required in the preparation of the first solid composition (a).

[0054] The second solid composition (b) may comprise water. For example, the second solid composition may comprise less than 10% by weight, such as less than 9% by weight, preferably less than 6% by weight, and / or more than 1% by weight, such as more than 3% by weight, of water, based on the total weight of the second solid composition. For example, the second solid composition may comprise 3 to 9% by weight, such as 3 to 6% by weight, of water.

[0055] The second solid composition (b) comprises one or more additives selected from a second binder, an emulsifier, and a filler. For example, the second solid composition (b) may comprise one of the second binder, the emulsifier, and the filler, or may comprise two or more of the second binder, the emulsifier, and the filler.

[0056] As used herein, the term "emulsifier" refers to a compound (or mixture of compounds) that promotes the formation of an emulsion. Any suitable emulsifier may be used, for example, lecithin. A suitable emulsifier may be Sun Lecithin A1 (available from Taiyo Co., Ltd.). When the second solid composition (b) includes an emulsifier, the emulsifier may be present in an amount of 0.005 to 2% by weight, for example, 0.025 to 1.25% by weight, based on the total weight of the second solid composition. Alternatively, the emulsifier may be present in the second solid composition in an amount of 0.5 to 5.0% by weight, for example, 1.0 to 4.5% by weight, based on the weight of the second gelling agent in the second solid composition.

[0057] As used herein, the term "filler" refers to a compound (or compounds) that increases the total mass (i.e., dry matter mass) of the composition. Preferably, a suitable filler does not affect the flavor of the composition. Any suitable filler may be used, for example, a starch hydrolysate. Starch hydrolysate refers to a substance obtained or obtainable by hydrolyzing starch, such as dextrin or resistant dextrin. Suitable fillers include Pinedex #100, Pinefiber, and TK-16 (all commercially available from Matsutani Chemical Industry Co., Ltd.). When the second solid composition (b) includes a filler, the filler may be present in any suitable amount. For example, the filler may be present in an amount of 5 to 95% by weight, based on the total weight of the second solid composition. Alternatively, the filler may be present in the second solid composition in an amount of 100 to 500 wt % or 200 to 500 wt % based on the weight of the second gelling agent in the second solid composition.

[0058] The first solid composition and the second solid composition may contain any other additives typically known to those skilled in the art, such as preservatives (e.g., sodium benzoate) and / or antioxidants (e.g., ascorbic acid).

[0059] Some compounds may play multiple roles in the composition; for example, lecithin may be included as an emulsifier or a gelling agent. Thus, in some instances, lecithin may be included in the second solid composition (b) as both a second gelling agent and an emulsifier. Preferably, each role is played by a separate compound; for example, when the second solid composition (b) includes lecithin as a second gelling agent, the second solid composition (b) may preferably include additional additives as a second binder, emulsifier, and / or filler.

[0060] The aerosol-generating substrate may be provided in any suitable shape. Preferably, the aerosol-generating substrate is a molded substrate, the shape of which may be formed by the application of heat and / or pressure. Preferably, the substrate has a flat plate-like structure (otherwise referred to as a flat-shaped consumable). The flat plate-like structure is useful for maximizing aerosol production and / or achieving uniform heating within the aerosol-generating device / system. The substrate may include grooves and / or recesses on at least one side thereof. The grooves and / or recesses may extend from a first edge to a second edge of the substrate.

[0061] The aerosol-generating substrate of the first aspect can be formed into any suitable shape. A particular shape may be desired to fit into the aerosol-generating article. This shape can be achieved by any suitable means; for example, the shape can be formed by applying heat and / or pressure. For example, the aerosol-generating substrate can be pressed into a mold of the desired shape by pressing under suitable pressure.

