Aerosol generating materials

Abstract

Disclosed are an aerosol-generating material containing plant-based material and a method for producing such an aerosol-generating material. The method includes the steps of supplying an initial material containing particulate plant-based material and processing the initial material by subjecting it to increased mechanical pressure to produce an aerosol-generating material.

Description

Technical Field

[0001] The present disclosure relates to an aerosol - forming material comprising a vegetable material and a method of manufacturing such a material.

Background Art

[0002] An aerosol - forming material is typically heated 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 reconstituted tobacco materials.

Summary of the Invention

[0003] According to a first aspect of the present disclosure, a method of manufacturing an aerosol - forming material, comprising: supplying an initial material comprising at least 20% by mass of particulate non - tobacco vegetable material; processing the initial material by subjecting the initial material to an elevated mechanical pressure to produce an aerosol - forming material; and further comprising applying an additive selected from an aerosol - forming material, an active substance, and a binder to the initial material before or during subjecting the initial material to an elevated mechanical pressure, and applying an additive selected from an aerosol - forming material, an active substance, and a binder to the aerosol - forming material after subjecting the initial material to an elevated mechanical pressure. A method of manufacturing an aerosol - forming material is provided, comprising at least one of the above. [[ID=三十五]]

[0004] [[ID=三十六]] [[ID=三十七]] The method may further comprise applying an additive selected from an aerosol - forming material, an active substance, and a binder to the aerosol - forming material after subjecting the initial material to an elevated mechanical pressure.

[0005] The aerosol - forming material may be a discontinuous aerosol - forming material. Thus, the method may be a method of manufacturing a discontinuous aerosol - forming material.

[0006] The initial material may contain less than 60% by mass of tobacco material.

[0007] The initial material may contain more than 30% by mass of particulate non-tobacco plant material.

[0008] The aerosol-generating material does not need to contain tobacco material.

[0009] The particulate non-tobacco plant material may be derived from species belonging to the following families: Asteracae family, Fabaceae family, Myrtaceae family, Apiaceae family, Camellia taliensis, Solanaceae family, Brassicaceae family, Caricaceae family, Asclepiadaceae family, Equisetaceae family, Oleaceae family, Lamiaceae family, and tisanes.

[0010] The particulate non-tobacco plant material may be selected from species such as Matricaria (including chamomile), Pimpinella anisum (including anise), Foeniculum vulgare (including fennel), and Aspalathus linearis (including jasmine, lavender, clove, eucalyptus, and rooibos).

[0011] The particulate non-tobacco plant material may include mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove material.

[0012] In some embodiments, the initial material further comprises non-tobacco cellulose fibers. The initial material may contain at least 5% by mass of cellulose fibers. The initial material may contain at least 5-20% by mass of cellulose fibers.

[0013] This method may further include the step of supplying an initial material by combining a plant material with non-tobacco cellulose fibers, the initial material comprising at least 50% by mass of particulate non-tobacco plant material.

[0014] This delicious, A step of processing the initial material, To produce an aerosol-generating material by binding particulate non-tobacco plant material to non-tobacco cellulose fibers, The process of setting the initial material to a predetermined water content, A process of subjecting the initial material to a temperature increase, and A process of subjecting the initial material to increased pressure. The process may further include a step of processing the initial materials by means of [a specific method].

[0015] The particulate non-tobacco plant material and the non-tobacco cellulose fibers may each be pre-sized, and their sizes may substantially overlap or have corresponding particle size distributions.

[0016] According to a second aspect of this disclosure, A method for producing an aerosol generating material, The process involves supplying an initial material comprising particulate tobacco plant material and non-tobacco cellulose fibers, wherein the initial material comprises at least 20% by mass of particulate tobacco plant material. The process involves processing the initial material by subjecting it to increased mechanical pressure to produce an aerosol-generating material. It includes, and further, The steps include: applying an additive selected from an aerosol-forming material, an active substance, and a binder to the initial material before or during the application of increased mechanical pressure to the initial material; The first step involves subjecting the initial material to increased mechanical pressure, and then applying an additive selected from an aerosol-forming material, an active substance, and a binder to the aerosol-generating material. A method for producing an aerosol-generating material is provided, comprising at least one of the following.

[0017] This method may further include the step of subjecting the initial material to increased mechanical pressure, and then applying an additive selected from an aerosol-forming material, an active substance, and a binder to the aerosol-generating material.

[0018] The aerosol-generating material may be a discontinuous aerosol-generating material. Therefore, this method may also be a method for producing a discontinuous aerosol-generating material.

[0019] This delicious, A step of processing the initial material, To produce an aerosol-generating material by binding particulate tobacco plant material to non-tobacco cellulose fibers, The process of setting the initial material to a predetermined water content, A process of subjecting the initial material to a temperature increase, and A process of subjecting the initial material to increased pressure. The process may further include a step of processing the initial materials by means of [a specific method].

[0020] The initial material and / or aerosol-generating material may contain at least 5% by mass of non-tobacco cellulose fibers.

[0021] Non-tobacco cellulose fibers may contain wood pulp or consist of wood pulp.

[0022] The initial material may contain 5-20% by mass of non-tobacco cellulose fibers.

[0023] Non-tobacco cellulose fibers may be pre-sized and may have Dp90 values ​​of 130 to 200 micrometers, Dp50 values ​​of 50 to 100 micrometers, and Dp10 values ​​of 10 to 50 micrometers.

[0024] The initial material and / or aerosol-generating material may include more than 3% or 4% by mass, preferably more than 5% by mass, for example, 10 to 25% by mass of aerosol-forming material.

[0025] The initial material and / or aerosol-generating material may contain 15 to 20% by mass of aerosol-forming material.

[0026] The aerosol-forming material may include glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

[0027] The initial material and / or aerosol-generating material may contain a binder in an amount of up to 25% by mass.

[0028] The binder may include carboxymethylcellulose (CMC), starch, guar gum, xanthan gum, acacia gum, and / or hydroxypropylcellulose (HPC).

[0029] The initial material and / or aerosol-generating material may include 10-20% by mass, preferably about 15% by mass, of an aerosol-forming material such as glycerol, and the packing value of the aerosol-generating material in these embodiments is 40-46 cm³. 3 It may be 10g. The initial material and / or aerosol-generating material may contain 2 to 10% by mass, preferably about 5% by mass, of a binder. The binder may contain CMC.

[0030] The initial material and / or aerosol-generating material may include 2 to 10% by mass, preferably about 5% by mass, of an aerosol-forming material such as glycerol, and the filling value of the aerosol-generating material in these embodiments is 45 or 46 cm³.3 The amount may exceed 10g. The initial material and / or aerosol-generating material may contain 2 to 10% by mass, preferably about 5% by mass, of a binder. The binder may contain CMC.

[0031] The active substance may be selected from nutritional supplements, nootropics, and psychostimulants.

[0032] The active substance may include nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or their components, derivatives, or combinations, or components, derivatives, or extracts of one or more species of tobacco, cannabis, or other plants.

[0033] The active substance may contain nicotine or a nicotine salt. The nicotine salt may be selected from nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or a combination thereof.

[0034] The initial material and / or aerosol-generating material may contain up to 3% by mass of nicotine.

[0035] The initial material and / or aerosol-generating material may further contain an acid.

[0036] The initial material and / or aerosol-generating material may contain an amount of acid ranging from about 0.1% to about 5% by weight.

[0037] The acid may include one or more acids selected from lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and 2-methylvaleric acid.

[0038] The aerosol-generating material may have a Dp90 value of 1.2 mm to 6.0 mm, a Dp50 value of 1.1 mm to 2.4 mm, and a Dp10 value of 0.2 mm to 1.5 mm.

[0039] The aerosol generating material is 25 cm 3 / 10g or more, for example, 30cm3 The filling value may exceed 10g. The aerosol generating material is 25-50cm 3 / 10g, for example, 27-48cm 3 / 10g or 29-45cm 3 It may have a filling capacity of 10g.

[0040] The initial material processing step may include transporting the initial material through a conveyor that increases mechanical pressure, with the conveyor operating at a throughput of 25–75 kg / hour.

[0041] The step of processing the initial material may include the use of a water flow rate of less than 12 L / hour.

[0042] The step of processing the initial material may include pressurizing the initial material to a pressure in the range of 15 to 35 bar.

[0043] This method may include extrusion and cutting of the material in a single process.

[0044] The method may further include the step of feeding the processed material through a shear gap, the shear gap being positioned between shear surfaces, and a rotatable shearing member being positioned on one of the shear surfaces, the method including the step of rotating the shearing member at an angular velocity of 500 to 850 rpm.

[0045] This method may further include the step of applying an aerosol-forming material and an active substance to the initial material before or during the application of increased mechanical pressure to the initial material.

[0046] This method may further include the step of subjecting the initial material to increased mechanical pressure, and then applying an aerosol-forming material and an active substance to the aerosol-generating material.

[0047] This method may further include the step of applying an aerosol-forming material and a binder to the initial material before or during the application of increased mechanical pressure to the initial material.

[0048] This method may further include the step of subjecting the initial material to increased mechanical pressure, and then applying an aerosol-forming material and a binder to the aerosol-generating material.

[0049] This method may further include the step of applying an active substance and a binder to the initial material before or during the application of increased mechanical pressure to the initial material.

[0050] This method may further include the step of subjecting the initial material to increased mechanical pressure, and then applying an active substance and a binder to the aerosol-generating material.

[0051] This method may further include the step of applying an aerosol-forming material, an active substance, and a binder to the initial material before or during the application of increased mechanical pressure to the initial material.

[0052] This method may further include the step of subjecting the initial material to increased mechanical pressure, and then applying an aerosol-forming material, an active substance, and a binder to the aerosol-generating material.

[0053] According to a third aspect of this disclosure, A method for producing an aerosol generating material, A step of supplying pre-sized particulate plant material containing less than 95% by mass of tobacco material, A step of supplying cellulose fibers of a predetermined size, The steps include: supplying an initial material containing at least 50% by mass of plant material by combining plant material with cellulose fibers; A step of processing initial materials, wherein plant material is bonded to cellulose fibers in order to produce an aerosol-generating material, The process of setting the initial material to a predetermined water content, A process of subjecting the initial material to a temperature increase, and A process of subjecting the initial material to increased pressure. The steps of processing the initial materials and A method for producing an aerosol-generating material is provided, which includes [the specified element].

[0054] The aerosol-generating material may be a discontinuous aerosol-generating material. Therefore, this method may also be a method for producing a discontinuous aerosol-generating material.

[0055] The plant-based material may contain less than 60% by mass of tobacco material, for example, less than 55% by mass, less than 50% by mass, less than 45% by mass, less than 40% by mass, less than 35% by mass, less than 30% by mass, or less than 25% by mass of tobacco material.

[0056] The plant-based material may contain less than 20% by mass, or less than 15% by mass, for example, less than 10% by mass of tobacco material.

[0057] The plant-based material may contain less than 1% by mass of tobacco material, or it may not contain any tobacco material at all.

[0058] The plant-based material may be a non-tobacco plant-based material. The aerosol-generating material does not need to contain tobacco material.

[0059] The plant-based material may include more than 30% by mass of non-tobacco plant-based material, for example, more than 40% by mass, more than 50% by mass, more than 60% by mass, more than 70% by mass, more than 80% by mass, more than 90% by mass, or more than 95% by mass of non-tobacco plant-based material.

[0060] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove materials.

[0061] The initial material and / or aerosol-generating material may contain at least 5% by mass of cellulose fibers. The initial material may contain at least 5-20% by mass of cellulose fibers.

[0062] The cellulose fibers may be non-tobacco cellulose fibers. The cellulose fibers may contain wood pulp or consist of wood pulp.

[0063] The initial material and / or aerosol-generating material may contain 60-75% by mass of plant-based material.

[0064] The initial material and / or aerosol-generating material may include an aerosol-forming material. The aerosol-forming material may be present in an amount of 5 to 30% by mass, for example, 10 to 25% by mass or 15 to 20% by mass.

[0065] The aerosol-forming material may include glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

[0066] The aerosol-generating material may have a Dp90 value of 1.2 mm to 6.0 mm, a Dp50 value of 1.1 mm to 2.4 mm, and a Dp10 value of 0.2 mm to 1.5 mm.

[0067] Pre-sized cellulose fibers may have Dp90 values ​​for 130 to 200 micrometers, Dp50 values ​​for 50 to 100 micrometers, and Dp10 values ​​for 10 to 50 micrometers.

[0068] Pre-sized plant materials and pre-sized cellulose fibers may have substantially overlapping sizes or corresponding particle size distributions.

[0069] The initial material and / or aerosol-generating material may further contain a binder. The binder may be present in an amount of up to 15% by mass, 20% by mass, or 25% by mass.

[0070] The binder may include carboxymethylcellulose (CMC), starch, guar gum, xanthan gum, acacia gum, and / or hydroxypropylcellulose (HPC).

[0071] The initial material processing step may include transporting the initial material through a conveyor that increases mechanical pressure, with the conveyor operating at a throughput of 25–75 kg / hour.

[0072] The step of processing the initial material may include the use of a water flow rate of less than 12 L / hour.

[0073] The step of processing the initial material may include pressurizing the initial material to a pressure in the range of 15 to 35 bar.

[0074] The method may further include the step of feeding the processed material through a shear gap, the shear gap being positioned between shear surfaces, and a rotatable shearing member being positioned on one of the shear surfaces, the method including the step of rotating the shearing member at an angular velocity of 500 to 850 rpm.

[0075] The initial material and / or aerosol-generating material may contain nicotine or a nicotine salt. The nicotine salt may be selected from nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or a combination thereof. Nicotine may be present in an amount of up to 3% by weight of the initial material and / or the resulting aerosol-generating material, for example, about 0.5% by weight, 1% by weight, or 2% by weight.

[0076] The initial material and / or aerosol-generating material may contain an acid. The total amount of acid may be about 0.1% to about 5% by weight of the initial material and / or the resulting aerosol-generating material. The acid may be selected from the group consisting of lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and 2-methylvaleric acid. In some embodiments, the acid is lactic acid.

[0077] According to the fourth aspect of this disclosure, At least 20% by mass of particulate plant material, Non-tobacco cellulose fibers, below: Aerosol-forming materials, An active substance, and a binder and at least one additive selected from are provided with an aerosol - generating material.

[0078] The particulate vegetable material may include a particulate tobacco material, a particulate non - tobacco material, or a combination thereof.

[0079] The particulate vegetable material may include a particulate tobacco material, a particulate non - tobacco vegetable material, or a combination thereof.

[0080] The aerosol - generating material may be a discontinuous aerosol - generating material.

[0081] According to a fifth aspect of the present disclosure, there is provided an aerosol - generating material produced, obtained, or obtainable by any one or more of the methods of the first, second, and / or third aspects.

[0082] The aerosol - generating material may have a filling power (also referred to as "filling value" or "fill value") exceeding 25 cm 3 / 10 g, for example, exceeding 30 cm 3 / 10 g. The aerosol - generating material may have a filling power of 25 - 50 cm 3 / 10 g, for example, 27 - 48 cm 3 / 10 g or 29 - 45 cm 3 / 10 g. The aerosol - generating material may have a filling power exceeding 25 cm 3 / 10 g, exceeding 30 cm 3 / 10 g, exceeding 35 cm 3 / 10 g, or exceeding 40 cm 3 / 10 g. The aerosol - generating material may have a filling power less than 65 cm 3 / 10 g, less than 60 cm 3 / 10 g, less than 58 cm 3 / 10 g, or less than 55 cm 3 / 10 g.

[0083] The aerosol-generating material has a high packing value and a low density. As a result, the aerosol-generating material may preferably contain a high level of aerosol-forming material, for example, up to 40% by mass. In some embodiments, the aerosol-generating material may contain an amount of 10-30% aerosol-forming material.

[0084] A sixth aspect of the present disclosure provides a component for a delivery system, the component comprising an aerosol-generating material of the fourth and / or fifth aspect, or an aerosol-generating material manufactured, obtained, or obtainable by any one or more of the first, second and / or third aspects.

[0085] The components may be for use in an aerosol supply system.

[0086] According to a seventh aspect of this disclosure, a product is provided which includes components according to a sixth aspect.

[0087] This product may be a non-combustible aerosol supply system. The non-combustible aerosol supply system may also be an aerosol-generating material heating system, also known as a non-combustible heating system. The non-combustible aerosol supply system may also be a cigarette heating system.

[0088] According to the eighth aspect of this disclosure, an article is provided for use in or for use as an aerosol supply system, comprising components according to the sixth aspect.

[0089] According to the ninth aspect of this disclosure, an article is provided comprising an aerosol-generating material manufactured according to one or more of the methods of the first, second, and / or third aspects.

[0090] According to a tenth aspect of this disclosure, the use of aerosol-generating material of the fourth or fifth aspect in an article for use in an aerosol supply system is provided.

[0091] According to an eleventh aspect of the present disclosure, an article is provided for use in, or for use as, an aerosol supply system comprising an aerosol generating material of the fourth or fifth aspect.

[0092] A system is provided that includes an aerosol-generating material according to a fourth or fifth embodiment and a device configured to heat the aerosol-generating material and generate an aerosol from the aerosol-generating material.

[0093] Pre-sized plant-based materials "Pre-sized" materials refer to materials that have undergone a pre-sizing step before being combined with other materials to form the initial material.

[0094] As used herein, the term “plant material” includes, but is not limited to, any material derived from any part of a plant, including leaves, bark, buds, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, and / or husks.

[0095] The plant material is preferably an aromatic plant material. "Aromatic" refers to any material that has a distinctive aromatic scent. Therefore, an aromatic plant material is any plant material that can be identified by its aroma. Examples of plant materials include eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, and elderflower. It may include, or consist of, one or a combination of plant materials derived from or obtained therefrom, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.

[0096] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove materials.

[0097] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, ginger, cinnamon, and / or clove materials.

[0098] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, ginger, and / or cinnamon materials.

[0099] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, ginger, rooibos, and / or cinnamon materials.

[0100] The plant-based materials may include, or consist of, mint, eucalyptus, lavender, and / or cinnamon materials.

[0101] The plant-based material may contain mint material or consist of mint material.

[0102] The plant-based material may include eucalyptus material or consist solely of eucalyptus material.

[0103] The plant-based material may contain lavender material or consist solely of lavender material.

[0104] The plant-based material may contain clove material or consist of clove material.

[0105] The plant-based material may contain ginger material or consist of ginger material.

[0106] The plant-based material may contain rooibos material or consist solely of rooibos material.

[0107] The plant-based material may be a non-tobacco plant-based material, and preferably does not contain or is free from tobacco material.

[0108] The initial material may contain 50% to 95% by mass of plant-based material, for example, 52% to 90% by mass, 55% to 85% by mass, or 57% to 80% by mass.

[0109] Preferably, the initial material may contain 60% to 75% by mass, for example, 62% to 73% by mass, of plant-based material.

[0110] In embodiments in which the initial material and / or aerosol-generating material comprises less than 10% by mass of aerosol-forming material, the initial material may include 60% to 95% by mass, for example, 65% to 90% by mass, 67% to 87% by mass, 70% to 85% by mass, or 72% to 82% by mass of plant-derived material.

[0111] The plant material may be pre-sized to the required particle size range by any suitable method or combination of methods. Suitable methods may include size reduction methods such as suitable grinding methods, and / or size selection methods such as suitable sieving and / or sorting methods.

[0112] The plant material may be modified, such as by drying, to provide a predetermined moisture content. This modification may be performed before and / or after any size reduction and / or selection process.

[0113] The plant-based material may have a water content of more than 2%, more than 3%, more than 4%, or more than 5%, or may be adjusted to have a water content.

[0114] The plant-based material may have a water content of less than 30%, less than 28%, or less than 25%, or may be adjusted to have a water content.

[0115] The pre-sized plant material may have a particle size smaller than that of the pre-sized cellulose fibers, for example, based on the mean (mode, median, or average) particle size. In the disclosed method, the pre-sized plant material is bonded to the pre-sized cellulose fibers by applying increasing temperature and pressure to form an aerosol-generating material.

[0116] In some embodiments, pre-sized plant materials may substantially overlap in size with or have a corresponding particle size distribution to those of pre-sized cellulose fibers. The use of plant materials and cellulose fiber materials with similar and / or overlapping particle size distributions improves mixing and produces a more homogeneous mixture, resulting in the production of a more reproducible and consistent material.

[0117] In some embodiments, the pre-sized plant material may have a particle size larger than that of the pre-sized cellulose fibers, for example, based on the mean (mode, median, or average) particle size.

[0118] The values ​​Dp90, Dp50, and Dp10 refer to particle sizes smaller than these values, representing 90% by mass, 50% by mass, and 10% by mass, respectively, of the material. For example, if the Dp90 value is 1 mm, then 90% by mass of the material, such as a pre-sized plant material or aerosol-generating material (as shown), has a particle size of less than 1 mm.

[0119] In some embodiments, the plant material may be used in particulate form. In embodiments where the plant material is in particulate form, the pre-sized plant material may have a Dp90 value greater than 3 mm, a Dp50 value greater than 1.5 mm, and / or a Dp10 value of 0.2 mm to 0.8 mm, for example, 0.3 mm to 0.6 mm, or about 0.4 mm. Preferably, the plant material that may be used in particulate form may consist of, for example, clove or lavender material, or include plant materials containing such materials.

[0120] In some embodiments, the plant material may be used in powder form. In embodiments where the plant material is in powder form, the pre-sized plant material may have a Dp90 value of 0.2 mm to 1.5 mm, for example, 0.35 mm to 1.15 mm; a Dp50 value of 0.1 mm to 0.8 mm, for example, 0.15 mm to 0.7 mm; and / or a Dp10 value of 0.01 mm to 0.5 mm, for example, 0.03 mm to 0.25 mm. Preferably, the plant material that may be used in powder form consists of, for example, mint, eucalyptus, cinnamon, and / or lavender material, or includes pulverized plant material containing these.

[0121] In some embodiments, the plant-based material may include a combination of particulate and powder-based materials. The use of a combination of particulate and powder-based plant-based materials has been found to improve the properties of the aerosol-generating material compared to formulations containing only powder-based materials.

[0122] In some embodiments, the lavender plant material may include a combination of particulate and powdered materials. In such embodiments, the lavender plant material may include a combination of particulate lavender flower material and lavender powder. The ratio of lavender powder to lavender flower material may be about 58:15 (w / w).

[0123] In some embodiments, the clove plant material may include clove bud material. The clove plant material may include a combination of particulate and powdered materials. In such embodiments, the clove plant material may include a combination of clove bud particulate material and clove powder. The ratio of clove powder to clove bud material may be about 51.5:14.5 (w / w).

[0124] In some embodiments, the use of pre-sized plant materials having larger particle sizes may be advantageous. For example, the use of larger particles has been found to offer manufacturing advantages. In particular, for plant materials with small particle sizes, such as materials in powder form, lower feed rates are preferred to reduce the risk of clogging the system. In such embodiments, the use of larger particles, such as materials in particulate form, is advantageous because it allows for the use of higher feed rates and provides manufacturing efficiency.

[0125] In some embodiments, the use of pre-sized plant materials having smaller particle sizes may be advantageous. For example, in some embodiments, it has been found that there is an inverse relationship between particle size and packing density, so that using plant materials with smaller particle sizes may provide an aerosol-generating material with a larger packing density.

[0126] Plant-derived materials having a particle size of less than 1 mm are called "plant-derived fine powder" materials. Plant-derived fine powder materials may include, be derived from, or essentially consist of dust from the processing of plant-derived materials, which may include the manufacture of any product containing plant-derived materials. Thus, the advantage of the disclosed method is that plant-derived materials that would otherwise be considered waste can be used productively in the manufacture of the disclosed aerosol-generating materials.

[0127] Surprisingly, volatile aromatic and flavor compounds were found to be retained in aerosol-generating materials in amounts previously impossible, particularly in relation to the disclosed plant-based materials, and to provide flavor and sensory profiles previously impossible in aerosol-generating materials.

[0128] Mint plant-based ingredients The plant-based material may be a mint plant-based material. The mint plant-based material may contain or consist of materials derived from the mint plant.

[0129] "Mint," "mint material," and "mint plant material" refer to any material derived from plants of the genus Mentha in the family Lamiaceae. Any plant of this genus may also be called a "mint plant." The mint plant material may include, or consist of, materials from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens. The mint plant material may include material from any part of the mint plant, preferably including or consisting of mint leaves and / or mint stem material. The mint plant material may also contain menthol.

[0130] The mint plants may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0131] The pre-sized particulate mint plant material may include material from any part of the mint plant, such as mint leaves and / or mint stems. Preferably, the pre-sized particulate mint plant material may include mint leaves and / or mint stems.

[0132] Pre-sized particulate mint plant material may have a water content of more than 2%, more than 3%, more than 4%, or more than 5%, or may be adjusted to have a water content.

[0133] Pre-sized particulate mint plant material may have a water content of less than 10%, less than 8%, less than 7%, or less than 6%, or may be adjusted to have a water content.

[0134] The pre-sized particulate mint plant material may include materials with a particle size greater than 0.85 mm in amounts exceeding 0.1% by mass, 0.2% by mass, or 0.3% by mass. The pre-sized particulate mint plant material may also include materials with a particle size greater than 0.85 mm in amounts less than 5% by mass, less than 3% by mass, or less than 1% by mass.

[0135] The pre-sized particulate mint plant material may include materials with a particle size of less than 0.85 mm that make up more than 90% by mass, more than 95% by mass, more than 99% by mass, or more than 99.5% by mass. The pre-sized particulate mint plant material may also include materials with a particle size of less than 0.85 mm that make up less than 99.995% by mass, less than 99.95% by mass, less than 99.9% by mass, or less than 99.8% by mass.

[0136] The pre-sized particulate mint plant material may include mint plant material having a particle size greater than 0.5 mm in amounts exceeding 0.1% by mass, 0.5% by mass, 1% by mass, or 1.5% by mass. The pre-sized particulate mint plant material may also include mint plant material having a particle size greater than 0.5 mm in amounts less than 10% by mass, less than 5% by mass, less than 3% by mass, or less than 2% by mass.

[0137] The pre-sized particulate mint plant material may include mint fine powder material having a particle size of less than 0.5 mm and comprising more than 95% by mass, more than 96% by mass, more than 97% by mass, or more than 98% by mass. The pre-sized particulate mint plant material may also include mint fine powder material having a particle size of less than 0.5 mm and comprising less than 99.95% by mass, less than 99.5% by mass, less than 99% by mass, or less than 98.5% by mass.

[0138] The pre-sized particulate mint plant material may include mint plant material having a particle size exceeding 355 micrometers in amounts exceeding 1% by mass, 3% by mass, 5% by mass, or 8% by mass. The pre-sized particulate mint plant material may also include mint plant material having a particle size exceeding 355 micrometers in amounts less than 20% by mass, 15% by mass, 12% by mass, or 10% by mass.

[0139] The pre-sized particulate mint plant material may include mint fine powder material having a particle size of less than 355 micrometers in amounts exceeding 75% by mass, exceeding 80% by mass, exceeding 85% by mass, or exceeding 90% by mass. The pre-sized particulate mint plant material may also include mint fine powder material having a particle size of less than 355 micrometers in amounts less than 99% by mass, less than 97% by mass, less than 95% by mass, or less than 92% by mass.

[0140] The pre-sized particulate mint plant material may include mint plant material having a particle size exceeding 250 micrometers in amounts exceeding 5% by mass, exceeding 10% by mass, exceeding 15% by mass, or exceeding 20% ​​by mass. The pre-sized particulate mint plant material may also include mint plant material having a particle size exceeding 250 micrometers in amounts less than 35% by mass, less than 30% by mass, less than 25% by mass, or less than 23% by mass.

[0141] The pre-sized particulate mint plant material may include mint fine powder material having a particle size of less than 250 micrometers in amounts exceeding 50% by mass, exceeding 60% by mass, exceeding 70% by mass, or exceeding 75% by mass. The pre-sized particulate mint plant material may also include mint fine powder material having a particle size of less than 250 micrometers in amounts less than 95% by mass, less than 90% by mass, less than 85% by mass, or less than 80% by mass.

[0142] The pre-sized particulate mint plant material may include mint plant material having a particle size exceeding 100 micrometers in amounts exceeding 40% by mass, exceeding 50% by mass, exceeding 55% by mass, or exceeding 60% by mass. The pre-sized particulate mint plant material may also include mint plant material having a particle size exceeding 100 micrometers in amounts less than 80% by mass, less than 70% by mass, less than 65% by mass, or less than 62% by mass.

[0143] The pre-sized particulate mint plant material may include mint fine powder material having a particle size of less than 100 micrometers in amounts exceeding 20% ​​by mass, 25% by mass, 30% by mass, or 35% by mass. The pre-sized particulate mint plant material may also include mint fine powder material having a particle size of less than 100 micrometers in amounts less than 60% by mass, 50% by mass, 45% by mass, or 40% by mass.

[0144] The mint powder material may include, be derived from, or essentially consist of dust from the processing of mint material, which may include the manufacture of any product containing mint material.

[0145] Pre-sized particulate mint plant material may have a Dp90 value of 0.1 mm to 0.6 mm, for example, 0.3 mm to 0.4 mm. Pre-sized particulate mint plant material may have a Dp90 particle size of approximately 0.35 mm.

[0146] Pre-sized particulate mint plant material may have a Dp50 value of 0.05 mm to 0.4 mm, for example, 0.1 mm to 0.2 mm. Pre-sized particulate mint plant material may have a Dp50 particle size of approximately 0.15 mm.

[0147] Pre-sized particulate mint plant material may have a Dp10 value of 0.01 mm to 0.1 mm, for example, 0.02 mm to 0.06 mm. Pre-sized particulate mint plant material may have a Dp10 particle size of approximately 0.03 mm.

[0148] Eucalyptus plant-based materials The plant-based material may be eucalyptus plant-based material. The eucalyptus plant-based material may contain or consist of material derived from the eucalyptus plant.

[0149] "Eucalyptus," "eucalyptus material," and "eucalyptus plant material" refer to any material derived from plants of the genus Eucalyptus, including various species of flowering trees, shrubs, or marigolds of the family Myrtaceae. Any plant or tree of this genus may be called a "eucalyptus plant" or "eucalyptus tree." Eucalyptus plant material may include material from any part of a eucalyptus tree, and preferably, eucalyptus plant material may include or consist of eucalyptus leaves and / or eucalyptus stems and / or eucalyptus flower material. Eucalyptus plant material may contain cineole.

[0150] Pre-sized particulate eucalyptus plant material may include material from any part of the eucalyptus plant. Preferably, pre-sized particulate eucalyptus plant material may include eucalyptus leaf material.

[0151] Pre-sized particulate eucalyptus plant material may have a water content of more than 5%, more than 7%, more than 9%, or more than 10%, or may be adjusted to have a water content.

[0152] Pre-sized particulate eucalyptus plant material may have a water content of less than 18%, less than 15%, less than 12%, or less than 11%, or may be adjusted to have a water content.

[0153] The pre-sized particulate eucalyptus plant material may include materials with a particle size greater than 0.85 mm in amounts exceeding 20% ​​by mass, 30% by mass, or 35% by mass. The pre-sized particulate eucalyptus plant material may also include materials with a particle size greater than 0.85 mm in amounts less than 50% by mass, 45% by mass, 40% by mass, or 37% by mass.

[0154] The pre-sized particulate eucalyptus plant material may include materials with a particle size of less than 0.85 mm in amounts exceeding 50% by mass, 55% by mass, 60% by mass, or 63% by mass. The pre-sized particulate eucalyptus plant material may also include materials with a particle size of less than 0.85 mm in amounts less than 80% by mass, 70% by mass, 65% by mass, or 64% by mass.

[0155] The pre-sized particulate eucalyptus plant material may include eucalyptus plant material having a particle size greater than 0.5 mm in amounts exceeding 50% by mass, exceeding 60% by mass, exceeding 63% by mass, or exceeding 66% by mass. The pre-sized particulate eucalyptus plant material may also include eucalyptus plant material having a particle size greater than 0.5 mm in amounts less than 80% by mass, less than 75% by mass, less than 70% by mass, or less than 67% by mass.

[0156] The pre-sized particulate eucalyptus plant material may include eucalyptus fine powder material having a particle size of less than 0.5 mm in amounts exceeding 20% ​​by mass, exceeding 25% by mass, exceeding 30% by mass, or exceeding 33% by mass. The pre-sized particulate eucalyptus plant material may also include eucalyptus fine powder material having a particle size of less than 0.5 mm in amounts less than 50% by mass, less than 40% by mass, less than 37% by mass, or less than 34% by mass.

[0157] Pre-sized particulate eucalyptus plant material may include eucalyptus plant material having a particle size exceeding 355 micrometers in amounts exceeding 60% by mass, exceeding 70% by mass, exceeding 75% by mass, or exceeding 78% by mass. Pre-sized particulate eucalyptus plant material may also include eucalyptus plant material having a particle size exceeding 355 micrometers in amounts less than 95% by mass, less than 90% by mass, less than 85% by mass, or less than 80% by mass.

[0158] The pre-sized particulate eucalyptus plant material may include eucalyptus fine powder material having a particle size of less than 355 micrometers in amounts exceeding 5% by mass, exceeding 10% by mass, exceeding 15% by mass, or exceeding 20% ​​by mass. The pre-sized particulate eucalyptus plant material may also include eucalyptus fine powder material having a particle size of less than 355 micrometers in amounts less than 40% by mass, less than 30% by mass, less than 25% by mass, or less than 22% by mass.

[0159] The pre-sized particulate eucalyptus plant material may include eucalyptus plant material having a particle size exceeding 250 micrometers in amounts exceeding 70% by mass, exceeding 80% by mass, exceeding 85% by mass, or exceeding 87% by mass. The pre-sized particulate eucalyptus plant material may also include eucalyptus plant material having a particle size exceeding 250 micrometers in amounts less than 97% by mass, less than 95% by mass, less than 90% by mass, or less than 88% by mass.

[0160] The pre-sized particulate eucalyptus plant material may include eucalyptus fine powder material having a particle size of less than 250 micrometers in amounts exceeding 5% by mass, exceeding 7% by mass, exceeding 10% by mass, or exceeding 12% by mass. The pre-sized particulate eucalyptus plant material may also include eucalyptus fine powder material having a particle size of less than 250 micrometers in amounts less than 30% by mass, less than 20% by mass, less than 15% by mass, or less than 13% by mass.

[0161] Pre-sized particulate eucalyptus plant material may include eucalyptus plant material having a particle size exceeding 100 micrometers in amounts exceeding 80% by mass, exceeding 90% by mass, exceeding 93% by mass, or exceeding 96% by mass. Pre-sized particulate eucalyptus plant material may also include eucalyptus plant material having a particle size exceeding 100 micrometers in amounts less than 99.5% by mass, less than 99% by mass, less than 98% by mass, or less than 97% by mass.

[0162] The pre-sized particulate eucalyptus plant material may contain eucalyptus fine powder material having a particle size of less than 100 micrometers in amounts exceeding 0.5% by mass, 1% by mass, 2% by mass, or 3% by mass. The pre-sized particulate eucalyptus plant material may also contain eucalyptus fine powder material having a particle size of less than 100 micrometers in amounts less than 15% by mass, 10% by mass, 7% by mass, or 4% by mass.

[0163] Eucalyptus plant material may include, be derived from, or essentially be derived from dust from the processing of eucalyptus plant material, which may include the manufacture of any product containing eucalyptus material.

[0164] Pre-sized particulate eucalyptus plant material may have a Dp90 value of 0.8 mm to 1.5 mm, for example, 1 mm to 1.3 mm. Pre-sized particulate eucalyptus plant material may have a Dp90 particle size of approximately 1.15 mm.

[0165] Pre-sized particulate eucalyptus plant material may have a Dp50 value of 0.4 mm to 1 mm, for example, 0.6 mm to 0.8 mm. Pre-sized particulate eucalyptus plant material may have a Dp50 particle size of approximately 0.7 mm.

[0166] Pre-sized particulate eucalyptus plant material may have a Dp10 value of 0.05 mm to 0.5 mm, for example, 0.1 mm to 0.3 mm. Pre-sized particulate eucalyptus plant material may have a Dp10 particle size of approximately 0.2 mm.

[0167] lavender plant material The plant-based material may be lavender plant-based material. The lavender plant-based material may contain or consist of material derived from the lavender plant.

[0168] "Lavender," "lavender material," and "lavender plant material" refer to any material derived from a plant of the genus Lavandula in the family Lamiaceae. Any plant of this genus may be called a "lavender plant." Lavender plant material may include material from any part of the lavender plant, and preferably, lavender plant material may include or consist of lavender leaf and / or lavender bud material. Lavender plant material may include, for example, limonene, linalool, linalyl acetate, and / or camphor.

[0169] Pre-sized particulate lavender plant material may include material from any part of the lavender plant. Preferably, pre-sized particulate lavender plant material may include lavender leaf and / or lavender stem material.

[0170] Pre-sized particulate lavender plant material may have a water content of more than 8%, more than 10%, more than 12%, or more than 13%, or may be adjusted to have a water content.

[0171] Pre-sized particulate lavender plant material may have a water content of less than 20%, less than 17%, less than 15%, or less than 14%, or may be adjusted to have a water content.

[0172] The pre-sized particulate lavender plant material may contain material with a particle size greater than 0.85 mm in amounts exceeding 20% ​​by mass, 25% by mass, or 30% by mass. The pre-sized particulate lavender plant material may also contain material with a particle size greater than 0.85 mm in amounts less than 40% by mass, less than 35% by mass, or less than 31% by mass.

[0173] The pre-sized particulate lavender plant material may include materials with a particle size of less than 0.85 mm in amounts exceeding 50% by mass, 60% by mass, 65% by mass, or 69% by mass. The pre-sized particulate lavender plant material may also include materials with a particle size of less than 0.85 mm in amounts less than 90% by mass, 80% by mass, 75% by mass, or 70% by mass.

[0174] The pre-sized particulate lavender plant material may include lavender plant material having a particle size of 0.5 mm or larger in amounts exceeding 50% by mass, 55% by mass, 60% by mass, or 65% by mass. The pre-sized particulate lavender plant material may also include lavender plant material having a particle size of 0.5 mm or larger in amounts less than 80% by mass, 75% by mass, 70% by mass, or 66% by mass.

[0175] The pre-sized particulate lavender plant material may contain lavender fine powder material having a particle size of less than 0.5 mm in amounts exceeding 20% ​​by mass, exceeding 25% by mass, exceeding 30% by mass, or exceeding 34% by mass. The pre-sized particulate lavender plant material may also contain lavender fine powder material having a particle size of less than 0.5 mm in amounts less than 50% by mass, less than 45% by mass, less than 40% by mass, or less than 35% by mass.

[0176] The pre-sized particulate lavender plant material may include lavender plant material having a particle size exceeding 355 micrometers in amounts exceeding 60% by mass, exceeding 70% by mass, exceeding 75% by mass, or exceeding 78% by mass. The pre-sized particulate lavender plant material may also include lavender plant material having a particle size exceeding 355 micrometers in amounts less than 90% by mass, less than 85% by mass, less than 83% by mass, or less than 79% by mass.

[0177] The pre-sized particulate lavender plant material may include lavender fine powder material having a particle size of less than 355 micrometers in amounts exceeding 10% by mass, exceeding 15% by mass, exceeding 18% by mass, or exceeding 21% by mass. The pre-sized particulate lavender plant material may also include lavender fine powder material having a particle size of less than 355 micrometers in amounts less than 40% by mass, less than 30% by mass, less than 25% by mass, or less than 22% by mass.

[0178] The pre-sized particulate lavender plant material may include lavender plant material having a particle size exceeding 250 micrometers in amounts exceeding 70% by mass, exceeding 80% by mass, exceeding 85% by mass, or exceeding 88% by mass. The pre-sized particulate lavender plant material may also include lavender plant material having a particle size exceeding 250 micrometers in amounts less than 98% by mass, less than 95% by mass, less than 92% by mass, or less than 89% by mass.

[0179] The pre-sized particulate lavender plant material may include lavender fine powder material having a particle size of less than 250 micrometers in amounts exceeding 2% by mass, exceeding 5% by mass, exceeding 8% by mass, or exceeding 11% by mass. The pre-sized particulate lavender plant material may also include lavender fine powder material having a particle size of less than 250 micrometers in amounts less than 30% by mass, less than 20% by mass, less than 15% by mass, or less than 12% by mass.

[0180] The pre-sized particulate lavender plant material may include lavender plant material having a particle size exceeding 100 micrometers in amounts exceeding 80% by mass, exceeding 90% by mass, exceeding 95% by mass, or exceeding 98% by mass. The pre-sized particulate lavender plant material may also include lavender plant material having a particle size exceeding 100 micrometers in amounts less than 99.95% by mass, less than 99.5% by mass, less than 99% by mass, or less than 98.5% by mass.

[0181] The pre-sized particulate lavender plant material may include lavender fine powder material having a particle size of less than 100 micrometers in amounts exceeding 0.1% by mass, exceeding 0.5% by mass, exceeding 1% by mass, or exceeding 1.5% by mass. The pre-sized particulate lavender plant material may also include lavender fine powder material having a particle size of less than 100 micrometers in amounts less than 10% by mass, less than 5% by mass, less than 2% by mass, or less than 1.7% by mass.

[0182] The lavender plant material may include, be, or essentially consist of dust from the processing of the lavender plant material, which may include the manufacture of any product containing the lavender material.

[0183] Pre-sized particulate lavender plant material may have a Dp90 value of 0.7 mm to 1.5 mm, for example, 0.9 mm to 1.2 mm. Pre-sized particulate lavender plant material may have a Dp90 particle size of approximately 1.05 mm.

[0184] Pre-sized particulate lavender plant material may have a Dp50 value of 0.3 mm to 1 mm, for example, 0.5 mm to 0.8 mm. Pre-sized particulate lavender plant material may have a Dp50 particle size of approximately 0.65 mm.

[0185] Pre-sized particulate lavender plant material may have a Dp10 value of 0.1 mm to 0.5 mm, for example, 0.2 mm to 0.3 mm. Pre-sized particulate lavender plant material may have a Dp10 particle size of approximately 0.25 mm.

[0186] Cinnamon plant-based ingredients The plant-based material may be a cinnamon plant-based material. The cinnamon plant-based material may contain or consist of materials derived from cinnamon.