[0062] The aerosol-generating substrate can be pressed into a mold of the desired shape by pressing at a suitable temperature and / or pressure. Suitable pressures for forming the aerosol-generating substrate can be from 1 bar to 50 bar, or from 1 bar to 50 bar. This pressure range can form the substrate while maintaining the pores necessary for aerosol release. Suitable pressures can be greater than 1 bar, for example greater than 3 bar, typically greater than 5 bar. Suitable pressures can be less than 50 bar, for example less than 30 bar, typically less than 20 bar. Suitable temperatures for forming the aerosol-generating substrate can be from 60°C to 200°C, or from 60°C to 200°C. Such temperatures are high enough to soften the substrate but low enough to prevent premature loss of the aerosol. Suitable temperatures can be greater than 60°C, for example greater than 80°C, typically greater than 90°C. Suitable temperatures can be less than 200°C, for example less than 160°C, typically less than 130°C. Suitably, the temperature used may be from 100°C to 110°C or between 100°C and 110°C.

[0063] The second solid composition (b) of the first aspect of the present invention may be provided in a variety of forms. Suitable forms may include films, flakes, granules, and / or combinations thereof.

[0064] As used herein, the term "flake" refers to a piece of a film of material. The flakes can be regular or irregular in shape, depending on the method of manufacture.

[0065] The second solid composition (b) may be in the form of a film. When the second solid composition (b) is in the form of a film, the film may be applied on and between layers of the first solid composition (a), for example, the film may be embedded between layers of the first solid composition (a). Suitably, the film of the second solid composition may have a thickness of less than 1 mm. Preferably, the film of the second solid composition may have a thickness of 0.01 to 0.30 mm, for example, 0.05 to 0.15 mm.

[0066] The membrane of the second solid composition (b) can be produced by any suitable means. The membrane can be present on and / or in the first solid composition (a) in any configuration. For example, the membrane can be embedded between layers of the first solid composition (a).

[0067] The second solid composition (b) may be in the form of fine particles.

[0068] The fine pieces of the second solid composition (b) can be produced by any suitable means, for example, by breaking down the film by cutting, chopping, grinding, and / or a combination thereof. The fine pieces of the second solid composition (b) can have the thickness of the film from which they are produced, for example, this thickness can be less than 1 mm. Preferably, the fine pieces of the second solid composition have a thickness of 0.01 to 0.30 mm, for example, 0.05 to 0.15 mm. The surface area (of the largest face) of the fine pieces can be less than 50 mm 2 Less than, for example, 30 mm 2 Less than, preferably 25 mm 2 It may be less than.

[0069] The particles of the second solid composition (b) may be present on and / or in the first solid composition (a) in any distribution. Preferably, the particles may be evenly distributed on and / or in the first solid composition (a). Such a distribution improves ease of manufacture and flavor consistency across the substrate. Preferably, the particles may be unevenly distributed on and / or in the first solid composition (a). Such a distribution provides greater control over the flavor profile and flavor release rate during use. When the particles are unevenly distributed, any uneven distribution may be used. A preferred uneven distribution is one in which the particles are distributed on and / or in the first solid composition (a) primarily at and / or in the region adjacent to the edge of the substrate. For example, up to 50% by weight of the particles may be evenly distributed in the first solid composition (a), and at least 50% by weight of the particles may be distributed on and / or in the first solid composition (a) at and / or in areas adjacent to the edges of the substrate.

[0070] The present invention may provide an aerosol-generating article for use in an aerosol-generating device, the aerosol-generating article comprising an aerosol-generating substrate according to the first aspect of the present invention.

[0071] The aerosol-generating article may be any article suitable for use in / with an aerosol-generating device. The aerosol-generating article may contain an aerosol-generating substrate according to the first aspect. The aerosol-generating article may be replaceable.

[0072] The aerosol-generating article may further comprise a support unit such that the article (including the support unit) can be inserted into an aerosol-generating device. The aerosol-generating article may further comprise a filter and / or a cooling chamber.

[0073] References herein to an aerosol-generating device may include any type of aerosol-generating device known to those skilled in the art. Generally, the terms "aerosol-generating device," "electronic cigarette," "e-cigarette," or "cold vaporization device" refer to an electronic inhaler that generates an aerosol from a substrate to simulate the act of smoking a cigarette. Generally, an aerosol-generating device includes four main components: a mouthpiece, a housing for the aerosol-generating article, a heating chamber, and a battery.