[0187] "Cinnamon," "cinnamon material," and "cinnamon plant material" refer to any material derived from plants of the genus Cinnamomum in the family Lauraceae. Cinnamon is a spice obtained from the inner bark of various tree species of this genus, and any tree of this genus may be called "cinnamon plant" or "cinnamon tree." Cinnamon plant material may include material from any part of the cinnamon plant, and preferably, cinnamon plant material may include or consist of cinnamon bark material. Cinnamon plant material may include, for example, cinnamaldehyde, trans-cinnamaldehyde (cin), procyanidins, and / or catechins.

[0188] Pre-sized particulate cinnamon plant material may include material from any part of the cinnamon plant. Preferably, pre-sized particulate cinnamon plant material may include cinnamon bark material.

[0189] Pre-sized particulate cinnamon plant material may have a water content of more than 8%, more than 10%, more than 12%, or more than 14%, or may be adjusted to have a water content.

[0190] Pre-sized particulate cinnamon plant material may have a water content of less than 20%, less than 18%, less than 16%, or less than 15%, or may be adjusted to have a water content.

[0191] The pre-sized particulate cinnamon plant material may contain material with a particle size greater than 0.85 mm in amounts exceeding 20% ​​by mass, 30% by mass, or 34% by mass. The pre-sized particulate cinnamon plant material may also contain material with a particle size greater than 0.85 mm in amounts less than 50% by mass, 40% by mass, or 35% by mass.

[0192] The pre-sized particulate cinnamon plant material may include materials with a particle size of less than 0.85 mm in amounts exceeding 50% by mass, 55% by mass, 60% by mass, or 65% by mass. The pre-sized particulate cinnamon plant material may also include materials with a particle size of less than 0.85 mm in amounts less than 80% by mass, 75% by mass, 70% by mass, or 66% by mass.

[0193] The pre-sized particulate cinnamon plant material may include cinnamon plant material having a particle size greater than 0.5 mm in amounts exceeding 50% by mass, exceeding 55% by mass, exceeding 60% by mass, or exceeding 63% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon plant material having a particle size greater than 0.5 mm in amounts less than 80% by mass, less than 70% by mass, less than 67% by mass, or less than 64% by mass.

[0194] The pre-sized particulate cinnamon plant material may contain cinnamon fine powder material having a particle size of less than 0.5 mm in amounts exceeding 20% ​​by mass, exceeding 30% by mass, exceeding 33% by mass, or exceeding 36% by mass. The pre-sized particulate cinnamon plant material may also contain cinnamon fine powder material having a particle size of less than 0.5 mm in amounts less than 50% by mass, less than 45% by mass, less than 40% by mass, or less than 37% by mass.

[0195] The pre-sized particulate cinnamon plant material may include cinnamon plant material having a particle size exceeding 355 micrometers in amounts exceeding 50% by mass, exceeding 60% by mass, exceeding 70% by mass, or exceeding 74% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon plant material having a particle size exceeding 355 micrometers in amounts less than 90% by mass, less than 85% by mass, less than 80% by mass, or less than 75% by mass.

[0196] The pre-sized particulate cinnamon plant material may include cinnamon fine powder material having a particle size of less than 355 micrometers in amounts exceeding 10% by mass, 15% by mass, 20% by mass, or 25% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon fine powder material having a particle size of less than 355 micrometers in amounts less than 40% by mass, 35% by mass, 30% by mass, or 26% by mass.

[0197] The pre-sized particulate cinnamon plant material may include cinnamon plant material having a particle size exceeding 250 micrometers in amounts exceeding 70% by mass, 75% by mass, 80% by mass, or 83% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon plant material having a particle size exceeding 250 micrometers in amounts less than 95% by mass, 90% by mass, 87% by mass, or 84% by mass.

[0198] The pre-sized particulate cinnamon plant material may include cinnamon fine powder material having a particle size of less than 250 micrometers in amounts exceeding 5% by mass, exceeding 10% by mass, exceeding 13% by mass, or exceeding 16% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon fine powder material having a particle size of less than 250 micrometers in amounts less than 30% by mass, less than 25% by mass, less than 20% by mass, or less than 17% by mass.

[0199] The pre-sized particulate cinnamon plant material may include cinnamon plant material having a particle size exceeding 100 micrometers in amounts exceeding 80% by mass, 85% by mass, 90% by mass, or 94% by mass. The pre-sized particulate cinnamon plant material may also include cinnamon plant material having a particle size exceeding 100 micrometers in amounts less than 99.5% by mass, 99% by mass, 97% by mass, or 95% by mass.

[0200] The pre-sized particulate cinnamon plant material may contain cinnamon fine powder material having a particle size of less than 100 micrometers in amounts exceeding 0.5% by mass, exceeding 1% by mass, exceeding 3% by mass, or exceeding 5% by mass. The pre-sized particulate cinnamon plant material may also contain cinnamon fine powder material having a particle size of less than 100 micrometers in amounts less than 20% by mass, less than 15% by mass, less than 10% by mass, or less than 6% by mass.

[0201] The cinnamon plant material may include, be derived from, or essentially consist of dust from the processing of the cinnamon plant material, which may include the manufacture of any product containing the cinnamon material.

[0202] Pre-sized particulate cinnamon plant material may have a Dp90 value of 0.8 mm to 1.5 mm, for example, 1.0 mm to 1.3 mm. Pre-sized particulate cinnamon plant material may have a Dp90 particle size of approximately 1.15 mm.

[0203] Pre-sized particulate cinnamon plant material may have a Dp50 value of 0.4 mm to 1 mm, for example, 0.6 mm to 0.8 mm. Pre-sized particulate cinnamon plant material may have a Dp50 particle size of approximately 0.65 mm.

[0204] Pre-sized particulate cinnamon plant material may have a Dp10 value of 0.05 mm to 0.5 mm, for example, 0.1 mm to 0.3 mm. Pre-sized particulate cinnamon plant material may have a Dp10 particle size of approximately 0.15 mm.

[0205] Clove plant material The plant material may be clove plant material. The clove material may also include clove bud material, and references to clove material and / or clove plant material herein may refer to material derived from clove buds.

[0206] "Clove," "clove material," and "clove plant material" refer to any material derived from the plant of the species *Syzygium aromaticum*, which may also be called "clove plant" or "clove tree." The clove material for use in the disclosed manner may be derived from the buds of the clove plant material. The clove material may include, but is not limited to, the following types of clove material: Java, Bali, Manado, and / or Manado second grade. The use of clove material may provide end-users with a distinctive flavor and sensory experience. The clove material may provide sensory effects including aromatic, pungent, numbing, crackling, and / or throat-soothing characteristics. The clove plant material may contain eugenol.

[0207] Pre-sized particulate clove plant material may have a water content of more than 15%, more than 18%, more than 21%, or more than 23%, or may be adjusted to have a water content.

[0208] Pre-sized particulate clove plant material may have a water content of less than 30%, less than 28%, less than 26%, or less than 24%, or may be adjusted to have a water content.

[0209] The pre-sized particulate clove plant material may contain material with a particle size greater than 0.85 mm in amounts exceeding 60% by mass, 70% by mass, or 75% by mass. The pre-sized particulate clove plant material may also contain material with a particle size greater than 0.85 mm in amounts less than 90% by mass, 80% by mass, or 76% by mass.

[0210] The pre-sized particulate clove plant material may include materials with a particle size of less than 0.85 mm in amounts exceeding 10% by mass, 15% by mass, 20% by mass, or 24% by mass. The pre-sized particulate clove plant material may also include materials with a particle size of less than 0.85 mm in amounts less than 40% by mass, 35% by mass, 30% by mass, or 25% by mass.

[0211] The pre-sized particulate clove plant material may include clove plant material having a particle size greater than 0.5 mm in amounts exceeding 75% by mass, exceeding 80% by mass, exceeding 83% by mass, or exceeding 86% by mass. The pre-sized particulate clove plant material may also include clove plant material having a particle size greater than 0.5 mm in amounts less than 95% by mass, less than 92% by mass, less than 90% by mass, or less than 87% by mass.

[0212] The pre-sized particulate clove plant material may contain clove fine powder material having a particle size of less than 0.5 mm in amounts exceeding 5% by mass, exceeding 7% by mass, exceeding 10% by mass, or exceeding 13% by mass. The pre-sized particulate clove plant material may also contain clove fine powder material having a particle size of less than 0.5 mm in amounts less than 30% by mass, less than 20% by mass, less than 17% by mass, or less than 14% by mass.

[0213] The pre-sized particulate clove plant material may include clove plant material having a particle size exceeding 355 micrometers in amounts exceeding 80% by mass, 85% by mass, 90% by mass, or 93% by mass. The pre-sized particulate clove plant material may also include clove plant material having a particle size exceeding 355 micrometers in amounts less than 99% by mass, 97% by mass, 95% by mass, or 94% by mass.

[0214] The pre-sized particulate clove plant material may contain clove fine powder material having a particle size of less than 355 micrometers in amounts exceeding 1% by mass, 3% by mass, 5% by mass, or 6% by mass. The pre-sized particulate clove plant material may also contain clove fine powder material having a particle size of less than 355 micrometers in amounts less than 20% by mass, 15% by mass, 10% by mass, or 7% by mass.

[0215] The pre-sized particulate clove plant material may include clove plant material having a particle size exceeding 250 micrometers in amounts exceeding 90% by mass, exceeding 95% by mass, exceeding 97% by mass, or exceeding 99% by mass. The pre-sized particulate clove plant material may also include clove plant material having a particle size exceeding 250 micrometers in amounts less than 99.95% by mass, or less than 99.5% by mass.

[0216] The pre-sized particulate clove plant material may contain clove fine powder material having a particle size of less than 250 micrometers in amounts exceeding 0.05% by mass, exceeding 0.1% by mass, exceeding 0.5% by mass, or exceeding 0.6% by mass. The pre-sized particulate clove plant material may also contain clove fine powder material having a particle size of less than 250 micrometers in amounts less than 5% by mass, less than 2% by mass, less than 1% by mass, or less than 0.7% by mass.

[0217] Pre-sized particulate clove plant material may include clove plant material having a particle size exceeding 100 micrometers in amounts exceeding 95% by mass, 98% by mass, 99% by mass, or 99.9% by mass. Substantially all pre-sized particulate clove plant material, for example, 100% by mass of clove plant material, may have a particle size exceeding 100 micrometers.

[0218] Pre-sized particulate clove plant material may include clove fine powder material having a particle size of less than 100 micrometers in amounts of less than 1% by mass, less than 0.5% by mass, or less than 0.1% by mass. Substantially zero pre-sized particulate clove plant material, for example, 0% by mass of clove plant material, may have a particle size of less than 100 micrometers.

[0219] The clove plant material may include, be derived from, or essentially consist of dust from the processing of clove bud material, which may include the manufacture of any product containing clove material.

[0220] Pre-sized particulate clove plant material may have Dp90 values ​​greater than 2 mm, greater than 2.5 mm, or greater than 3 mm.

[0221] Pre-sized particulate clove plant material may have Dp50 values ​​greater than 1 mm, greater than 1.25 mm, or greater than 1.5 mm.

[0222] Pre-sized particulate clove plant material may have a Dp10 value of 0.1 mm to 0.8 mm, for example, 0.3 mm to 0.5 mm. Pre-sized particulate clove plant material may have a Dp10 particle size of approximately 0.4 mm.

[0223] Ginger plant-based ingredients The plant-based material may be a ginger plant-based material. The ginger plant-based material may contain or consist of materials derived from ginger.

[0224] "Ginger," "ginger material," and "ginger plant material" refer to any material derived from a plant of the genus Zingiber of the family Zingiberaceae. Any plant of this genus may be called a "ginger plant." Preferably, the ginger plant is Zingiber officinale, a flowering plant whose rhizome, known as ginger root or ginger, is widely used as a spice. The ginger plant material may include material from any part of the ginger plant, and preferably, the ginger plant material may include or consist of ginger root / rhizome material. The ginger plant material may include, for example, sesquiterpene hydrocarbons, gingerol, shogaol, and / or oleoresin.

[0225] The pre-sized particulate ginger plant material may include material from any part of the ginger plant. Preferably, the pre-sized particulate ginger plant material may include ginger root material.

[0226] The ginger plant material may include, be, or essentially consist of dust from the processing of the ginger plant material, which may include the manufacture of any product containing the ginger material.

[0227] Rooibos plant-based material The plant-based material may be a rooibos plant-based material. The rooibos plant-based material may contain or consist of materials derived from rooibos.

[0228] "Rooibos," "Rooibos material," and "Rooibos plant material" refer to any material derived from plants of the genus Aspalathus in the family Fabaceae, particularly Aspalathus linearis. Preferably, the rooibos plant is Aspalathus linearis, a bush whose leaves are widely used to make tea known as bush tea, black tea, or red bush tea. The rooibos plant material may include material from any part of the rooibos plant, and preferably, the rooibos plant material may include or consist of rooibos leaf material. The rooibos plant material may contain vitamin C and / or polyphenols including flavanols, flavones, flavanones, dihydrochalcones, aspalathin, and / or notofagin. The rooibos plant material may additionally, or instead, contain benzoic acid and / or cinnamic acid.

[0229] The pre-sized particulate rooibos plant material may include material from any part of the rooibos plant. Preferably, the pre-sized particulate rooibos plant material may include rooibos leaf material.

[0230] Rooibos plant material may include, be derived from, or essentially be derived from dust from the processing of rooibos plant material, which may include the manufacture of any product containing rooibos material, such as tea.

[0231] Pre-sized cellulose fibers Specifically, it was found that using pre-sized cellulose fibers, rather than other structural fiber materials such as pre-sized tobacco fibers, offers several advantages to the resulting aerosol-generating material.

[0232] In particular, compared to the use of other fibrous materials, the use of pre-sized cellulose fibers has been found to surprisingly, and preferably, result in the production of strands of aerosol-generating material that are thinner, lighter, more flexible, less prone to breakage, and have a smoother surface. These properties offer various manufacturing and processing advantages.

[0233] This can be seen in the particle size distribution of aerosol-generating materials produced using pre-sized cellulose fiber material compared to pre-sized tobacco fiber material. Aerosol-generating materials produced using pre-sized tobacco fiber but without pre-sized cellulose fiber material had Dp10 values ​​of 0.7 mm, Dp50 values ​​of 1.5 mm, and Dp90 values ​​of 4.0 mm. In contrast, equivalent aerosol-generating materials produced using corresponding pre-sized cellulose fiber, in this case wood pulp, but without pre-sized tobacco fiber (all other parameters identical), had Dp10 values ​​of 1.0 mm, Dp50 values ​​of 1.7 mm, and Dp90 values ​​of 5.0 mm. The significantly higher Dp90 value of the material produced using cellulose fiber indicates longer strand lengths, and the higher Dp10 value of the material indicates less fine dust due to reduced strand breakage. By measuring the generation of fine powder material using Dp10 in this way, a comparative index of the strand's ability to break can be obtained, making it possible to predict the suitability of the material for subsequent processing such as blending and smoking product manufacturing.

[0234] These advantageous properties, provided by the use of pre-sized cellulose fibers rather than other fibrous structural materials, also enable the production of aerosol-generating materials with higher fill values ​​and lower densities. A lower material density means that an increase in the level of aerosol-forming material, such as glycerol, can be supported by the aerosol-generating material.

[0235] The initial material may contain pre-sized cellulose fibers in amounts of up to 30%, 40%, or 50% by mass. Preferably, the initial material may contain pre-sized cellulose fibers in amounts of 1-25%, 2-22%, or 3-20% by mass. Preferably, the initial material may contain pre-sized cellulose fibers in amounts of 5.5-18% by mass.

[0236] Pre-sized cellulose fibers include or consist of any suitable cellulose fiber material.

[0237] Cellulose fibers may be aromatic or non-aromatic cellulose fiber materials. "Non-aromatic" refers to any material that has no odor or is substantially odorless.

[0238] Cellulose fibers may include, or consist of, fibers derived from cellulose found in woody plants. Cellulose fibers may include, or consist of, materials or combinations of materials derived from jute, wood, grass, flax, bamboo, hemp, ramie, straw, or cotton.

[0239] The pre-sized cellulose fibers may contain wood pulp or consist solely of wood pulp.

[0240] Preferably, the pre-sized cellulose fibers are non-tobacco cellulose fibers and do not contain or are not derived from tobacco or tobacco-derived materials.

[0241] Pre-sized cellulose fibers may have densities exceeding 70 g / L, 75 g / L, 80 g / L, or 85 g / L.

[0242] Pre-sized cellulose fibers may have densities of less than 110 g / L, less than 105 g / L, less than 100 g / L, or less than 95 g / L.

[0243] Pre-sized cellulose fibers may have a density of approximately 90 g / L.

[0244] Pre-sized cellulose fibers may have a water content of more than 0.5%, more than 1%, more than 1.5%, or more than 1.8%, or may be adjusted to have a water content.

[0245] Pre-sized cellulose fibers may have a water content of less than 10%, less than 7%, less than 5%, or less than 3%, or may be adjusted to have a water content.

[0246] The pre-sized cellulose fibers may have a water content of approximately 2%, or may be adjusted to have a water content.

[0247] The pre-sized cellulose fibers may include fibers with a particle size exceeding 200 micrometers in amounts exceeding 0.1% by mass, 0.5% by mass, 1% by mass, or 1.5% by mass. The pre-sized cellulose fibers may also include fibers with a particle size exceeding 200 micrometers in amounts less than 10% by mass, 7% by mass, 5% by mass, or 3% by mass.

[0248] The pre-sized cellulose fibers may include fibers with a particle size of less than 200 micrometers in amounts exceeding 80% by mass, 90% by mass, 95% by mass, or 97% by mass. The pre-sized cellulose fibers may also include fibers with a particle size of less than 200 micrometers in amounts less than 99.9% by mass, 99.5% by mass, 99% by mass, or 98.5% by mass.

[0249] The pre-sized cellulose fibers may contain fibers having a particle size exceeding 90 micrometers in an amount of more than 10% by mass, more than 20% by mass, more than 25% by mass, or more than 27% by mass. The pre-sized cellulose fibers may contain fibers having a particle size exceeding 90 micrometers in an amount of less than 40% by mass, less than 35% by mass, less than 32% by mass, or less than 29% by mass.

[0250] The pre-sized cellulose fibers may contain fibers having a particle size less than 90 micrometers in an amount of more than 50% by mass, more than 60% by mass, more than 67% by mass, or more than 71% by mass. The pre-sized cellulose fibers may contain fibers having a particle size less than 90 micrometers in an amount of less than 90% by mass, less than 80% by mass, less than 75% by mass, or less than 73% by mass.

[0251] The pre-sized cellulose fibers may contain fibers having a particle size exceeding 32 micrometers in an amount of more than 70% by mass, more than 80% by mass, more than 85% by mass, or more than 87% by mass. The pre-sized cellulose fibers may contain fibers having a particle size exceeding 32 micrometers in an amount of less than 99% by mass, less than 95% by mass, less than 92% by mass, or less than 89% by mass.

[0252] The pre-sized cellulose fibers may contain fibers having a particle size less than 32 micrometers in an amount of more than 1% by mass, more than 5% by mass, more than 8% by mass, or more than 11% by mass. The pre-sized cellulose fibers may contain fibers having a particle size less than 32 micrometers in an amount of less than 30% by mass, less than 20% by mass, less than 15% by mass, or less than 13% by mass.

[0253] The pre-sized cellulose fibers may have a Dp90 value of 130 micrometers to 200 micrometers, for example, 140 micrometers to 190 micrometers, 150 micrometers to 180 micrometers, or 160 micrometers to 170 micrometers. The pre-sized cellulose fibers may have a Dp90 particle size of about 165 micrometers.

[0254] Pre-sized cellulose fibers may have a Dp50 value of 50 to 100 micrometers, for example, 55 to 90 micrometers, 60 to 80 micrometers, or 65 to 75 micrometers. Pre-sized cellulose fibers may also have a Dp50 particle size of approximately 70 micrometers.

[0255] Pre-sized cellulose fibers may have a Dp10 value of 10 to 50 micrometers, for example, 15 to 40 micrometers, or 20 to 30 micrometers. Pre-sized cellulose fibers may have a Dp10 particle size of approximately 25 micrometers.

[0256] The pre-sized cellulose fibers may be fine powder material. In particular, the pre-sized cellulose fibers may have a particle size of less than 2 mm, preferably less than 1.5 mm, and more preferably less than 1 mm.

[0257] Composition of initial materials The initial material may include a combination of pre-sized particulate plant material and pre-sized cellulose fibers. The initial material contains at least 20% by mass, at least 30% by mass, at least 40% by mass, preferably at least 50% by mass of pre-sized particulate plant material. The plant material may be non-tobacco plant material.

[0258] The initial material may contain 20% by mass, 15% by mass, 10% by mass, or less than 5% by mass of tobacco material. Preferably, the initial material does not contain tobacco material.

[0259] The initial material may consist of a combination of pre-sized particulate plant material and pre-sized cellulose fibers.

[0260] The initial material may include pre-sized particulate plant material and pre-sized cellulose fibers, wherein the average, intermediate, and / or mode mean particle size of the pre-sized particulate plant material is smaller than that of the pre-sized cellulose fibers.

[0261] In some embodiments, the pre-sized plant material may substantially overlap in size with or have a corresponding particle size distribution to that of the pre-sized cellulose fibers.

[0262] In some embodiments, the pre-sized plant material may have a particle size larger than that of the pre-sized cellulose fibers, for example, based on the mean (mode, median, or average) particle size.

[0263] The initial material may include an aerosol-forming material or a combination of aerosol-forming materials.

[0264] The initial material may include a binder or a combination of binders.

[0265] The initial ingredients may include additional flavorings.

[0266] Aerosol-forming materials The initial material may include an aerosol-forming material, which may be called a wetting agent.

[0267] The aerosol-forming material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0268] Preferably, the initial material may include glycerol and / or propylene glycol.

[0269] The initial material may contain 1 to 30% by mass or 3 to 28% by mass of aerosol-forming material. Preferably, the initial material may contain 5 to 25% by mass of aerosol-forming material. Preferably, the initial material may contain 5 to 20% by mass, for example, at least or about 15% by mass of aerosol-forming material.

[0270] The aerosol-generating material may be a "high aerosol-forming aerosol-generating material," and in these embodiments, the initial material and / or aerosol-generating material may contain a relatively high aerosol-forming material content, including about 10-30% by mass, for example, 12-25% by mass, or 14-20% by mass, preferably about 15% by mass of aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The packing value of the aerosol-generating material in these embodiments is 35, 36, or 38 cm³. 3 It can be more than 10g, for example, 40-46cm 3 It may be 10g. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of CMC or contain CMC.

[0271] The aerosol-generating material may be a "high-fill-value aerosol-generating material," and in these embodiments, the initial material and / or aerosol-generating material may contain a lower aerosol-forming material content, such as about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, and preferably substantially glycerol. The fill value of the aerosol-generating material in these embodiments is 40, 42, or 44 cm³.3 It may also be over 10 g, for example, 45 to 60 cm 3 It may also be 10 g. The initial material and / or the aerosol-forming material may contain 2 to 10% by mass, or 3 to 8% by mass, preferably about 5% by mass of a binder. The binder may consist of CMC or may contain CMC.

[0272] In some embodiments including some embodiments where the aerosol-forming material is a high-fill aerosol-forming material, the cutting speed, which is the speed at which the shear gap surfaces move relative to each other (also referred to as "cone rotation", i.e., the rotation in rpm of the conical shearing member 10 shown in Figure 2), may be at a substantially maximum level, for example, 80 to 100%, preferably 90 to 95% of the maximum value. The maximum cutting speed is about 850 rpm, and in some embodiments including some embodiments where the aerosol-forming material is a high-fill aerosol-forming material, the cutting speed may be at least 700 rpm, 725 rpm, or 750 rpm. Preferably, the cutting speed is 770 to 850 rpm, for example, about 790 to 830 or about 810 rpm.

[0273] In some embodiments including some embodiments where the aerosol-forming material is a high-fill aerosol-forming material, the cutting pressure, which is the pressure applied to the material within the shear gap 9 shown in Figure 2 (also referred to as the pressure of the hydraulic system), may be at a substantially maximum level, for example, 80 to 100%, preferably 90 to 95% of the maximum value. The maximum cutting pressure is about 150 bar, and in some embodiments including some embodiments where the aerosol-forming material is a high-fill aerosol-forming material, the cutting pressure may be at least 100 bar, 110 bar, or 120 bar. Preferably, the cutting pressure is 125 to 148 bar, for example, about 130 to 146 bar, 135 to 144 bar, or about 140 to 142 bar.

[0274] In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the material supply rate (also called the rotation of the supply screw, i.e., the rotation of the conveyor screw of the preparation device 20 shown in Figure 3 (rpm)) may be significantly lower than the maximum level, for example, 30-50% or 35-45% of the maximum value, preferably about 40%. The maximum rotation speed of the supply screw is about 30 rpm, and in some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the material supply rate may be 5-20 rpm, 6-18 rpm, 7-17 rpm, 8-16 rpm, 9-15 rpm, preferably 10-14 rpm or 11-13 rpm, for example, about 12 rpm.

[0275] In some embodiments, including some embodiments in which the aerosol-generating material is a high-fillness aerosol-generating material, the material may be included in the components for the delivery system together with the second aerosol-generating material. The second aerosol-generating material may contain at least 15% by mass of the aerosol-forming material. The second aerosol-generating material may consist of, or include, an aerosol-generating material, for example, a high-aerosol-forming aerosol-generating material, manufactured by the disclosed method. The second aerosol-generating material may consist of, or include, an aerosol-generating material, manufactured by a method different from the disclosed method, for example, an amorphous solid or dry gel containing the aerosol-forming material, or include the same.

[0276] Binder The initial materials may include a binder.

[0277] The binder may contain or consist of carboxymethylcellulose (CMC), starch, guar gum, xanthan gum, acacia gum and / or hydroxypropylcellulose (HPC).

[0278] Preferably, the binder may include CMC, guar gum, xanthan gum, and / or HPC. The use of these binders, and in particular CMC, in the manufacture of aerosol-generating materials has been found to provide strands that are thinner, lighter, more resistant to breakage, and have a smoother surface compared to formulations containing other binders such as starch. Aerosol-generating materials manufactured using these binders have also been found to have a higher fill value compared to formulations containing other binders such as starch.

[0279] In some embodiments, the binder may include xanthan gum, which has been found to provide an aerosol-generating material having strands of maximum length and lowest density.

[0280] The use of CMC, guar gum, or xanthan gum, and especially CMC, has been found to preferably provide a high level of aerosol-forming material, such as a glycerol-supporting aerosol-generating material.

[0281] The use of CMC, xanthan gum, or HPC has been found to preferably provide an aerosol-generating material with a high packing value.

[0282] The initial material may contain combinations of two, three, or more binders. In embodiments where starch is used as a binder, it may be used in combination with a second binder.

[0283] The initial material may contain a total amount of binder of about 1-20% by mass, 2-18% by mass, 3-15% by mass, or 4-12% by mass. Preferably, if present, the binder is included in the initial material in an amount of up to about 12% by mass.

[0284] The initial material may include a combination of starch and a second binder. In such embodiments, the starch may be present in a larger amount than the second binder. The starch may be present in an amount of 0.5 to 12% by mass, 1 to 10% by mass, or 2 to 8% by mass, for example, about 3% by mass, 4% by mass, 5% by mass, 6% by mass, or 7% by mass. The second binder used in combination with starch may be guar gum or xanthan gum. The second binder may be present in an amount of 0.5 to 8% by mass, 1 to 7% by mass, for example, about 2% by mass, 3% by mass, 4% by mass, 5% by mass, or 6% by mass.

[0285] Specific plant-based materials and formulations In embodiments where the plant material is a mint plant material and includes or consists of material derived from the mint plant, the initial material may contain 60-75% by mass, for example, 62-73% by mass, of the plant material. In such embodiments, the initial material may contain 5-20% by mass, for example, 8-18% by mass, of cellulose fibers. The initial material may also contain 10-20% by mass, 12-18% by mass, or about 15% by mass, of an aerosol-forming material such as glycerol. The initial material may further contain 3-6% by mass, for example, 4-5% by mass, of a binder in total amount. The binder may be a combination of two or more binders, for example, a combination of starch and guar gum. The binders may each be present in substantially equal amounts, such as 1-3% by mass or about 2% by mass, of the initial material, or the binders may be present in different amounts, such as in a ratio of 1:2-1:5 or 1:3-1:4.

[0286] The aerosol-generating material containing mint may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 65-80% by mass, for example, 70-75% by mass, or about 72% by mass, of plant material. In such embodiments, the initial material may contain 10-25% by mass, for example, 15-20% by mass, or about 18% by mass, of cellulose fiber. The packing values ​​of the aerosol-generating material in these embodiments are 48, 50, 52, or 54 cm³. 3 It can be more than 10g, for example, 56-70cm 3 / 10g is also acceptable.

[0287] The aerosol-forming material containing mint may also be a "high aerosol-forming aerosol-forming material," in which the initial material and / or aerosol-forming material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass, of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-forming material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 55-70% by mass, for example, 60-65% by mass, or about 62% by mass, of the plant material. In such embodiments, the initial material may contain cellulose fibers in an amount of 10-25% by mass, for example, 15-20% by mass, or about 18% by mass. The filling value of the aerosol-generating material in these embodiments is 35, 38, or 40 cm³. 3 It can be more than 10g, for example, 41-55cm 3 / 10g is also acceptable.

[0288] In embodiments in which the plant material is a eucalyptus plant material and includes or consists of material derived from the eucalyptus plant, the initial material may contain 70-75% by mass, for example, 72-74% by mass, or about 73% by mass, of the plant material. In such embodiments, the initial material may contain 5-12% by mass, for example, 6-10% by mass, or 8% by mass, of cellulose fibers. The initial material may also contain 10-20% by mass, 12-18% by mass, or about 15% by mass, of an aerosol-forming material such as glycerol. The initial material may further contain a total amount of binder, for example, 2-6% by mass, for example, 3-5% by mass, or about 4% by mass. The binder may be a combination of two or more binders, for example, a combination of starch and guar gum. The binders may be present in substantially equal amounts, such as 1-3% by mass or about 2% by mass of the initial material, or they may be present in different amounts, such as in a ratio of 1:2-1:5 or 1:3-1:4.

[0289] The aerosol-generating material containing eucalyptus may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 75-90% by mass, for example, 80-85% by mass, or about 82% by mass, of plant material. In such embodiments, the initial material may contain 3-15% by mass, for example, 5-10% by mass, or about 8% by mass, of cellulose fibers. The filling values ​​of the aerosol-generating material in these embodiments are 40, 42, or 44 cm³. 3 It can be more than 10g, for example, 45-60cm 3 / 10g is also acceptable.

[0290] The aerosol-forming material containing eucalyptus may also be a "high aerosol-forming aerosol-forming material," in which the initial material and / or aerosol-forming material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass, of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-forming material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 65-80% by mass, for example, 70-75% by mass, or about 72 or 73% by mass, of the plant material. In such embodiments, the initial material may contain cellulose fibers in an amount of 3 to 15% by mass, for example, 5 to 10% by mass, or about 8% by mass. The packing value of the aerosol-generating material in these embodiments is 35, 38, or 40 cm³. 3 It can be more than 10g, for example, 41-55cm 3 / 10g is also acceptable.

[0291] In embodiments where the plant-based material is a cinnamon plant-based material and includes or consists of material derived from the cinnamon plant, the initial material may contain 70-75% by mass, for example, 72-74% by mass, or about 73% by mass, of the plant-based material. In such embodiments, the initial material may contain 5-12% by mass, for example, 6-10% by mass, or 8% by mass, of cellulose fibers. The initial material may also contain 10-20% by mass, 12-18% by mass, or about 15% by mass, of an aerosol-forming material such as glycerol. The initial material may further contain a total amount of binder, for example, 2-6% by mass, for example, 3-5% by mass, or about 4% by mass. The binder may be a combination of two or more binders, for example, a combination of starch and guar gum. The binders may be present in substantially equal amounts, such as 1-3% by mass or about 2% by mass of the initial material, or they may be present in different amounts, such as in a ratio of 1:2-1:5 or 1:3-1:4.

[0292] The aerosol-generating material containing cinnamon may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 75-90% by mass, for example, 80-85% by mass, or about 82% by mass, of plant material. In such embodiments, the initial material may contain 3-15% by mass, for example, 5-10% by mass, or about 8% by mass, of cellulose fiber. The packing values ​​of the aerosol-generating material in these embodiments are 42, 45, or 48 cm³. 3 It can be more than 10g, for example, 49-60cm 3 / 10g is also acceptable.

[0293] The aerosol-forming material containing cinnamon may also be a "high aerosol-forming aerosol-forming material," in which the initial material and / or aerosol-forming material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass, of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-forming material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 65-80% by mass, for example, 70-75% by mass, or about 72 or 73% by mass, of the plant material. In such embodiments, the initial material may contain cellulose fibers in an amount of 3 to 15% by mass, for example, 5 to 10% by mass, or about 8% by mass. The filling value of the aerosol-generating material in these embodiments is 40, 42, or 44 cm³. 3 It can be more than 10g, for example, 45-55cm 3 / 10g is also acceptable.

[0294] In embodiments where the plant material is clove plant material, the initial material may contain a total amount of plant material of 60-75% by mass, for example, 65-70% by mass, or 66-68% by mass. The clove plant material may contain a combination of clove bud particulate material and clove powder. The particulate material from clove buds may be included in an amount of 10-20% by mass, for example, 12-18% by mass, or about 14-15% by mass, and the remainder of the clove plant material may be included in powder form in an amount of 47-57% by mass, for example, 50-55% by mass, or 51-53% by mass. In such embodiments, the initial material may contain an amount of cellulose fiber of 5-18% by mass, for example, 10-16% by mass, or 12-14% by mass. The initial material may also contain an aerosol-forming material such as glycerol in an amount of 10-20% by mass, 12-18% by mass, or about 15% by mass. The initial material may further contain a total amount of binder in the form of 2-8% by mass, for example, 4-7% by mass, or 5-6% by mass. The binder may be a combination of two or more binders, for example, a combination of starch and guar gum. The binders may be present in substantially equal amounts, such as 1-4% by mass or 2-3% by mass of the initial material, or the binders may be present in different amounts, such as in a ratio of 1:2-1:5 or 1:3-1:4, for example, 4:7.

[0295] The clove-containing aerosol-generating material may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 65-85% by mass, for example, 70-80% by mass, or about 75 or 76% by mass, of the plant material. In such embodiments, the initial material may contain 8-20% by mass of cellulose fibers, for example, 10-18% by mass, 12-16% by mass, or about 14% by mass. The filling values ​​of the aerosol-generating material in these embodiments are 42, 45, or 47 cm³. 3 It can be more than 10g, for example, 48-60cm 3 / 10g is also acceptable.

[0296] The clove-containing aerosol-generating material may also be a "high aerosol-forming aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass of a binder. The binder may consist of or contain CMC. The initial material may contain 55-75% by mass, for example, 60-70% by mass, or about 65 or 66% by mass of the plant material. In such embodiments, the initial material may contain 8-20% by mass of cellulose fibers, for example, 10-18% by mass, 12-16% by mass, or about 14% by mass. The packing values ​​of the aerosol-generating material in these embodiments are 35, 37, or 39 cm³. 3 It can be more than 10g, for example, 40-55cm 3 / 10g is also acceptable.

[0297] In embodiments where the plant-based material is a lavender plant-based material and includes or consists of materials derived from the lavender plant, the initial material may contain a total amount of plant-based material of 70-75% by mass, for example, 72-74% by mass, or about 73% by mass. The lavender plant-based material may include a combination of materials from lavender flowers and other parts of the lavender plant. The material from lavender flowers may be included in an amount of 10-20% by mass, for example, 12-18% by mass, or about 15% by mass, and the remaining part of the lavender plant-based material may be included in an amount of 50-65% by mass, for example, 55-60% by mass, or about 58% by mass. In such embodiments, the initial material may contain cellulose fibers in an amount of 5-12% by mass, for example, 6-10% by mass, or 8% by mass. The initial material may also contain aerosol-forming materials such as glycerol in an amount of 10-20% by mass, 12-18% by mass, or about 15% by mass. The initial material may further contain a total amount of binder, such as 2-6% by mass, for example, 3-5% by mass, or about 4% by mass. The binder may be a combination of two or more binders, for example, a combination of starch and guar gum. The binders may be present in substantially equal amounts, such as 1-3% by mass or about 2% by mass of the initial material, or the binders may be present in different amounts, such as in a ratio of 1:2-1:5 or 1:3-1:4.

[0298] The aerosol-generating material containing lavender may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC. The initial material may contain 75-90% by mass, for example, 80-85% by mass, or about 82% by mass, of plant material. In such embodiments, the initial material may contain 3-15% by mass, for example, 5-10% by mass, or about 8% by mass, of cellulose fibers. The filling values ​​of the aerosol-generating material in these embodiments are 40, 42, or 44 cm³. 3 It can be more than 10g, for example, 46-60cm 3 / 10g is also acceptable.

[0299] The aerosol-forming material containing lavender may also be a "high aerosol-forming aerosol-forming material," in which the initial material and / or aerosol-forming material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-forming material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass of a binder. The binder may consist of or contain CMC. The initial material may contain 65-80% by mass, for example, 70-75% by mass, or about 72 or 73% by mass of the plant material. In such embodiments, the initial material may contain 3 to 15% by mass, for example, 5 to 10% by mass, or about 8% by mass, of cellulose fibers. The packing values ​​of the aerosol-generating material in these embodiments are 35, 37, or 39 cm³. 3 It can be more than 10g, for example, 40-55cm 3 / 10g is also acceptable.

[0300] The aerosol-generating material containing rooibos may also be a "high-filling-value aerosol-generating material," in which the initial material and / or aerosol-generating material may contain about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-generating material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass, of a binder. The binder may consist of or contain CMC, guar gum, and / or starch. The initial material may contain 70-90% by mass, for example, 75-85% by mass, or about 79% by mass, of plant material. In such embodiments, the initial material may contain 5-20% by mass, for example, 8-15% by mass, or about 12% by mass, of cellulose fibers. The filling value of the aerosol-generating material in these embodiments is 45, 48, or 50 cm³. 3 It can be more than 10g, for example, 52-60cm 3 / 10g is also acceptable.

[0301] The aerosol-forming material containing rooibos may also be a "high aerosol-forming aerosol-forming material," in which the initial material and / or aerosol-forming material may contain about 8-30% by mass, 10-25% by mass, 12-18% by mass, or 14-16% by mass, preferably about 15% by mass of the aerosol-forming material. In such embodiments, the aerosol-forming material may consist of or contain glycerol and / or propylene glycol, preferably substantially glycerol. The initial material and / or aerosol-forming material may contain 2-10% by mass, or 3-8% by mass, preferably about 5% by mass of a binder. The binder may consist of or contain CMC, guar gum, and / or starch. The initial material may contain 60-80% by mass, for example, 65-75% by mass, or about 69% by mass of the plant material. In such embodiments, the initial material may contain 5-20% by mass, for example, 8-15% by mass, or about 12% by mass, of cellulose fibers. The filling value of the aerosol-generating material in these embodiments is 40, 42, or 44 cm³. 3 It can be more than 10g, for example, 46-55cm 3 / 10g is also acceptable.

[0302] The following specific compositions were found to be particularly advantageous in delivering a high level of optimally scented aerosol during use.

[0303] The initial material containing mint plant material has the following composition: 73% particulate mint plant material, 8% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0304] The initial material containing mint plant material has the following composition: 69% particulate mint plant material, 12% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0305] The initial material containing mint plant material has the following composition: 62% particulate mint plant material, 18% cellulose fiber, 4% starch, 1% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0306] The following composition: A formulation containing mint plant material for producing a "high-filling-value aerosol-generating material," comprising 72% particulate mint plant material, 18% cellulose fiber, 5% CMC, and 5% glycerol (all percentage values ​​are by mass).

[0307] The following composition: A formulation containing mint plant material for producing a "high aerosol-forming aerosol generating material," comprising 62% particulate mint plant material, 18% cellulose fiber, 4% starch, 1% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0308] The initial material containing eucalyptus plant material has the following composition: 73% particulate eucalyptus plant material, 8% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0309] The following composition: A eucalyptus plant material formulation for producing a "high-filling-value aerosol-generating material" containing 82% particulate eucalyptus plant material, 8% cellulose fiber, 5% CMC, and 5% glycerol (all percentage values ​​are by mass).

[0310] The following composition: A eucalyptus plant material formulation for producing a "high aerosol-forming aerosol-generating material" containing 72% particulate eucalyptus plant material, 8% cellulose fiber, 5% CMC, and 15% glycerol (all percentage values ​​are by mass).

[0311] The following composition: Initial material containing cinnamon plant material, including 73% particulate cinnamon plant material, 8% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0312] The following composition: A cinnamon plant material formulation for producing a "high-filling aerosol generating material," comprising 82% particulate cinnamon plant material, 8% cellulose fiber, 5% CMC, and 5% glycerol (all percentage values ​​are by mass).

[0313] The following composition: A cinnamon plant material formulation for producing a "high aerosol-forming aerosol-generating material" containing 72% particulate cinnamon plant material, 8% cellulose fiber, 5% CMC, and 15% glycerol (all percentage values ​​are by mass).

[0314] The initial material containing lavender plant-derived materials (all percentage values ​​are by mass) has the following composition: 15% particulate plant-derived material from lavender flowers, 58% particulate plant-derived material from other parts of the lavender plant, 8% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol.

[0315] The following composition: A lavender plant material formulation for producing a "high-filling aerosol generating material" containing 82% particulate lavender plant material, 8% cellulose fiber, 5% CMC, and 5% glycerol (all percentage values ​​are by mass).

[0316] The following composition: A lavender plant material formulation for producing a "high aerosol-forming aerosol-generating material" containing 72% particulate lavender plant material, 8% cellulose fiber, 5% CMC, and 15% glycerol (all percentage values ​​are by mass).

[0317] The initial material containing clove plant material has the following composition: 14.5% particulate plant material derived from clove buds, 53% clove powder, 12% cellulose fiber, 3.5% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0318] The initial material containing clove plant material has the following composition: 14.5% particulate plant material derived from clove buds, 51.5% clove powder, 14% cellulose fiber, 4% starch, 1% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0319] The following composition: A clove plant material formulation for producing a "high-filling-value aerosol-generating material" containing 76% particulate clove plant material, 14% cellulose fiber, 5% CMC, and 5% glycerol (all percentage values ​​are by mass).