[0074] According to a second aspect of the present invention, there is provided an aerosol-generating article for use in an aerosol-generating device, the aerosol-generating article comprising an upstream segment located at the upstream end of the aerosol-generating article, the upstream segment comprising an aerosol-generating substrate according to the first aspect, and a downstream segment located at the downstream end of the aerosol-generating article, preferably the downstream segment comprising a support element, a cooling element, a filter element, or a combination thereof.

[0075] As used herein, the terms "upstream" and "downstream" refer to the direction of aerosol flow through an aerosol-generating article / system / device. Thus, the downstream end is the end where the aerosol flows out of the article / system / device and is the end closer to the consumer's mouth during use. The downstream end may equally refer to the proximal end of the aerosol-generating article / system / device. The upstream end is the end where the aerosol flows into the article / system / device. The upstream end may equally refer to the distal end of the aerosol-generating article / system / device.

[0076] The arrangement of the aerosol-generating article of the second embodiment allows the aerosol generated at the aerosol-generating substrate to be cooled and / or filtered before it leaves the device.

[0077] The aerosol-generating article of the second aspect of the present invention may further comprise a wrapper. The upstream segment and the downstream segment may be packaged together using at least one packaging element. The packaging element may be breathable. The packaging element may further comprise at least one ventilation zone to improve the breathability of the packaging element, as needed. Preferably, the packaging element is a paper wrapper. The aerosol-generating article may mirror the shape of the aerosol-generating structure, for example, it may have a flat structure.

[0078] According to a third aspect of the present invention, there is provided the use of a second solid composition (b) according to the first aspect to enhance the stability of a flavoring agent in an aerosol-generating substrate, improve flavor distribution, and / or delay release of a flavoring agent from the aerosol-generating substrate. The use of the second solid composition for these purposes may improve the sensory experience of consuming an aerosol generated using the aerosol-generating substrate. References to enhancing stability, improving flavor distribution, and delaying release are intended to mean a comparison with an aerosol-generating substrate that does not include the second solid composition, as defined herein, present as a separate phase on and / or in solid composition (a).

[0079] According to a fourth aspect of the present invention, there is provided an aerosol generating system comprising an aerosol-generating article according to the second aspect and an aerosol generating device comprising a heated chamber for receiving the aerosol-generating article (e.g., during use).

[0080] The heating chamber may include any suitable heater for heating the aerosol-generating article (and substrate) to produce an inhalable aerosol. The heating chamber serves to heat, rather than burn, the tobacco within the aerosol-generating article or substrate. The aerosol-generating device may be an electronic cigarette, particularly a "heat-not-burn" system or product.

[0081] The heating chamber may include a resistive or inductive heater. The heating chamber may further include a heat transfer element that absorbs heat from the heater and transfers the heat to the substrate.

[0082] The aerosol generating device may further include one or more components selected from a battery, a mouthpiece, a microcontroller, a pressure / flow sensitive switch, and / or combinations thereof.

[0083] Suitably, in the fourth aspect, the heating chamber of the aerosol-generating device comprises a heating element, wherein the heating element does not directly contact the second solid composition (b) contained in the aerosol-generating article.

[0084] The aerosol-forming substrate of the first aspect may be manufactured by any suitable method.

[0085] According to a fifth embodiment of the present invention, there is provided a method of producing an aerosol-generating substrate according to the first aspect, the method comprising contacting a first solid composition (a) with a second solid composition (b), placing the contacted compositions in a mould and applying heat and / or pressure to form the substrate.

[0086] Preferably, the first solid composition and the second solid composition are solid prior to contacting the composition.

[0087] The method of the fifth aspect can include any suitable step of contacting a first solid composition (a) with a second solid composition (b). For example, the method can include mixing the second solid composition (b) into the first solid composition (a). Alternatively, the method can include contacting at least one layer of composition (a) with at least one layer of composition (b), e.g., alternately. The method can include placing the contacted compositions in a mold and applying heat and / or pressure to form the substrate. Alternatively, the method can include stamping a desired shape from a sheet of substrate. The shape can preferably be a flat plate-like structure.