[0320] The following composition: A clove plant material formulation for producing a "high aerosol-forming aerosol-generating material" containing 66% particulate clove plant material, 14% cellulose fiber, 5% CMC, and 15% glycerol (all percentage values ​​are by mass).

[0321] A formulation containing rooibos plant material for producing a "high-filling-value aerosol-generating material," comprising the following composition: 89% particulate rooibos plant material (e.g., 39.5% particulate rooibos superior plant material and 39.5% particulate rooibos fine-cut plant material), 12% cellulose fiber, 2% starch, 2% guar gum, and 5% glycerol (all percentage values ​​are by mass).

[0322] A formulation containing rooibos plant materials for producing a "high aerosol-forming aerosol-generating material," comprising the following composition: 79% particulate rooibos plant material (e.g., 34.5% particulate rooibos superior plant material and 34.5% particulate rooibos fine-cut plant material), 12% cellulose fiber, 2% starch, 2% guar gum, and 15% glycerol (all percentage values ​​are by mass).

[0323] Processing parameters This method may include the step of pre-conditioning the plant material to one or more of the following parameters: Temperature: 80~147[degrees]℃, Moisture content: 5-25% by mass, Pressure (gas excess pressure): 1.2 to 4.5 bar.

[0324] In embodiments in which the plant material consists of or includes mint plant material, the method may include the step of pre-conditioning the mint plant material to one or more of the following parameters: Temperature: 120-147°C, preferably 130-140°C. Moisture content: 3-8% by mass, preferably 4-6% by mass, Pressure (gas excess pressure): 1.5 to 3.5 bar, preferably 2 to 3 bar.

[0325] In embodiments in which the plant material consists of or includes lavender plant material, the method may include the step of pre-conditioning the lavender plant material to one or more of the following parameters: Temperature: 100-140°C, preferably 110-130°C. Moisture content: 10-20% by mass OV, preferably 12-15% by mass OV, Pressure (gas excess pressure): 2 to 4 bar, preferably 2.5 to 3.5 bar.

[0326] In embodiments in which the plant material consists of or includes eucalyptus plant material, the method may include the step of pre-conditioning the eucalyptus plant material to one or more of the following parameters: Temperature: 120-147°C, preferably 130-147°C. Moisture content: 5-15% by mass, preferably 8-12% by mass, Pressure (gas excess pressure): 1.5 to 4.5 bar, preferably 2.5 to 4.5 bar.

[0327] In embodiments in which the plant material consists of or includes cinnamon plant material, the method may include the step of pre-conditioning the cinnamon plant material to one or more of the following parameters: Temperature: 120-147°C, preferably 130-140°C. Moisture content: 10-20% by mass OV, preferably more than 14% by mass OV, Pressure (gas excess pressure): 1.2 to 3.5 bar, preferably 1.2 to 2 bar.

[0328] In embodiments in which the plant material consists of or includes clove plant material, the method may include the step of pre-conditioning the clove plant material to one or more of the following parameters: Temperature: 90-120°C, preferably 100-110°C. Moisture content: 20-25% by mass OV, preferably 21-24% by mass OV, Pressure (gas excess pressure): 1.2 to 3.5 bar, preferably 1.2 to 2 bar.

[0329] The step of processing the initial material may include a step of continuously transporting it. The step of processing the initial material may include a step of transporting the initial material through a conveyor that increases mechanical pressure.

[0330] The conveyor may include an extruder.

[0331] Surprisingly, this method for producing aerosol-forming material was found to provide particularly advantageous material when much slower flow rates through a conveyor are used compared to equivalent methods used for processing tobacco material. Typically, the corresponding tobacco processing method requires a throughput of 80–100 kg / hour. In contrast, this method was found to deliver improved material with high levels of plant flavor and aroma, high fill value, and low density, preferably when flow rates of 25–75 kg / hour are used. Furthermore, the use of even lower flow rates, such as less than 60, 50, or 40 kg / hour, was found to be associated with providing material that can support increased levels of aerosol-forming material.

[0332] In embodiments in which the plant material includes or consists of mint material, the method may include a flow rate of 35-45 kg / hour, preferably 37-41 kg / hour.

[0333] In embodiments in which the plant-based material includes or consists of lavender material, the method may include a flow rate of 55-68 kg / hour, preferably 60-64 kg / hour.

[0334] In embodiments in which the plant material includes or consists of eucalyptus material, this method may include a flow rate of 50-65 kg / hour, preferably 55-60 kg / hour.

[0335] In embodiments where the plant material includes or consists of cinnamon material, the method may include a flow rate of 65-80 kg / hour, preferably 70-75 kg / hour.

[0336] In embodiments in which the plant material includes or consists of clove material, this method may include a flow rate of 50-65 kg / hour, preferably 55-60 kg / hour.

[0337] Furthermore, this method for producing aerosol-generating materials was found to provide particularly advantageous materials when a much slower water flow rate through the conveyor is used compared to equivalent methods used for processing tobacco materials. When a water flow rate of less than 12 L / hour is used, improved materials with high levels of plant flavor and aroma, high fill value, and low density are provided.

[0338] In embodiments in which the plant material includes or consists of mint material, the method may include a water flow rate of less than 12 L / hour, preferably less than 11 L / hour.

[0339] In embodiments in which the plant material includes or consists of eucalyptus or cinnamon material, the method may include a water flow rate of less than 11 L / hour, preferably less than 10 L / hour.

[0340] In embodiments in which the plant-based material includes or consists of lavender material, the method may include a water flow rate of less than 10 L / hour, preferably less than 9 L / hour, less than 8 L / hour, or less than 7 L / hour.

[0341] In embodiments in which the plant material includes or consists of clove material, the method may include a water flow rate of less than 7 L / hour, preferably less than 5 L / hour, less than 4 L / hour, or less than 3 L / hour.

[0342] Surprisingly, this method for producing aerosol-generating materials was found to be preferably carried out at lower expander pressures for processing the initial material than those used in equivalent methods for processing tobacco materials. Typically, the corresponding tobacco processing method requires the use of expander pressures in the range of 35–50 bar. The production of equivalent materials, including tobacco without binders, typically requires pressures of at least 60 bar, e.g., in the range of 60–70 bar.

[0343] Preferably, the disclosed processing method may include a step of pressurizing the initial material to a pressure in the range of 15 to 35 bar. This pressure is much lower than that used in the production of corresponding materials containing only tobacco. Furthermore, it has been found that the use of even lower pressures, such as less than 30 bar or less than 25 bar, provides a material capable of supporting the maximum level of aerosol-forming material. The described processing conditions have also been found to provide an aerosol-forming material that retains and provides high levels of plant flavor and aroma.

[0344] In embodiments in which the plant material includes or consists of mint material, the method may include the step of pressurizing the initial material to a pressure in the range of 15 to 25 bar, preferably 18 to 21 bar.

[0345] In embodiments in which the plant-based material includes or consists of lavender material, the method may include a step of pressurizing the initial material to a pressure in the range of 12 to 20 bar, preferably 14 to 17 bar.

[0346] In embodiments in which the plant material includes or consists of eucalyptus material, the method may include a step of pressurizing the initial material to a pressure of less than 35 bar, preferably in the range of 25 to 34.8 bar.

[0347] In embodiments in which the plant material includes or consists of cinnamon material, the method may include a step of pressurizing the initial material to a pressure in the range of 25 to 34 bar, preferably 28 to 31 bar.

[0348] In embodiments in which the plant material includes or consists of clove material, the method may include the step of pressurizing the initial material to a pressure in the range of 12 to 23 bar, preferably 16 to 19 bar.

[0349] The step of processing the initial material may include heating the initial material to a temperature in the range of 60 to 180°C, for example, 100 to 170°C, 120 to 160°C, or 130 to 150°C.

[0350] The temperature increase may be achieved by applying external heat and / or as a result of generating mechanical pressure.

[0351] In some embodiments, the step of pressurizing the initial material to a certain pressure is performed before feeding the processed tobacco material through the shear gap.

[0352] In some embodiments, the method includes the step of feeding the treated tobacco material through a shear gap so that the treated tobacco material is defibrated by expansion. The shear gap may be located between the shear surfaces. A rotatable shearing member may include one of the shear surfaces. The shearing member may include at least 140 grooves. Each of these grooves may have a maximum width of 0.7 mm to 1 mm in the circumferential direction of the shearing member.

[0353] This method may further include a step of exposing the processed tobacco material to a pressure drop to induce flash evaporation.

[0354] This method may further include the step of supplying the treated material through a shear gap so that the treated material is defibrated by expansion.

[0355] The shear gap may have a width in the range of 10 to 2000 microns, preferably in the range of 50 to 300 microns.

[0356] The shear gap may be located between the shear surfaces, and the rotatable shear member includes one of the shear surfaces.

[0357] The shearing member may include at least 80 grooves, preferably at least 90, 100, 120, 140, 160, or 180 grooves.

[0358] Each of these grooves may have a maximum width of 0.3 to 2 mm, 0.5 to 1.5 mm, preferably 0.7 to 1 mm, in the circumferential direction of the shearing member.

[0359] This method may include the step of rotating the shearing member at an angular velocity of at least 10 rpm, preferably at least 100 rpm, 300 rpm, 300 rpm, or 350 rpm. In some embodiments, this method includes the step of rotating the shearing member at an angular velocity of 900 rpm or less. In particular, this method may include the step of rotating the shearing member at an angular velocity of 500 to 850 rpm.

[0360] In embodiments in which the plant-based material includes or consists of mint, lavender, eucalyptus, and / or cinnamon material, the method may include the step of rotating the shearing member at an angular velocity of 500 to 600 rpm.

[0361] In embodiments in which the plant material includes or consists of clove material, the method may include the step of rotating the shearing member at an angular velocity of 800 to 850 rpm.

[0362] Before feeding the processed tobacco material through the shear gap, a step may be performed in which the initial material is heated to a high temperature.

[0363] Before feeding the processed tobacco material through the shear gap, a step may be performed in which the initial material is pressurized to a high pressure.

[0364] Product Material Characteristics The aerosol-generating material is preferably a discontinuous aerosol-generating material.

[0365] Surprisingly, it was found that aerosol-generating materials can hold, support, and deliver far greater amounts of aerosol-forming material than comparable materials manufactured by the same method but containing only tobacco material. Typically, less than 15% by mass of aerosol-forming material can be included in comparable tobacco material.

[0366] The aerosol-generating material may contain 5 to 30% by mass of aerosol-forming material. Typically, the aerosol-generating material may contain more than 15% by mass of aerosol-forming material, for example, 16%, 17%, 18%, 19%, or more than 20% by mass. In some embodiments, the aerosol-generating material may contain more than 22%, 23%, 24%, or 25% by mass of aerosol-forming material.

[0367] This aerosol-generating material may contain up to 30% by mass, 35% by mass, or even 40% by mass of the aerosol-forming material.

[0368] The aerosol-generating material containing mint plant material may contain more than 22% by mass, 23% by mass, 24% by mass, 25% by mass, or 26% by mass of aerosol-forming material, and may contain up to 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0369] The aerosol-forming material containing eucalyptus plant material may contain more than 15% by mass, 16% by mass, 17% by mass, 18% by mass, or 19% by mass of aerosol-forming material, and may contain up to 25% by mass, 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0370] The aerosol-generating material containing clove plant material may contain more than 17% by mass, 18% by mass, or 19% by mass of aerosol-forming material, and may contain up to 25% by mass, 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0371] The aerosol-generating material containing cinnamon plant material may contain more than 16% by mass, 17% by mass, 18% by mass, or 19% by mass of aerosol-forming material, and may contain up to 25% by mass, 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0372] The aerosol-generating material containing lavender plant material may contain more than 19% by mass of aerosol-forming material, and may contain up to 25% by mass, 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0373] It has been found that aerosol-generating materials can preferably provide a filling value that is equivalent to that of equivalent materials, manufactured by at least the same method but containing only tobacco material. This is surprising considering the generally more delicate and finer nature of the plant-based materials used in the manufacture of aerosol-generating materials. Typically, an equivalent filling value of tobacco material is about 30 cm³. 3 It is / 10g.

[0374] Aerosol-generating material is 30, 33, 35, 37, or 40 cm². 3 It may have a filling value exceeding 10g.

[0375] The filling value may also be calculated using the following formula. Filling value [cm] 3 / 10g] = 0.1 × (volume [cm³) 3 ] / mass[g]) The measured water content is M%.

[0376] If necessary, the filling value may be corrected to the standard water content using the following formula. FV0 = ((FV × (100 - M0) × (M / M0) 0.8 ) / (100-M) Here, FV0=water content M o Filling value in percentage FV = Filling value determined by water content in m% M o = Appropriate target moisture content (%) M = Actual moisture content of the test cigarette (%) 0.8 = constant (Grandpre, 1987)

[0377] An increase in the fill value of aerosol-generating material compared to a material containing only tobacco material, manufactured by the same method, is due to an increase in the flexibility of the disclosed aerosol-generating material, resulting in a reduction in brittleness. The increase in flexibility is obtained from including a binder in the initial material and from the amount used, as a result of the smaller particle size range of plant-based materials compared to the particle size of tobacco materials typically used, and / or the generally higher water content of aerosol-generating materials.

[0378] As a result of the increased flexibility, the tendency of the aerosol-generating material strands to snap is reduced, and therefore the strand length distribution of the material is such that the strands of the material have increased length compared to the strands of material produced from tobacco alone by the same method.

[0379] Therefore, the particle size distribution of the aerosol-generating material also contributes to the packing density. For example, the presence of small particles resulting from strand breakage increases the density of the material and decreases the packing density. The disclosed aerosol-generating material has been found to have a significantly lower proportion of small particles compared to a similar material containing only tobacco, which contributes to the high packing density of the material. The aerosol-generating material may have a particle size distribution of less than 40% of particles with a mass percentage of less than 1 mm.

[0380] The use of binders has been shown to increase the flexibility and reduce the brittleness of aerosol-generating materials, and may therefore be used to increase the filling value of the material.

[0381] The aerosol-generating material may have a Dp90 value of 1.2 mm to 6.0 mm, for example, 1.5 mm to 5.8 mm, or 1.9 mm to 5.6 mm. The aerosol-generating material may have a Dp50 value of 1.1 mm to 2.4 mm, for example, 1.15 mm to 2.2 mm, or 1.2 mm to 2.0 mm. The aerosol-generating material may have a Dp10 value of 0.2 mm to 1.5 mm, for example, 0.4 mm to 1.3 mm, or 0.6 mm to 1.1 mm.

[0382] Aerosol-generating material containing mint plant material may have a Dp90 value of 4.0 mm to 6.0 mm, for example, 4.5 mm to 5.5 mm, or about 5.0 mm. Aerosol-generating material containing mint plant material may have a Dp50 value of 1.2 mm to 2 mm, for example, greater than 1.5 mm but less than 1.8 mm, or about 1.6 mm. Aerosol-generating material containing mint plant material may have a Dp10 value of 0.9 mm to 1.3 mm, for example, 1 mm to 1.2 mm, or about 1.1 mm.

[0383] Aerosol-generating materials containing eucalyptus plant material may have a Dp90 value of 4.0 mm to 6.0 mm, for example, 4.5 mm to 5.5 mm, or about 5.0 mm. Aerosol-generating materials containing eucalyptus plant material may have a Dp50 value of 1.2 mm to 2 mm, for example, greater than 1.5 mm but less than 1.8 mm, or about 1.65 mm. Aerosol-generating materials containing eucalyptus plant material may have a Dp10 value of 0.6 mm to 1.0 mm, for example, 0.7 mm to 0.9 mm, or about 0.8 mm.

[0384] Aerosol-generating material containing lavender plant material may have a Dp90 value of 1.5 mm to 2.3 mm, for example, 1.7 mm to 2.1 mm, or about 1.9 mm. Aerosol-generating material containing lavender plant material may have a Dp50 value of 1.0 mm to 1.4 mm, for example, 1.1 mm to 1.3 mm, or about 1.2 mm. Aerosol-generating material containing lavender plant material may have a Dp10 value of 0.4 mm to 0.8 mm, for example, 0.5 mm to 0.7 mm, or about 0.6 mm.

[0385] Aerosol-generating material containing cinnamon plant material may have a Dp90 value of 3.8 mm to 4.6 mm, for example, 4.0 mm to 4.4 mm, or about 4.2 mm. Aerosol-generating material containing cinnamon plant material may have a Dp50 value of 1.2 mm to 2 mm, for example, greater than 1.5 mm but less than 1.8 mm, or about 1.6 mm. Aerosol-generating material containing cinnamon plant material may have a Dp10 value of 0.9 mm to 1.3 mm, for example, 1 mm to 1.2 mm, or about 1.1 mm.

[0386] Aerosol-generating material containing clove plant material may have a Dp90 value of 5.0 mm to 6.2 mm, for example, 5.3 mm to 5.9 mm, or about 5.6 mm. Aerosol-generating material containing clove plant material may have a Dp50 value of 1.6 mm to 2.4 mm, for example, 1.8 mm to 2.2 mm, or about 2.0 mm. Aerosol-generating material containing clove plant material may have a Dp10 value of 0.9 mm to 1.3 mm, for example, 1 mm to 1.2 mm, or about 1.1 mm.

[0387] Components for delivery systems Aerosol-generating materials may be included as components.

[0388] The components may further include a second material which may be a smokeable material and / or an aerosol-generating material.

[0389] The second material may be a second material such as a second aerosol generating material. The second material may be an aerosol generating material that does not contain plant-derived materials. The second material may be an aerosol generating material that contains plant-derived materials different from those of the first aerosol generating material.

[0390] The second ingredient may contain tobacco. For example, the second ingredient may contain reconstituted tobacco material and / or cut rag tobacco. The second ingredient may contain a Kretek blend.

[0391] The components may include the disclosed aerosol-generating material and a second material in the form of a blend. The blend may contain the aerosol-generating material in an amount of 5% to 50% of the total material in the blend. For example, the blend may contain the aerosol-generating material in an amount of 10% to 40%, or 15% to 30%, of the total material in the blend, for example, about 12.5% ​​or 25%.

[0392] The aerosol-generating material may be configured such that, by including the aerosol-generating material, a modified and / or improved flavor profile is obtained during use of the component compared to an equivalent component that does not include the aerosol-generating material or does not include plant-based materials such as tobacco alone.

[0393] In some embodiments, the aerosol-generating material may be used in a blend as a flavor and / or aroma modifier for use in aerosol-delivering components. Thus, aerosol-generating materials that provide high levels of flavor or aroma from various plant materials preferably provide designers with a selection of materials that can be used individually or in combination to provide components having novel and different aroma and flavor profiles.

[0394] The high fill value of aerosol-generating materials offers further advantages for use in blends, as less material is required to achieve the same fill capacity and product performance.

[0395] The aerosol-generating material may be configured to provide increased aerosol delivery during use of the component compared to equivalent components that do not contain the aerosol-generating material or that do not contain plant-based materials such as tobacco.

[0396] The components may be for use in non-combustion aerosol supply systems.

[0397] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0398] Next, an embodiment will be described with reference to the drawings, merely as a non-limiting example. [Brief explanation of the drawing]

[0399] [Figure 1] This flowchart shows one embodiment of a method for processing plant materials into aerosol-generating materials. [Figure 2] This is a schematic diagram of one embodiment of a pressure fiber defibrillator. [Figure 3] This is a schematic diagram of the pressure regulation and defibration system. [Figure 4] This is a schematic diagram of another embodiment of the pressure regulation and defibration system. [Figure 5] This graph shows the properties of aerosols produced by a test article containing an aerosol-generating material consisting of (A) Rooibos aerosol-generating material formulation T37.4, (B) Rooibos aerosol-generating material formulation T37.6, or (C) Reconstituted paper material manufactured from a similar formulation. [Modes for carrying out the invention]

[0400] Referring to Figure 1, a method for processing plant materials into aerosol-generating materials is shown.

[0401] The aerosol-generating material produced by this method can then be incorporated into a product. The product may be a component for a delivery system as described herein, for example, an aerosol supply system.

[0402] In some embodiments, the aerosol supply system is a non-combustion aerosol supply system.

[0403] The component may be, for example, a rod of a smokeable material. In one particular embodiment, the component is a rod of a smokeable material for a tobacco heating system.

[0404] The product may be an article intended for use in, or comprising, a non-combustion aerosol supply system that releases compounds from an aerosol-generating material without burning the aerosol-generating material, such as a hybrid system that generates an aerosol using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials.

[0405] The product may be an article used in a combustion aerosol supply system, such as cigarettes, cigarillos, cigars, or pipe tobacco, or roll-your-own or make-your-own cigarettes.

[0406] material In this disclosure, “plant material” refers to any material derived from a plant. The plant material may be an aromatic plant material. In this context, “aromatic” refers to any material having a distinctive aromatic scent. Therefore, an aromatic plant material is any material that can be identified by its scent. The plant material may contain a flavoring agent or consist of a flavoring agent, and therefore the plant material may be a flavored plant material. The plant material is preferably an aromatic flavored plant material.

[0407] In some embodiments, the plant material does not have to contain tobacco material and may therefore be called "non-tobacco plant material." Thus, the non-tobacco plant material is any material or mixture of materials derived from any one or more plants, and does not contain material derived from plants of the genus Nicotiana.

[0408] The plant material may be a non-tobacco plant material. In some embodiments, the non-tobacco plant material is selected from plant materials that have desirable aroma properties for use in non-combustible aerosol supply systems. For example, the non-tobacco plant material may contain relatively fewer aromatic compounds compared to conventional tobacco materials. Therefore, aerosols produced from non-tobacco plant materials may have a different profile of volatile compounds compared to aerosols produced from tobacco materials. The non-tobacco plant material can deliver aerosols that are considered desirable by consumers of tobacco-based delivery systems. In some embodiments, when heated, the non-tobacco plant material can produce an aerosol that has a sensory experience comparable to that provided by conventional combustible 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 highly valued for their medicinal or sensory properties. In some embodiments, it may be preferable to provide an aerosol-generating material for use in non-combustible aerosol supply systems that does not contain any tobacco plant material.

[0409] Therefore, non-tobacco plant materials are not limited to tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, safflower This includes orchid, clove, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.

[0410] Preferably, the plant material may include, or consist of, mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove material.

[0411] "Mint," "mint material," and "mint plant material" refer to any material derived from plants of the genus Mentha in the family Lamiaceae. Any plant of this genus may also be called a "mint plant."

[0412] The mint plant material may include, or consist of, materials from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0413] The mint plant material may include material from any part of the mint plant, and preferably, the mint plant material may include or consist of mint leaves and / or mint stem material.

[0414] "Eucalyptus," "eucalyptus material," and "eucalyptus plant material" refer to any material derived from plants of the genus Eucalyptus, including various species of flowering trees, shrubs, or marigolds of the family Myrtaceae. Any plant or tree of this genus may also be called a "eucalyptus plant" or "eucalyptus tree."

[0415] The eucalyptus plant material may include material from any part of the eucalyptus tree, and preferably, the eucalyptus plant material may include, or consist of, eucalyptus leaves and / or eucalyptus stems and / or eucalyptus flower material.

[0416] "Lavender," "lavender material," and "lavender plant material" refer to any material derived from plants of the genus Lavandula in the family Lamiaceae. Any plant of this genus may also be called a "lavender plant."

[0417] The lavender plant material may include material from any part of the lavender plant, and preferably, the lavender plant material may include or consist of lavender leaves and / or lavender bud material.

[0418] "Ginger," "ginger material," and "ginger plant material" refer to any material derived from a plant of the genus Zingiber in the family Zingiberaceae. Any plant of this genus may also be called a "ginger plant." Preferably, the ginger plant is Zingiber officinale, a flowering plant whose rhizome, known as ginger root or ginger, is widely used as a spice.

[0419] The ginger plant material may include material from any part of the ginger plant, and preferably, the ginger plant material may include or consist of ginger root / rhizome material.

[0420] "Rooibos," "Rooibos material," and "Rooibos plant material" refer to any material derived from plants of the genus Aspalathus in the family Fabaceae, particularly Aspalathus linearis. Preferably, the rooibos plant is Aspalathus linearis, a bush whose leaves are widely used to make tea known as bush tea, black tea, or red bush tea.

[0421] The rooibos plant material may include material from any part of the rooibos plant, and preferably, the rooibos plant material may include rooibos leaf material or consist of them.

[0422] "Cinnamon," "cinnamon material," and "cinnamon plant material" refer to any material derived from plants of the genus Cinnamomum in the family Lauraceae. Cinnamon is a spice obtained from the inner bark of various tree species in this genus, and any tree in this genus may be called a "cinnamon plant" or "cinnamon tree."

[0423] The cinnamon plant material may include material from any part of the cinnamon plant, and preferably, the cinnamon plant material may include or consist of cinnamon bark material.

[0424] "Clove," "clove material," and "clove plant material" refer to any material derived from the plant of the species *Syzygium aromaticum*, which may also be called "clove plant" or "clove tree."

[0425] Preferably, the clove material for use in the disclosed method may be derived from the buds of the clove plant material.

[0426] The clove material may include, but is not limited to, the following types of clove material: Java, Bali, Manado, and / or Manado second grade.

[0427] The use of clove material can provide end-users with a unique flavor and sensory experience. Cloves are known to have sensory effects, particularly aromatic, pungent, numbing, crackling, and throat-soothing characteristics. Therefore, the sensory stimulation properties of aerosol-generating materials produced by the disclosed method may provide improved flavor and sensory characteristics compared to previous clove-containing smoky materials such as Kretek material.

[0428] The plant-based material for use in the disclosed method may consist of non-tobacco plant-based materials.

[0429] "Tobacco" and "tobacco materials" refer to any material derived from plants of the genus Nicotiana.

[0430] A key advantage of the disclosed method is provided in terms of the efficiency obtained by using particulate plant material that would otherwise be considered waste, or by-products of processing plant material for other purposes. For example, small pieces of plant material generated in the processing of plant material for other purposes, which would have previously been discarded as waste, may be used in the disclosed method in the production of aerosol-generating materials. Thus, as a result of the disclosed method, aerosol-generating materials may be produced that may be used as components of a delivery system in place of or in blend with other materials, thereby providing economics in the production of these systems by using by-products of plant material processing.

[0431] "Fine powder" material refers to any plant-derived material for use in the disclosed process having a particle size of less than 1 mm.

[0432] Aerosol-forming materials The aerosol generating material preferably includes an aerosol-forming material.

[0433] Aerosol-forming materials may comprise one or more components capable of forming aerosols. In this context, “aerosol-forming materials” are agents that promote aerosol formation. Aerosol-forming materials can promote aerosol formation by facilitating the initial vaporization and / or condensation of gases into inhalable solid and / or liquid aerosols. In some embodiments, aerosol-forming materials can improve the delivery of flavor and aromatic compounds from aerosol-forming materials.

[0434] The aerosol-forming material may also function as a wetting agent.

[0435] When an aerosol-generating material is heated, it aerosolizes and absorbs flavor and aromatic compounds from the plant material in the aerosol. As a result, the aerosol-generating material functions to improve the sensory performance of the aerosol-generating material by helping to transfer compounds such as flavor and aromatic compounds from the aerosol-generating material to the user.

[0436] A problem associated with including aerosol-forming materials in components for delivery systems, such as non-combustible aerosol supply systems, is that it can be difficult to incorporate large amounts of aerosol-forming materials into components without damaging the components, such as through leaching of the aerosol-forming material and / or discoloration of the components. Furthermore, the amount of aerosol-forming material is not the only important factor for the uptake and delivery of compounds, such as flavor compounds, from the aerosol-forming material to the user. Another important factor is how the aerosol-forming material is incorporated into the aerosol-forming material, and therefore how easily, in what quantity, and under what conditions it can be released when the components are used. Surprisingly, and preferably, this aerosol-forming material containing plant-based materials has been found to be able to hold, support, and deliver far greater amounts of aerosol-forming material than comparable materials manufactured by the same method but containing only tobacco materials. Typically, less than 15% by mass of aerosol-forming material can be included in comparable tobacco materials, while in contrast, this aerosol-forming material may contain more than 15% by mass of aerosol-forming material.

[0437] In fact, the aerosol-generating material may contain 16% by mass, 17% by mass, 18% by mass, 19% by mass, or more than 20% by mass of aerosol-forming material. In some embodiments, the aerosol-generating material may contain 22% by mass, 23% by mass, 24% by mass, or more than 25% by mass of aerosol-forming material. In some embodiments, the aerosol-generating material may contain up to 30% by mass, 35% by mass, or even 40% by mass of aerosol-forming material.

[0438] Furthermore, when used in materials manufactured by the disclosed method, the combination of the aerosol-forming material and the plant-based material was found to surprisingly provide the user with an unexpectedly enhanced level of flavor and aroma from the plant-based material.

[0439] The aerosol-forming material may contain or consist of one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0440] In particular, the aerosol-forming material may contain or consist of glycerol and / or propylene glycol.

[0441] Binder The aerosol-forming material may contain one or more types of binders.

[0442] Conventionally manufactured reconstituted tobacco-type materials do not contain binders and are formed simply by applying mechanical pressure and high temperatures to the constituent mixture. In fact, the fact that these materials do not contain binders has been seen as an advantage, for example, that it allows for the production of materials from fewer components using simplified processing methods.

[0443] However, the inventors have surprisingly found that in some embodiments, it may be advantageous to include a binder.

[0444] For example, the use of a binder has been found to provide an aerosol-forming material containing plant-based materials with increased packing strength. This provides an important and highly advantageous tool for the production of materials with high packing strength that contain plant-based materials.

[0445] It has been found that the inclusion of a binder results in a material that is more elastic and less brittle. However, increasing the level of binder provides a material that is difficult to cut and process.

[0446] It was found that using a binder in combination with pre-sized, smaller particle sizes of plant-based materials makes it possible to further increase the packing strength of these materials.

[0447] Therefore, the binder content level and the predetermined particle size of the plant material provide useful and simple variables that can be adjusted by those skilled in the art to obtain aerosol-forming materials containing plant materials with various filling strengths.

[0448] The binder may contain or consist of carboxymethylcellulose (CMC), starch, guar gum, acacia gum, xanthan gum, and / or hydroxypropylcellulose (HPC).

[0449] The initial material may contain combinations of two, three, or more types of binders.

[0450] The initial material may contain a total amount of binder of about 1-20% by mass, 2-18% by mass, 3-15% by mass, or 4-12% by mass. Preferably, if present, the binder is included in the initial material in an amount of up to about 12% by mass.

[0451] The initial material may include a combination of starch and a second binder. In such embodiments, the starch may be present in a larger amount than the second binder. The starch may be present in an amount of 0.5 to 12% by mass, 1 to 10% by mass, or 2 to 8% by mass, for example, about 3% by mass, 4% by mass, 5% by mass, 6% by mass, or 7% by mass. The second binder used in combination with starch may be guar gum or xanthan gum. The second binder may be present in an amount of 0.5 to 8% by mass, 1 to 7% by mass, for example, about 2% by mass, 3% by mass, 4% by mass, 5% by mass, or 6% by mass.

[0452] overview Figure 1 shows a flowchart illustrating a disclosed method for processing plant materials and cellulose fibers into aerosol-generating materials. The method consists of the following steps: Step 0 (S0) provides a pre-sized particulate plant material containing less than 95% by mass of tobacco material, for example, 50% by mass, 20% by mass, 10% by mass, 5% by mass, less than 1% by mass, preferably 0% by mass. Step 1 (S1) provides cellulose fibers of a predetermined size, Step 2(S2) provides the initial material by combining pre-sized particulate plant material with pre-sized cellulose fibers, wherein the initial material contains at least 50% by mass, for example, 60-75% by mass of plant material, preferably 5-20% by mass of cellulose fibers. Step (S3) involves processing the initial material by setting the initial material to a predetermined increased water content, subjecting the initial material to a temperature increase, and subjecting the initial material to an increased pressure, in order to bond the plant material to the cellulose fibers. Step (S4) involves supplying initial material through a shear gap to form an aerosol-generating material, Step (S5) involves cooling the aerosol-generating material. It may include.

[0453] It should be understood that in some embodiments (not shown), one or more of steps (S0), (S1), (S2), (S3), (S4), and / or (S5) may be combined. For example, the initial material may be adjusted while in the feeder, for example, while moving through the screw feeder of the feeder, or it may be adjusted within the defibration device.

[0454] This pre-conditioning may be carried out under atmospheric conditions. Alternatively, in some embodiments, the pre-conditioning process is operated at a pressure higher than atmospheric pressure. During and / or simultaneously during the pre-conditioning process (at or above atmospheric pressure), the casing and flavoring agents may be added in a manner known to those skilled in the art.

[0455] Preferably, step (S3) is performed based on all of the above parameters relating to temperature, moisture, and mechanical pressure. In other words, the material is subjected to the above values ​​of temperature, moisture, and pressure.

[0456] In step (S3), the initial material is subjected to the increased pressure as described above. In step (S4), in which the initial material is supplied through a shear gap to form the aerosol-generating material, this increased pressure decreases again. This usually occurs when the initial material is discharged from the processing device (e.g., extruder, screw conveyor, piston cylinder unit) that subjected it to increased temperature, pressure, and moisture. This pressure drop upon discharge from the shear gap results in flash evaporation, which causes the material to expand. This preferably increases the material's filling capacity.

[0457] In step (S3), the initial material is heated and placed under pressure to improve its flavor through a chemically manipulated process (e.g., Maillard reaction or caramelization), and to store energy, which is then promoted by shearing and expansion through a shear gap. Pressure generation and heating can be operated with a standard plug screw feeder, which can also heat its housing.

[0458] In some embodiments, the steps of processing the initial material (S3) and / or supplying the initial material through the shear gap to form the aerosol-generating material (S4) are performed using an apparatus configured as shown in Figure 3.

[0459] Step S1 - A step of supplying pre-sized particulate vegetable material. Pre-sized particulate plant-based materials refer to materials that have undergone a pre-sizing step before being combined with cellulose fibers to form the initial material.

[0460] The particle size distributions of various plant materials that have been found to be suitable for use in the manufacture of the disclosed aerosol-generating materials are discussed above.

[0461] The step of supplying pre-sized particulate plant material (S1) may include supplying the plant material to a particle size reduction device configured to reduce the size of the plant material.

[0462] The particle size reduction device may be a grinding / cutting / crushing device. The diameter reduction device may be a disc mill. Alternatively, a hammer mill or other grinding device may be used.

[0463] The pre-sizing step may include passing the plant material through a suitable sieve or a series of sieves, and, if necessary, discarding any material that does not pass through one or more sieves, or processing it to reduce its size.

[0464] It has been found that pre-sizing plant-based materials to provide the required particle size or particle size distribution improves the quality of manufactured aerosol-generating materials, including the organic quality of the components or product.

[0465] Adjusting a specific particle size or diameter distribution also provides an approach to control and adjust the packing force and density of the resulting aerosol-generating material.

[0466] Step S1 - Step of supplying pre-sized cellulose fibers. "Pre-sized cellulose fibers" refers to materials that have undergone a pre-sizing step before being combined with cellulose fibers to form the initial material.

[0467] The step of pre-sizing the cellulose fiber material offers several important advantages. For example, providing a combination of pre-sized cellulose fibers and pre-sized plant material has been found to preferably reduce the separation of the plant material and the cellulose material after they have been mixed and, for example, placed in a mixed silo.

[0468] In particular, it was found that pre-sizing cellulose fibers and plant materials to the specified size range reduces separation and demixing of materials within the mixing silo, thus resulting in a more consistently manufactured material with a more consistent density.

[0469] The step of pre-sizing cellulose fibers and plant materials was found to make material production more reproducible and consistent. Nevertheless, it was found to be advantageous to operate the device at a much lower throughput than that used for producing materials with high tobacco content. Such materials are produced at throughputs of at least 100 kg / hour, generally at least 110, 115, or 120 kg / hour. In contrast, this method was found to preferably deliver improved material when flow rates of 25–75 kg / hour are used.

[0470] Furthermore, the use of lower flow rates, such as less than 60, 50, or 40 kg / hour, was found to be associated with providing materials that can support increased levels of aerosol-forming material.

[0471] In some embodiments, the step of supplying pre-sized cellulose fibers (S1) includes the steps of supplying cellulose fibers and supplying cellulose fibers to a particle size reduction device configured to reduce the size of cellulose fiber particles.

[0472] The particle size reduction device may also be a grinding / cutting / crushing device. For example, the particle size reduction device may be a hammer mill, a centrifugal cutter, or a shredder.

[0473] Cellulose fibers may be pre-sized without grinding / cutting / shredding the material; instead, the cellulose fibers are sorted in such a way that material with particle sizes outside a specific range is removed. This pre-sizing step may include a sieving step and a step of removing material that does not pass through the sieve. The pre-sizing step may be optical (e.g., using a microscope), using sieves, or using a sorting or sieving machine.

[0474] Step S2 - A step in which materials are combined to form the initial material. In some embodiments, the step of forming the initial material (S2) further includes combining pre-sized particulate plant material and pre-sized cellulose fibers with further materials such as additional fine powder material, one or more aerosol-forming materials, and / or one or more binders.

[0475] Step S3 - Step of processing the initial materials In step (S3), the initial material is subjected to increased mechanical pressure, particularly increased temperature and moisture.

[0476] The initial material is given a predetermined increased water content. The material being processed also undergoes a temperature increase, which may be obtained by applying heat from an external source and / or by generating mechanical pressure.

[0477] In some embodiments, the initial material is heated to a temperature in the range of 60-180°C, for example, 100-170°C, 120-160°C, or 130-150°C.

[0478] Surprisingly, this method for producing aerosol-generating materials was found to be preferably carried out at lower expander pressures than those used in equivalent methods for processing tobacco materials. Typically, the corresponding tobacco processing method requires the use of expander pressures in the range of 35–50 bar. The production of equivalent materials, including tobacco without binders, typically requires pressures of at least 60 bar, for example, in the range of 60–70 bar.

[0479] Preferably, the disclosed processing method may include a step of pressurizing the initial material to a pressure in the range of 20 to 35 bar. This pressure is much lower than that used in the production of corresponding materials containing only tobacco. Furthermore, it has been found that the use of even lower pressures, such as less than 30 bar or less than 25 bar, provides a material that can support the maximum level of aerosol-forming material.

[0480] As a result of step (S3), the plant material and cellulose fibers are bonded together to produce an aerosol-generating material which may then be used in the manufacture of an aerosol supply system. This eliminates the need for expensive separate processes.

[0481] Therefore, the initial material is subjected to mechanical pressure at an elevated temperature and a specified moisture level (for example, in an extruder or conveyor screw conditioner).

[0482] Mechanical pressure compresses and bonds the plant material particles and cellulose fibers together. As a result, the bond between the materials is very strong, and the resulting aerosol-generating material can withstand the normal stresses that occur during subsequent processing. For example, the plant fine powder is not lost from the material when it is transported by air under normal manufacturing conditions. Therefore, the mechanical stability is higher than that of conventional tobacco film materials.

[0483] The use of smaller particles of plant-based materials, such as a higher proportion of plant-based pulp in the initial materials, is advantageous because it means that smaller particles of plant-based materials, which are generally by-products of manufacturing waste that would otherwise be discarded, can instead be recycled and reused productively.

[0484] Using smaller particles of plant-based materials in the initial material is also advantageous, as it has been shown to increase the packing strength of the material, especially when combined with the use of binders.

[0485] The process preferably yields a product that is an aerosol-generating material, particularly a fibrous and / or granular material or a filler material. In other words, this method yields a product that is ready for consumption and can be used directly in an aerosol supply system. This is quite different from producing a smokeable material film (continuous material), which is more complex to manufacture and still has to be cut and dried after manufacturing. The resulting product of this disclosure has a size and moisture content suitable for direct use as a filler material for aerosol supply systems, including tobacco heating devices.

[0486] In some embodiments, the initial material is processed in batches, and in particular, pressed in batches within, for example, a piston-cylinder unit.

[0487] Step S4 In step (S4), the initial material passes through the shear gap to form an aerosol-generating material.

[0488] When the material exits the shear gap and enters the atmosphere, a large proportion of the absorbed water evaporates rapidly. This causes the material to expand within the shear gap, in addition to the shear effect. Depending on the process pressure and temperature, the moisture content of the material decreases by flash evaporation to a range of 5-25%, for example, 7-20%, or 8-15%, and the components contained in the material also decrease to some extent.

[0489] It has been found that it is advantageous for the shear gap surfaces to move relative to each other in order to prevent clogging and ensure clearing. This ensures that the entire cross-section of the gap is used, that constant physical conditions are maintained within the gap, and that a uniform product is ultimately obtained. For this purpose, it has also been found to be advantageous when the gap surfaces are structured or contoured, for example, to have grooves, as will be described in more detail below.

[0490] The inventors have found that, depending on the properties of the plant material, the cutting speed, which is the speed at which the shear gap surfaces move relative to each other (also called "conical rotation," i.e., the rotation speed of the conical shear member 10 shown in Figure 2 at rpm), is relatively high, such as 50-100% of the maximum value, when both the filling value and quality score of the final material are maximized. Depending on the plant material, the maximum rotation speed of the shear member 10 is approximately 850 rpm, and the optimal rotation speed of the cone is approximately 450-850 rpm.

[0491] In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the cutting speed may be substantially at the maximum level, for example, 80-100% of the maximum value, preferably 90-95%. In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the cutting speed may be at least 700 rpm, 725 rpm, or 750 rpm. Preferably, the cutting speed is 770-850 rpm, for example, about 790-830 or about 810 rpm.

[0492] The inventors also found that both the fill value and quality score of the final material were maximized when the cutting pressure, which is the pressure applied to the material within the shear gap 9 shown in Figure 2 (also called the hydraulic system pressure), was relatively high, such as 40-100% of the maximum value. The maximum cutting pressure was found to be approximately 150 bar, and the optimal cutting pressure was found to be 60-150 bar, for example, approximately 142 bar.

[0493] In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the cutting pressure may be substantially at the maximum level, e.g., 80-100% of the maximum value, preferably 90-95%. In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the cutting pressure may be at least 100 bar, 110 bar, or 120 bar. Preferably, the cutting pressure is 125-148 bar, e.g., about 130-146 bar, 135-144 bar, or about 140-142 bar.

[0494] The inventors also found that both the filling value and the quality score were maximized when the material supply rate (also called the rotation of the supply screw, i.e., the rotation of the conveyor screw of the preparation device 20 shown in Figure 3 (rpm)) was significantly lower than the maximum level, for example, 20-60% of the maximum value, for example, about 40%. The maximum rotational speed of the supply screw was about 30 rpm, and the optimal rotational speed of the supply screw was found to be about 6-18 rpm, for example, about 12 rpm.