[0088] Preferably, the method of the fifth aspect does not include the step of contacting the substrate with a liquid composition (eg by spraying).

[0089] According to a sixth aspect of the present invention there is provided a method of generating an inhalable aerosol, the method comprising: (i) providing an aerosol generating system according to the fourth aspect; (ii) forming an inhalable aerosol by applying heat to the aerosol-generating article; Includes.

[0090] The aerosol-generating article may be heated to any suitable temperature to generate an inhalable aerosol, such as a temperature of about 350°C.

[0091] Embodiments of the present disclosure will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0092] [Figure 1] 1 shows a schematic cross-sectional view of an aerosol-generating substrate. [Figure 2] 1 shows a schematic cross-sectional view of an aerosol-generating substrate. [Figure 3] 1 shows a schematic cross-sectional view of an aerosol-generating substrate. DETAILED DESCRIPTION OF THE INVENTION

[0093] 1 is a schematic diagram of a flat aerosol-generating substrate according to a first embodiment of the present invention. A film (11) of a second solid composition (b) is embedded between layers (10) of a first solid composition (a). The film (11) of the second solid composition (b) contacts the layers (11) of the first solid composition, but exists as a separate phase in the substrate.

[0094] 2 is a schematic diagram of a flat aerosol-generating substrate according to a first embodiment of the present invention. The fine particles (20) of the second solid composition (b) are evenly distributed throughout the first solid composition (a) (10). The fine particles (20) of the second solid composition (b) contact the first solid composition (10) but exist as a separate phase within the substrate.

[0095] 3 is a schematic diagram of a flat aerosol-generating substrate according to a first embodiment of the present invention. The fine particles (20) of the second solid composition (b) are unevenly distributed throughout the first solid composition (a) (10), with at least 50% of the particles being in the region around the edge of the aerosol-generating substrate. The fine particles (20) of the second solid composition (b) contact the first solid composition (10), but exist as a separate phase within the substrate.

[0096] When used in an aerosol generating device, the top and bottom surfaces of the substrate are heated, which results in uniform heating without direct contact between the heating elements and the second solid composition (b).

[0097] Throughout this specification, the terms "comprising" or "comprises" mean including the specified components, but not excluding the presence of other components. The terms "consisting essentially of" or "consists essentially of" mean including the specified components, but excluding other components except for materials present as impurities, unavoidable materials present as a result of the process used to provide the components, and components added for purposes other than achieving the technical effects of the invention. Typically, when referring to a composition, a composition consisting essentially of a set of components will contain less than 5% by weight, typically less than 3% by weight, and more typically less than 1% by weight of unspecified components.

[0098] The recitation of numerical ranges by endpoints includes all integers and, where appropriate, fractions subsumed within that range (e.g., 1 to 5, e.g., when referring to the number of elements, may include 1, 2, 3, and 4; e.g., when referring to measurements, may also include 1.5, 2, 2.75, and 3.80). The recitation of endpoints also includes the endpoint values ​​themselves (e.g., 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all subranges subsumed therein.

[0099] For the avoidance of doubt, amounts of ingredients in a composition are described in terms of wt %, which means the weight percentage of the specified ingredient in relation to the total composition to which it refers. For example, "the aerosol-forming substrate comprises 1 to 15 wt % tobacco" means that between 1 wt % and 15 wt % of the aerosol-forming substrate is provided by tobacco.

[0100] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include both singular and plural referents unless the context clearly dictates otherwise.

[0101] The optional features described herein may be used individually or in combination with one another where appropriate, particularly in the combinations set out in the appended claims. Also, optional features of each aspect or exemplary embodiment of the invention described herein should be construed as applicable to any other aspect or exemplary embodiment of the invention, where appropriate. In other words, those skilled in the art reading this specification should regard optional features of each exemplary embodiment of the invention as interchangeable and combinable between different exemplary embodiments.

[0102] Attention is directed to all articles and documents in connection with this application that are filed contemporaneously with or prior to this application and that are published herewith and open to public inspection, and the contents of all such articles and documents are incorporated herein by reference.

[0103] All of the features disclosed in this specification (including the accompanying claims and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations in which at least some of such features and / or steps are mutually exclusive.

[0104] Each feature disclosed in this specification (including the accompanying claims and drawings), unless expressly stated otherwise, may be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.

[0105] The invention is not limited to the details of the foregoing embodiments, and extends to any novel one or any novel combination of features disclosed in this specification (including the accompanying claims and drawings), or any novel one or any novel combination of steps of any method or process so disclosed.

Claims

1. 1. An aerosol-generating substrate for use in an aerosol-generating article, the aerosol-generating substrate comprising: a) a first solid composition (a) comprising tobacco or a derivative thereof, a humectant, a first gelling agent, and a first binder; b) a second solid composition (b) comprising a flavoring agent, a second gelling agent, and one or more additives selected from a second binder, an emulsifier, and a filler; Including, 1. An aerosol-generating substrate, wherein the first solid composition (a) is granular and the second solid composition (b) is present as a separate phase on and / or within composition (a).

2. 10. The aerosol-generating substrate of claim 1, which is a shaped substrate, the shape being formed by the application of heat and / or pressure.

3. The aerosol-generating substrate according to claim 1 or 2, wherein the substrate has a flat plate-like structure.

4. 4. The aerosol-generating substrate according to claim 1, wherein the second solid composition (b) is substantially free of tobacco.

5. 5. The aerosol-generating substrate according to claim 1 , wherein the second solid composition (b) is in the form of a film, preferably the film being applied onto and between layers of the first solid composition (a), e.g. the film being embedded between layers of the first solid composition (a).

6. 5. The aerosol-generating substrate according to claim 1, wherein the second solid composition (b) is in the form of fine particles.

7. 7. The aerosol-generating substrate of claim 6, wherein the fine particles are evenly distributed on and / or within the first solid composition (a).

8. 7. The aerosol-generating substrate according to claim 6, wherein the particles are distributed unevenly on and / or in the first solid composition (a), preferably the particles are distributed mainly on and / or in the first solid composition (a) at and / or in regions adjacent to the edges of the substrate.

9. 9. The aerosol-generating substrate of claim 6 or 8, wherein up to 50% by weight of the fine particles are distributed evenly throughout the first solid composition (a), and at least 50% by weight of the fine particles are distributed on and / or within the first solid composition (a) at and / or in areas adjacent to the edges of the substrate.

10. 10. An aerosol-generating article for use in an aerosol-generating device, the aerosol-generating article comprising: an upstream segment located at an upstream end of the aerosol-generating article, the upstream segment comprising the aerosol-generating substrate according to any one of claims 1 to 9; and a downstream segment located at a downstream end of the aerosol-generating article, wherein the downstream segment preferably comprises a cooling element, a filter element, or a combination thereof.

11. 10. Use of the second solid composition (b) in the aerosol-generating substrate of claim 1 to enhance the stability of the flavoring agent in the aerosol-generating substrate, improve flavor distribution, and / or delay the release of the flavoring agent from the aerosol-generating substrate.

12. 11. An aerosol generating system comprising the aerosol-generating article of claim 10 and an aerosol-generating device including a heated chamber for receiving the aerosol-generating article.

13. 13. The aerosol generating system of claim 12, wherein the heating chamber includes a heating element, the heating element not directly contacting the second solid composition (b) contained in the aerosol-generating article.

14. 10. A method of making an aerosol-generating substrate according to any one of claims 1 to 9, the method comprising contacting the first solid composition (a) with the second solid composition (b), placing the contacted compositions in a mould, and applying heat and / or pressure to form the substrate.

15. 1. A method of generating an inhalable aerosol, said method comprising: (i) providing an aerosol generating system according to claim 12 or 13; (ii) forming an inhalable aerosol by applying heat to the aerosol-generating article; A method comprising:

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