[0495] In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the material supply rate is 30-50% or 35-45% of the maximum value, preferably about 40%. In some embodiments, including some embodiments in which the aerosol-generating material is a high-fill-value aerosol-generating material, the material supply rate may also be 5-20 rpm, 6-18 rpm, 7-17 rpm, 8-16 rpm, 9-15 rpm, preferably 10-14 rpm or 11-13 rpm, for example, about 12 rpm.

[0496] Step S5 In step (S5), the aerosol-generating material is cooled, for example, from a temperature above 100°C to room temperature. This may be done on a conveyor belt based on air suction or operated from below.

[0497] During the cooling process, the aerosol-generating material loses more moisture through cooling by evaporation, thereby enabling it to reach the moisture level of the final product without the need for a dryer. The cooled material may have a moisture content in the range of 5-25%, preferably 8-15%.

[0498] Device Referring to Figure 2, the processing device 1 is shown. In this embodiment, the processing device 1 is a pressure defibrillation device 1.

[0499] The pressure defibrillator 1 comprises a chamber housing 2 in which a conveyor screw 3, which is rotated by a drive mechanism 4, for example, an electric motor 4, is located.

[0500] The pressure defibration device 1 further comprises an initial material inlet 5A, a water inlet 6A, and a casing and / or flavoring inlet 6B. The pressure defibration device 1 may further comprise a steam inlet 7.

[0501] Initial material is supplied to the initial material inlet 5A and enters the chamber housing 2. As the conveyor screw 3 rotates, the initial material passes along the chamber housing 2 so that it passes from the initial material inlet 5A to the outlet 5B. The outlet 5B of the chamber housing 2 has a head 8 with a substantially conical recess 8A.

[0502] A shearing member 10 is housed in the recess 8A. A shearing gap 9 is formed between the shearing member 10 and the inner wall of the recess 8A. The initial material is conveyed through the gap 9 by the screw 3. The outlet 5B of the chamber 2 is in the form of an orifice that connects the inside of the chamber 2 to the recess 8A. The orifice may be located at the apex of the gap in the substantially conical recess 8A. The discharged material is shown by reference number 12.

[0503] In some embodiments, the shear member 10 is conical in shape. The shear gap 9 may be annular.

[0504] The shearing member 10 is coupled to an actuator mechanism 11 configured to rotate the shearing member 10. The shearing member 10 can rotate about its central axis, and this rotation is indicated by the curved arrow in Figure 2. In some embodiments, the actuator mechanism 11 comprises an electric motor.

[0505] In some embodiments, the actuator mechanism 11 is configured to move the shearing member 10 axially to adjust the size of the gap 9.

[0506] The axial movement of the shearing member 10 is indicated by a double arrow in Figure 2, showing that the shearing member 10 can move toward and away from the head 8. Thus, the shearing member 10 can be held firmly in its axial position, but may also be moved in the axial direction. As a result, the width of the gap 9 can be adjusted or adapted, and in some embodiments, a back pressure can be generated in the direction of closing the gap 9. The actuator mechanism 11 may be configured to move the shearing member 10 in the axial direction using a hydraulic or pneumatic actuator, or using a linear gear mechanism such as a rack and pinion gear mechanism driven by an electric motor.

[0507] The first part of the initial material processing is carried out in step (S3) at a pressure higher than atmospheric pressure. This excess pressure is generated when the initial material is supplied to the inlet 5A and transported along the chamber 2 via the screw 3.

[0508] The shear gap 9 is located at the outlet end 5B of the chamber 2. The gap 9 substantially closes the chamber 2, similar to an extruder.

[0509] The gap 9 may have a substantially annular cross-section. The width of the gap 9 in the axial direction of the screw-fastened conveyor is determined by the axial position of the shearing member 10. Therefore, in embodiments where the axial position of the shearing member 10 is adjustable, the width of the gap 9 is also adjustable.

[0510] In step (S3), the initial material is subjected to an increased pressure (up to 50 bar) and an increased temperature (especially above 100°C). In addition to the mechanical pressure generated by the initial material being conveyed toward the gap 9, a shear force acts on the pitch of the conveyor screw, and in conjunction with the wall, the initial material is cut and defibrated, thus acting an additional force on the initial material. The shear effect can be assisted by introducing a draft through the housing wall or by introducing additional flow resistance. Furthermore, steam may be introduced at several points to regulate the moisture, temperature, and pressure in the conveyor screw or chamber 2. As a result of the introduction of steam, and due to the natural moisture content of the plant material and cellulose fibers, as the material leaves the gap 9, the moisture evaporates rapidly, causing further defibration and expansion of the initial material. Under pressure, as the pressure drops to atmospheric pressure downstream of the gap 9, the moisture in the initial material evaporates rapidly, and thus flash evaporation occurs.

[0511] In some embodiments, the initial material is mechanically pressed and positioned, particularly against the shear gap 9 within the chamber 2. In this case, the material may be subjected to pressure by a conveyor screw that pushes the material toward the exit end of the chamber 2 of a heatable screw conveyor in which the shear gap 9 is positioned. The initial material may also be roughly pre-cut or roughly pre-fiberized within the chamber 2 when supplied toward the shear gap.

[0512] In some embodiments, the shear gap 9 is closed under pretension and intermittently opened by the pressure of the initial material to allow the material to pass through the gap 9. Alternatively, the material may also be supplied through a shear gap 9 that is preferably continuously open.

[0513] In some embodiments, the shear gap 9 has a width in the range of 50 to 300 micrometers.

[0514] In some embodiments, the pressure chamber 2 has a conveyor system in the form of a plug screw feeder for transporting initial material from an inlet 5A to an outlet 5B. In some embodiments, the pressure is generated by mechanical means, such as by a plug screw feeder, but in relation to the present disclosure, other systems may be used, in principle, not only mechanically, by using a piston system, for example, or not mechanically, or by using gas pressure such as a pressurized gas supply source.

[0515] When a plug screw feeder is used, in some embodiments, the plug screw feeder has a reduction mechanism, such as a smaller screw pitch, that reduces the chamber volume in the region toward the outlet.

[0516] In some embodiments, a mechanical pre-cutting mechanism or pre-defibration mechanism is located within the pressure chamber 2. In one embodiment, a screw chamber pressure regulating device is located upstream of the device proposed by the present invention, either in the same pressure chamber housing or in another device connected upstream. This type of pressure regulating device is described, for example, in German Patent Application Publication No. 10304629 and can be combined with the pressure defibration device 1 of the present disclosure. The pressure regulating device 1 is shown in Figure 1 and may incorporate all the structural features described in the relevant section of German Patent Application Publication No. 10304629, and these structural features may be referenced for further details.

[0517] In some embodiments, the pressure chamber 2 is provided with an inlet for a modifier or casing agent and a flavoring agent.

[0518] The conditioning and pressure defibration processes depend on the pressure conditions under which the conditioning is performed. In some embodiments, the initial material is conditioned under atmospheric conditions and supplied to inlet 5A, for example, via a hopper, by a supply device, such as a conveyor chute or conveyor belt. One or more components of the initial material may be conditioned separately. For example, the plant material and cellulose fibers may be conditioned separately or not conditioned at all, and then combined with each other and optionally with other materials such as fine powder. In some embodiments, the plant material and / or cellulose fibers may be conditioned before being pre-sized.

[0519] In some embodiments, the supply device includes a silo (not shown) and a screw feeder (not shown). Initial material is stored in the silo and supplied to the screw feeder, which supplies the initial material to the inlet 5A of the pressure defibration device 1.

[0520] The supply device may be configured to supply initial material to the processing device 1 at a predetermined flow rate. In some embodiments, the supply device is configured to supply initial material to the processing device 1 at a flow rate in the range of 20 to 100 kg / hour, preferably in the range of 25 to 80 kg / hour.

[0521] The adjustment process may be carried out at the axial midpoint of the chamber 2 by introducing water and casing into the respective inlets 6A and 6B. In some other embodiments (not shown), water and casing (and / or flavoring agent) are introduced into the same inlet, or only one of water or casing is introduced into the chamber 2.

[0522] In step (S4), the initial material passes through the gap 9, undergoes shearing between the wall of the head 8 and the shearing member 10, and the flash evaporation described above occurs in the material exiting the gap 9. Thus, the gap 9 acts as a shearing gap 9. Both shearing and flash evaporation contribute to a well-defibrated aerosol-generated product that can be used in the aerosol supply system.

[0523] In some embodiments, the shearing member 10 is rotated about its axis of rotation to help prevent blockage in the gap 9. This rotation of the shearing member 10 may be continuous or intermittent, or the direction of rotation may be alternating. In this case, the rotation may be a full rotation or only a quarter or a third of a rotation or a rotation in smaller / larger units. In another embodiment (not shown), the shearing member 10 is stationary, and the head 8 rotates, for example, coupled to a drive mechanism. However, in yet another embodiment, it should be understood that the head 8 and the shearing member 10 do not rotate relative to each other.

[0524] In some embodiments, the head 8 and the shearing member 10 have respective shear surfaces 13 and 14, and the gap 9 is formed between the shear surfaces 13 and 14. In some embodiments, the shear surfaces 13 and 14 are substantially opposite each other.

[0525] In some embodiments, one or both of the shear sections 13, 14 have one or more surface formations, such as grooves or other rough surfaces such as protrusions or depressions. In some embodiments, the surface formations, such as grooves, may have a radial depth of at least 0.2 mm or at least 1 mm. Surface formations can facilitate shearing of the initial material and may also promote more homogeneous pressure conditions, resulting in a more homogeneous final product. In some embodiments, the grooves extend parallel to the central axis of the shear member 10.

[0526] In some embodiments, the shearing member 10 has more than 80 grooves, preferably at least 90, 100, 120, 140, 160, or 180 grooves.

[0527] In some embodiments, each groove has a maximum width in the range of 0.5 to 1.5 mm. The width of each groove may be constant or different. It has been found that smaller groove widths result in smaller and lighter fibers in the aerosol-generating material. The groove widths are circumferential to the shear member 10.

[0528] In some embodiments, the shear surfaces 13 and 14 are movable toward each other, away from each other. In some embodiments, the shearing member 10 is biased toward the head 8 such that the shear surfaces 13 and 14 abut each other and thus the gap 9 is closed. Alternatively, the shear surfaces 13 and 14 are movable toward each other, away from each other, at a fixed or fixedly adjustable distance, in which case the shear surfaces 13 and 14 are at a fixed distance of 10 to 2000 microns, preferably 50 to 300 microns. These figures relate to smooth shear surfaces 13 and 14. Alternatively, if the shear surfaces 13 and 14 have grooves, for example, the distance refers to the distance between portions of the surfaces 13 and 14 between the grooves.

[0529] In some embodiments, the grooves of the shearing member 10 extend in a longitudinal or transverse direction with respect to the direction in which the shearing surfaces 13 and 14 move.

[0530] In some embodiments, the shear surface 14 of the head 8 is stationary, while the shear surface 13 of the shearing member 10 is displaced in the axial direction. In some embodiments, the shear surface 14 of the head 8 is displaced in the axial direction, while the shear surface 13 of the shearing member 10 is held stationary.

[0531] In some embodiments, the shear surface 14 of the head 8 is stationary, while the shear surface 13 of the shearing member 10 is rotating. In some embodiments, the shear surface 14 of the head 8 is rotating, while the shear surface 13 of the shearing member 10 is stationary and held.

[0532] The rotation and axial movement of the shear sections 13 and 14 may be caused by the same actuator mechanism 1. Alternatively, the first actuator mechanism may rotate one of the shear sections 13 and 14, and the second actuator mechanism may axially displace one or the other of the shear sections 13 and 14.

[0533] In some embodiments, the shear surfaces 13 and 14 are moved continuously or intermittently toward each other, in one direction or two directions, or back and forth.

[0534] In some embodiments, the gap 9 may be an annular gap, preferably a conical gap.

[0535] In step (S5), the material is cooled. The material may be cooled, for example, while being transported on a conveyor belt.

[0536] In some embodiments, the manufactured aerosol-generating material has an average fiber diameter of less than 0.95 mm, preferably about 0.9 mm or less than 0.85 mm. In some embodiments, the average fiber diameter is about 0.8 mm or less. The average fiber diameter may be less than 0.8 mm. In some embodiments, the average fiber diameter is in the range of 0.6 to 0.8 mm. A smaller average fiber diameter results in a lighter aerosol-generating material with a lower density.

[0537] Referring now to Figure 3, another embodiment of the processing apparatus is shown. The processing apparatus comprises a pressure defibrillator 1 of the type described above, with reference to Figure 3. The processing apparatus further comprises a pressure regulating device 20 connected upstream of the pressure defibrillator 1.

[0538] The pressure defibrillator 1 and the pressure regulating device 20 form part of a combined pressure regulating and defibrillator system.

[0539] The pressure regulating device 20 may be of the type shown in Figure 1 of German Patent Application Publication No. 10304629 and described in the relevant parts of the specification, the latter of which is incorporated herein by reference. It has an initial material inlet 25 and a differential pressure resistant cellular wheel sluice 26 into which the initial material is introduced into a pressure chamber 21 and conveyed using a conveyor screw 22. The conveyor screw 22 is driven by a drive mechanism, for example, a motor 24.

[0540] An outlet 27 for initial material is located at the end of the chamber 21, which supplies it to the inlet 5A of the pressure defibration device 1. In some embodiments, unlike the apparatus described in German Patent Application Publication No. 10304629, there is no differential pressure sluice at the outlet of the pressure regulating device. Instead, the initial material is transferred to the inlet 5A of the pressure defibration device 1 by the pressure of the chamber 22.

[0541] In other embodiments, the outlet from the pressure adjustment chamber 22 is operated using a cellular wheel sluice to reduce the pressure. In such embodiments, the initial material may be transferred to the pressure defibration process at a lower pressure than that inside the pressure adjustment chamber, for example, ambient pressure. In some embodiments, the initial material is first processed by the pressure adjustment device 20 and then transported to a separate pressure defibration device 1. The initial material may be transported manually between the pressure adjustment device 20 and the pressure defibration device 1, or automatically using, for example, a conveyor belt or a pneumatic conveyor.

[0542] However, as shown in the figure, it is preferable to avoid a pressure drop during transfer from the pressure adjustment device 20 to the pressure defibration device 1 so that a pressure higher than atmospheric pressure can be applied throughout the entire processing area from the start of pressure adjustment to the defibration process. The initial material is supplied through a differential pressure resistant cellular wheel sluice 26. The pressure resistance of the sluice 26 at one end and the gap 9, which is always filled with defibrated material during operation, enable the maintenance of a pressure higher than atmospheric pressure throughout the entire composite device. For this purpose, the sealing of the cellular wheel sluice 26 may be optimized by heating its housing.

[0543] Once the initial material is introduced into the chamber 22, it is under a pressure higher than atmospheric pressure, which can be maintained by introducing steam to compensate for the natural leakage rate (gap and leakage rate) of the cellular wheel sluice 26. The initial material is heated by the steam, increasing its moisture content. In principle, it is also possible to operate the drying process in such a chamber using supersaturated steam, but when used for defibration, it is usually advantageous for the introduced initial material to have a higher moisture content.

[0544] The initial material is conveyed through the adjustment chamber 21 by a conveyor screw 22. Different settings (screw pitch, chamber rotation speed, and inclination) may be used for this purpose, thereby setting the residence time of the initial material. In some embodiments, the residence time is 2 to 10 minutes.

[0545] After a pressure adjustment process to which water, casing, and / or flavoring materials may be added, the initial material is then transferred to the pressure defibration device 1 through outlet 27. The process of introducing the initial material may be made easier if the wugling is also of a hopper type design. In some embodiments, the typical residence time of the initial material in the pressure defibration device 1 is less than 2 minutes, particularly less than 1 minute. The material may then exit the pressure defibration device 1 in the desired state described above.

[0546] Instead of a pressure adjustment screw, it is also possible to use an adjustment screw that operates below atmospheric pressure.

[0547] In some embodiments, the pressure defibration device 1 comprises a single-screw or twin-screw conveyor having a shear gap outlet for the defibration material. The shear gap comprises an orifice through which the material is sheared as it passes.

[0548] Figure 4 shows another embodiment of the combined pressure adjustment and defibrillation system. The pressure adjustment device 20 and the pressure defibrillation device 1 are the same as those described above with reference to Figures 2 and 3, and therefore will not be described in detail again below. The difference is that the conveyor screw of the adjustment device 20 and the defibrillation screw of the pressure defibrillation device 1 are mounted on the same axis and driven by a single motor. When the same rotational speed is used for both screws, the different residence times in the two process steps may be obtained using different methods, for example, by different cross-sectional / volume or discharge options in the region of the adjustment process.

[0549] In the embodiments shown in Figures 3 and 4, steam and regulating agents, such as water and casing, are introduced through appropriate inlets of the pressure regulating device 20. The corresponding water, regulating, and steam inlets are omitted from the pressure defibrillation device 1. Flavoring agents and / or casing can be introduced into both pressure ranges, i.e., one or both of the pressure chambers, or into atmospheric pressure, i.e., outside the chambers.

[0550] water content In some embodiments, the manufactured aerosol-generating material has a water content in the range of 6–20%, 7–18%, or 8–15%. The water content of the material may be determined by any suitable method, such as using a Karl Fischer titrator.

[0551] In embodiments in which the manufactured aerosol-generating material contains or consists of mint plant material, the water content of the aerosol-generating material may be 8-20%, 10-18%, or 12-15%.

[0552] In embodiments in which the manufactured aerosol-generating material contains or consists of eucalyptus plant material, the water content of the aerosol-generating material may be 6-12%, 7-10%, or 8-9%.

[0553] In embodiments in which the manufactured aerosol-generating material contains or consists of cinnamon plant material, the water content of the aerosol-generating material may be 8-16%, 10-14%, or 11-12%.

[0554] In embodiments in which the manufactured aerosol-generating material contains or consists of lavender plant material, the water content of the aerosol-generating material may be 8-16%, 10-14%, or 11-12%.

[0555] In embodiments in which the manufactured aerosol-generating material contains or consists of clove plant material, the water content of the aerosol-generating material may be 6-15%, 8-12%, or 9-10%.

[0556] In embodiments in which the manufactured aerosol-generating material contains or consists of a rooibos plant material, the water content of the aerosol-generating material may be 8-20%, 10-18%, or 12-15%.

[0557] density index In some embodiments, the aerosol-generating material produced has a density of 20-200 kg / m³. 3 , 40-150 kg / m 3 , or 60-120 kg / m 3 It has a wet bulk density within the range of [specified range]. The wet bulk density may be calculated as mass / volume for a particular material.

[0558] In embodiments in which the manufactured aerosol-generating material contains or consists of mint plant material, the wet bulk density of the aerosol-generating material is 80-150 kg / m³. 3 For example, 100-130 kg / m 3 , or 110-120 kg / m 3 For example, approximately 114 kg / m³ 3 That's fine.

[0559] In embodiments in which the manufactured aerosol-generating material contains or consists of eucalyptus plant material, the wet bulk density of the aerosol-generating material is 50-100 kg / m³.3 For example, 60-80 kg / m 3 For example, approximately 70 kg / m 3 That's fine.

[0560] In embodiments in which the manufactured aerosol-generating material contains or consists of cinnamon plant material, the wet bulk density of the aerosol-generating material is 80-150 kg / m³. 3 For example, 90-120 kg / m 3 , or 100-110 kg / m 3 For example, approximately 103 kg / m³ 3 That's fine.

[0561] In embodiments in which the manufactured aerosol-generating material contains or consists of lavender plant material, the wet bulk density of the aerosol-generating material is 50-120 kg / m³. 3 For example, 70-100 kg / m 3 , or 80-90 kg / m 3 For example, approximately 83 kg / m 3 That's fine.

[0562] In embodiments in which the manufactured aerosol-generating material contains or consists of clove plant material, the wet bulk density of the aerosol-generating material is 60-130 kg / m³. 3 For example, 80-110 kg / m 3 , or 90-100 kg / m 3 For example, approximately 95 kg / m 3 That's fine.

[0563] In embodiments in which the manufactured aerosol-generating material contains or consists of rooibos plant material, the wet bulk density of the aerosol-generating material is 50-100 kg / m³. 3 For example, 65-80 kg / m 3 That's fine.

[0564] Delivery system This disclosure also relates to the manufacture of components for delivery systems, such as aerosol supply systems.

[0565] The delivery systems described herein can be implemented as non-combustible aerosol delivery systems or aerosol-free delivery systems.

[0566] This method includes the steps of: combining an aerosol-generating material with a tobacco material, such as cut tobacco, to form a mixture or blend; and then forming components from the mixture or blend.

[0567] In embodiments in which the aerosol-generating material consists of or includes clove plant material, it may be combined with Kretek tobacco material in components for a delivery system.

[0568] In some embodiments, for non-combustible products, such as non-combustible aerosol supply systems, the mixture may contain at least 5% by mass and up to 100% by mass of aerosol-generating material.

[0569] In some embodiments, the aerosol-generating material may be used in a blend with tobacco and / or one or more other materials. Depending on the desired sensory properties and the type of plant material used in the aerosol-generating material, the blend may contain, for example, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more than 99% of the aerosol-generating material. For example, the blend may be a blend with tobacco material and may include, for example, blend ratios of 95:5, 90:10, 85:15, 80:20, 75:25, 70:30, 65:53, 60:40, 55:45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85, 10:90, 5:95%, or substantially 0:100 (tobacco:aerosol-generating material).

[0570] In some embodiments, the aerosol-generating material may be combined with an "amorphous solid" (i.e., non-fibrous), which may be called a "monolithic solid" instead of an aerosol-forming material. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can hold some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid, or about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0571] In some embodiments, components for a non-combustible aerosol supply system are provided, comprising an aerosol-generating material. The method described herein yields an expanded aerosol-generating material, which can be supplied, for example, to the aerosol-generating portion of an article for use in a non-combustible aerosol supply system or non-combustible delivery system described herein. A non-combustible delivery system or non-combustible aerosol delivery system is also provided, comprising an aerosol-generating material, for example, a material produced by the method described herein. The non-combustible aerosol supply system can be a hybrid system in which one of the materials is an aerosol-generating material, for example, a tobacco heating product or a combination of aerosol-generating materials that generates an aerosol.

[0572] In some embodiments, the components are for a combustion-type aerosol supply system or a non-combustion-type aerosol supply system. In some embodiments, the components are rods of smokeable material.

[0573] This disclosure further relates to an aerosol supply system and components of an aerosol supply system, including aerosol-generating materials manufactured in accordance with this disclosure.

[0574] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user.

[0575] A combustion aerosol supply system for pipes, roll-your-own or make-your-own cigarettes, cigarettes, and tobacco (in any case, based on tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, tobacco substitutes, or other smokeable materials),

[0576] Non-combustion aerosol supply systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of e-cigarettes, tobacco heating products, and aerosol-generating materials,

[0577] an aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, comprising, but not limited to, articles containing lozenges, gums, patches, inhalable powders, and oral products such as oral tobacco containing snuff or moist snuff, wherein at least one substance may or may not contain nicotine.

[0578] As used herein, the term “aerosol delivery system” is intended to encompass combustion and non-combustion aerosol delivery systems that deliver at least one substance to a user.

[0579] Combustion aerosol supply systems for cigarettes, cigarillos, cigars, and tobacco for pipes or roll-your-own or make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, tobacco substitutes, or other smokeable materials),

[0580] This includes non-combustion aerosol supply systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of e-cigarettes, tobacco heating products, and aerosol-generating materials.

[0581] According to this disclosure, a “combustion-type” aerosol supply system is a system in which the aerosol-generating material (or its components) that make up the aerosol supply system is burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0582] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0583] In some embodiments, the disclosure relates to aerosol modifier release components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or components for use in combustion aerosol supply systems such as plug wraps, tip paper, or cigarette paper.

[0584] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0585] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0586] In some embodiments, the non-combustion aerosol supply system is an electronic cigarette, also known as a vaporization device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0587] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0588] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0589] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0590] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. These consumables may be referred to as articles throughout the disclosure.

[0591] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate to which energy can be supplied to distribute power in the form of heat to an aerosol-generating material or heat-transferring material located near the heat-generating power source.

[0592] In some embodiments, the non-combustion aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter and / or an aerosol modifier.

[0593] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle and / or an aerosol modifier.

[0594] In some embodiments, the delivered substance may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, any of the materials may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0595] active substance In some embodiments, the delivered substance includes an active substance.

[0596] The active substances used herein may be physiologically active materials intended to achieve or enhance physiological responses. Active substances may be selected from, for example, nutritional supplements, nootropics, and psychostimulants. Active substances may be naturally occurring or obtained by synthesis. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or their components, derivatives, or combinations. Active substances may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0597] The active substance may include nicotine salts. The nicotine salt may be nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or a combination thereof.

[0598] In some embodiments, the active substance includes nicotine. Nicotine may be applied to the aerosol-generating material using any suitable method. For example, in some embodiments, nicotine may be applied to the aerosol-generating material by a suitable applicator such as a spray. In addition, or instead, in some embodiments, nicotine may be combined with an aerosol-generating agent such as glycerol to be incorporated into the aerosol-generating material.

[0599] Nicotine or nicotine salts may be included in the material in a final amount of about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of nicotine or nicotine salts in the material may be about 0.2% to about 4% by weight, about 0.5% to about 3% by weight, for example, about 1% or about 2% by weight of the aerosol-generating material.

[0600] The nicotine content may be determined by any suitable method, such as using gas chromatography, or by any other method used in the art to quantify the levels of secondary alkaloids in tobacco.

[0601] In some embodiments, including some embodiments in which the active substance contains nicotine, the aerosol-generating material may also contain an acid. As a result, an aerosol-generating material containing an acid can produce an aerosol having a suitable composition, such as nicotine content.

[0602] The inclusion of acid has been shown to improve the release of other substances, such as nicotine, from the material. The total amount of acid may be about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of acid may be 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-generating material. For example, the total amount of acid may be 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-generating material.

[0603] In some embodiments, the aerosol-generating material contains an amount of acid (i.e., moles of acid) of about 50% to about 200%, about 75% to about 150%, about 85% to about 140%, about 95% to about 135%, about 105% to about 130%, or about 110% to about 125% relative to the moles of nicotine in the material. In some embodiments, the aerosol-generating material contains an amount of acid (i.e., moles of acid) of about 100% to about 200%, about 100% to about 180%, about 110% to about 180%, about 120% to about 180%, about 130% to about 180%, or about 135% to about 180% relative to the moles of nicotine in the material.

[0604] The acid may be present in a ratio of approximately 0.5 to 2.5 moles relative to the moles of free base nicotine.

[0605] The acid may be applied to the aerosol-generating material using any suitable method. The acid may be applied to the material together with another substance such as nicotine and / or the aerosol-forming material, or separately. For example, in some embodiments, the ratio of the acid to the aerosol-forming material in the aerosol-generating material is about 1:2 to about 1:50 (acid:aerosol-forming material).

[0606] The acid may be applied to the aerosol-generating material using any suitable method. In some embodiments, the acid may be included in the formulation of the aerosol-generating material before or during production. Additionally or alternatively, the acid may be applied to the aerosol-generating material after production.

[0607] In some embodiments, the acid is selected from the group consisting of lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is lactic acid. In some embodiments, the acid is levulinic acid. The term lactic acid is synonymous with the term 2-hydroxypropanoic acid and includes both the D and L enantiomers separately or as mixtures thereof. For example, lactic acid may be a mixture of D-2-hydroxypropanoic acid and L-2-hydroxypropanoic acid (e.g., a racemic mixture). The term levulinic acid is synonymous with the term 4-oxopentanoic acid.

[0608] In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0609] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0610] As described herein, the active substance may include or be derived from one or more plant substances, or their components, derivatives, or extracts. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include synthetically obtained active compounds that are naturally present in plant materials. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, flakes, strips, sheets, etc. Examples of plant materials include any of the plant materials described above.

[0611] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof.

[0612] In some embodiments, the active substance comprises or is derived from one or more plant materials or their components, derivatives, or extracts, where the plants are mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove materials.

[0613] In some embodiments, the delivered substance includes flavorings.

[0614] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring flavorings, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaves, 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, clove, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, cereal Bean oil from ginger, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, majolica It may also contain other additives such as lamb, olives, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant matter, or breath fresheners.Flavors and flavorings may be imitations, synthetics, natural raw materials, or blends thereof. Flavors and flavorings may be in any preferred form, such as a liquid such as oil, a solid such as a powder, or a gas.

[0615] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes eucalyptus. In some embodiments, the flavoring includes lavender. In some embodiments, the flavoring includes ginger. In some embodiments, the flavoring includes cinnamon. In some embodiments, the flavoring includes rooibos.

[0616] In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0617] In some embodiments, the flavor may include a sensory stimulant, which is usually chemically induced and intended to achieve somatosensory perception perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A preferred thermal agent is not limited to vanillyl ethyl ether, and a preferred cooling agent is not limited to eucolyptol or WS-3.

[0618] The aerosol-generating material may include one or more active substances and / or fragrances, and optionally one or more other functional materials.

[0619] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0620] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise these. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some other embodiments, the susceptor is on one or both sides of the material.

[0621] Consumables are articles containing or consisting of aerosol-generating materials, some or all of which are intended to be consumed during use by the user. Consumables may also include one or more other components such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to generate an aerosol in the aerosol-generating material. The heater may include, for example, a flammable material, an electrically conductive material, or a susceptor.

[0622] A susceptor is a material that can be heated by the penetration of a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and consequently, the penetration of the fluctuating magnetic field into the conductive material causes inductive heating of the heating material. The heating material may be a magnetic material, and consequently, the penetration of the fluctuating magnetic field into the magnetic material causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and consequently, the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0623] Aerosol modifiers are typically substances located downstream of the aerosol generation area and are configured to modify the generated aerosol by altering, for example, the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be contained within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0624] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorings, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier does not need to contain a filter material.

[0625] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material so as to release one or more volatile substances from the material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the aerosol-generating material to vibration, rising pressure, or electrostatic energy.

[0626] Examples Examples 1-4 describe initial experiments conducted by the inventors to investigate how the formulation of initial materials, including plant-based materials and cellulose fibers, relates to the resulting product, and in particular to investigate the production of materials containing particulate plant-based materials that have improved packing values ​​and can support high levels of aerosol-forming material.

[0627] In these initial experiments, tobacco material was used as the plant-based material. This was because tobacco is readily available and a well-understood material. Through testing with tobacco, the inventors were able to understand how parameters and formulations affect the resulting material. Subsequently, materials prepared using non-tobacco plant-based materials could be manufactured to have the desired properties. Ultimately, the objective was to manufacture aerosol-generating materials with high packing strength and low density (to enable the transport and delivery of high-level aerosol-forming materials such as glycerol) and to provide novel aromas and flavor profiles.

[0628] Example 1 In this example, an aerosol-generating material containing 65% tobacco material was produced. This material is referred to as T1. The initial material formulations found to be suitable for producing an aerosol-generating material containing 65% tobacco material are provided below.

[0629] [Table 1]

[0630] The parameters used in the production of the material were as follows:

[0631] [Table 2]

[0632] The aerosol-generating material obtained had the following properties: [Table 3]

[0633] Strands produced using this formulation showed high levels of decomposition and low expansion even with the addition of a binder. Overall, the extruded product flow was stable with minimal fluctuations. Strand formation was achieved with moderate flake content (standard for the process). The apparent moisture content of the product was approximately 12%.

[0634] Example 2 In this example, the increase in the level of plant-based material (in this case, tobacco) in an aerosol-generating material was investigated. It was possible to produce an aerosol-generating material containing 74% tobacco using the formulation shown below. This material is referred to as T2.

[0635] [Table 4]

[0636] To increase the tobacco content in the material, it would be advantageous to increase the tobacco content by reducing the proportion of binders (starch) and cellulose fibers in the material. It was found that modifying the formulation in this way resulted in an improved aerosol-generating material.

[0637] The advantages of the method for producing aerosol-generating materials from T2 formulations were found to be obtained using the following operating parameters. In particular, it was found that increasing the pressure and temperature of the expander and hydraulic system was advantageous.

[0638] [Table 5]

[0639] The aerosol-generating material obtained had the following properties: [Table 6]

[0640] Significant improvements were made to the process and product by installing a steam preheating system. Preheating the extruder enabled thermochemical activation of the binder used in tests T2-T4, providing physical changes to the filaments in tests T2, T3, and T4. The percentage of starch in the original formulation (12%) caused filament expansion beyond the desired limit, resulting in operational difficulties and malfunctions at the extruder outlet. Due to the presented problems, the T2 formulation was modified, changing the percentages of several components (starch was reduced from 12% to 5.5%). After the formulation adjustment, the initial process did not show any problems with filament formation. The application of glycerol altered the process water flow during manufacturing.

[0641] The discharge flow of extruded products without significant fluctuations during manufacturing. The manufactured filament has moderate expansion and high density. The apparent humidity of the product is approximately 12%. The damage index for a 106kg batch is approximately 49%.

[0642] Example 3 In this example, the effect of increasing the proportion of plant material (in this case, tobacco) present in the form of small particles (i.e., fine powder and dust with a particle size of less than 0.5 mm) was investigated. The initial formulation, called T3, was as shown in the table below. It was found that good aerosol-generating materials could be produced using the following adjusted formulations.

[0643] [Table 7]

[0644] Specifically, in this formulation, compared to the T2 formulation, the level of plant material (tobacco) in the form of fibers may be replaced with plant material (tobacco) in the form of small particles (i.e., fine powder and dust) by increasing the levels of cellulose fibers and total binders (starch and xanthan gum) used.

[0645] It was found that by changing the formulation in this way, an improved aerosol-generating material could be obtained.

[0646] The advantages of the method for producing aerosol-generating materials using the T3 formulation were found to be obtained by using the following operating parameters. In particular, the pressure of the first expander was increased and the pressure of the second expander was decreased for the pressures used for both the T1 and T2 formulations.

[0647] [Table 8]

[0648] The aerosol-generating material obtained had the following properties: [Table 9]

[0649] The starch content was reduced from 8% to 2.5% as a result of what happened in the previous test (T2), and the same proportion of tobacco powder was added to maintain the overall composition. The xanthan gum content was also reduced from 4% to 2.5%. Despite this reduction, the manufactured filaments exhibited significant resistance, making them difficult to cut and causing tangling at the extruder exit. The extruded product flowed out steadily overall with little variation. Filament formation was achieved with a moderate amount of flake (standard for the process). The apparent moisture content of the product was approximately 13%. The damage index for a 120kg batch was approximately 79%.

[0650] Example 4 In this example, the effect of using different binders was investigated. This material was designated as T4. The initial formulation was as shown in the table below. It was found that good aerosol-generating materials could be produced using the following adjusted formulations.

[0651] [Table 10]

[0652] Similar to T3, it was found that improved aerosol-generating materials are produced by reducing the level of plant material (tobacco) present in the form of fibers and increasing the levels of cellulose fibers and total binders used.

[0653] The advantages of using the T4 formulation in the method for producing aerosol-generating materials were found to be obtained using the following operating parameters. In general, the optimal parameters were found to be broadly similar to those used for the T1 formulation: [Table 11]

[0654] The aerosol-generating material obtained had the following properties: [Table 12]

[0655] Similar to previous alternatives, the percentage of starch was reduced from 8% to 2.5%, and the same percentage of tobacco powder was added. Based on previous test results, the percentage of guar gum was also reduced to adjust the product strength to an appropriate level. Strands produced with the T4 formulation showed excellent flexibility and sufficient resistance to the process. Overall stable extrusion of the product with little variation. Filament formation with moderate flakes (standard for the process). The apparent moisture content of the product was approximately 13%.

[0656] Using this combination of process parameters and formulations, an aerosol-generating material was produced that had improved thickness, lighter weight, greater resistance to fracture, a smoother surface, and reduced density compared to T1, T2, and T3.

[0657] Materials manufactured from the T4 formulation exhibited excellent flexibility and sufficient process resistance. The extruded product flow showed excellent stability without significant fluctuations.

[0658] Example 5 In this example, the effect of cellulose fibers was investigated. Materials containing cellulose fibers or other fibrous materials, in this case tobacco fibers, were manufactured.

[0659] [Table 13]

[0660] Materials containing cellulose fibers were found to have a higher filling value than materials containing other fibrous materials.

[0661] Materials containing cellulose fibers were found to have a significantly lower density than materials containing other fibrous materials. Specifically, the density of materials containing cellulose fibers was found to be 70-80% of the density of the corresponding materials containing other fibrous materials.

[0662] Materials containing cellulose fibers were also found to support higher levels of aerosol formation than materials containing other fibrous materials.

[0663] Furthermore, materials containing cellulose fibers were found to be significantly superior in terms of process performance because they are thicker, lighter, more resistant to fracture, smoother, and have a larger volume.

[0664] Example 6 In this example, the effects of using various binders were investigated. Materials containing various binders, as shown in the table below, were manufactured.

[0665] [Table 14]

[0666] Materials containing xanthan gum were found to have a higher packing value than materials containing other binders. Materials containing CMC or HPC were found to have the next highest packing value.

[0667] Materials containing xanthan gum were found to have a lower density than materials containing other binders. Materials containing CMC or guar gum were found to have the next lowest density. Materials containing HPC were found to have the highest density.

[0668] Materials containing CMC were found to support higher levels of aerosol formation than materials containing other fibrous materials. Materials containing guar gum or xanthan gum were found to have the next lowest density, followed by materials containing starch.

[0669] Materials containing xanthan gum were found to have the longest strands, followed by materials containing CMC or starch.

[0670] Materials containing CMC were found to be thicker, lighter, more fracture-resistant, smoother, and have a larger volume, resulting in superior process performance compared to materials containing other binders. Materials containing guar gum were found to be the next best, followed by materials containing HPC or starch.

[0671] Example 7 In this example, an aerosol-generating material was produced that included a plant-based material consisting of mint powder made from dried and pulverized mint leaves and mint stem material.

[0672] The mint material had the following particle size distribution: [Table 15] The mint material used had a moisture content of 5.76%.

[0673] The initial formulation was based on a preferred T4 formulation containing guar gum. This formulation was designated as T7.

[0674] The aerosol-generating material was found to be improved by replacing the proportion of mint powder (equal to 4% of the total composition) with cellulose fibers. This composition was designated as T9.

[0675] When a further amount of mint material was replaced with cellulose fibers, it was found to be advantageous to increase the total level of binder in the formulation. This formulation was designated as T14.

[0676] The formulations for T7, T9, and T14 materials are shown below: [Table 16]

[0677] The following operating parameters were found to be optimal for the production of T14 material: [Table 17]

[0678] The aerosol-generating material obtained had the following properties: [Table 18]

[0679] T14 material has a load capacity of 114 kg / m². 3 It had a wet bulk density of [value missing].

[0680] Nicotine was added to the T14 material at three different levels: 0.5% (w / w) (0.5g Nic / 100g Fibex formulation), 1% (w / w) (1.0g Nic / 100g Fibex formulation), and 3% (w / w) (3.0g Nic / 100g Fibex formulation).

[0681] S(-) nicotine analysis standard grade (enantiomer purity >99%) was dissolved in ethanol (base nicotine solution = 3% w / w). From this base solution, different amounts were applied using a spray to achieve 0.5%, 1%, and 3% (w / w) in the final formulation.

[0682] The nicotine content in the final material was determined using the GC-FID analysis method, which is used for the quantitative determination of nicotine and other secondary alkaloids in tobacco.

[0683] The nicotine recovery rate (%) was determined as (concentration determined by GC-FID / concentration applied to Fibex) × 100.

[0684] The results were as follows: [Table 19]

[0685] Example 8 In this example, an aerosol-generating material containing a plant-based material consisting of eucalyptus powder was produced.

[0686] The eucalyptus material was dried and ground, resulting in the following particle size distribution: [Table 20]

[0687] The moisture content of the eucalyptus material used was 10.38%.

[0688] The formulation was based on the T4 formulation and designated as T8 as follows: [Table 21]

[0689] In the production of T8 material, the following operating parameters were found to be optimal: The expander pressure was the same as that used for T4 formulations, but, similar to the use of mint, it was found to be advantageous to reduce the water flow rate and raw material flow rate compared to the production of tobacco material. The parameters were as follows: [Table 22]

[0690] The aerosol-generating material obtained had the following properties: [Table 23]

[0691] The material is 70 kg / m 3 It had a wet bulk density of [value missing].

[0692] As described above in Example 7, nicotine was added to the T8 material. The results were as follows. [Table 24]

[0693] Example 9 In this example, an aerosol-generating material containing a plant-based material consisting of cinnamon powder was produced.

[0694] The cinnamon material was dried and ground, resulting in the following particle size distribution: [Table 25]

[0695] The moisture content of the cinnamon ingredients used was 14.77%.

[0696] The formulation was based on the tobacco-containing T4 formulation, and T12 was determined as follows: [Table 26]

[0697] The following operating parameters were found to be optimal for the production of T12 material. [Table 27]

[0698] The aerosol-generating material obtained had the following properties: [Table 28]

[0699] The material is 103 kg / m 3 It had a wet bulk density of [value missing].

[0700] Example 10 In this example, an aerosol-generating material containing a plant-based material consisting of lavender was produced.

[0701] The lavender material was dried and ground, resulting in the following particle size distribution: [Table 29]

[0702] The lavender material used had a moisture content of 13.75%.

[0703] The formulation was based on the T4 formulation and designated as T13 as follows: [Table 30]

[0704] The following operating parameters were found to be optimal for the production of T13 material: [Table 31]

[0705] The aerosol-generating material obtained had the following properties: [Table 32]

[0706] The material is 83 kg / m 3 It had a wet bulk density of [value missing].

[0707] Example 11 In this example, an aerosol-generating material containing a plant-based material consisting of cloves was produced.

[0708] The clove material was dried and ground, resulting in the following particle size distribution: [Table 33]

[0709] The moisture content of the clove material used was 23.36%.

[0710] The initial formulation was based on formulation T4, but the clove content was reduced, and to compensate, the levels of cellulose fiber and total binder were increased. This formulation was designated T10. It was found that an improved formulation could be produced by further reducing the clove content, which was compensated for by further increasing the levels of cellulose fiber and total binder. This formulation was designated T16, and formulations T10 and T16 are shown below: [Table 34]

[0711] The following operating parameters were found to be optimal for the production of T16 material: [Table 35]

[0712] The aerosol-generating material obtained had the following properties: [Table 36]

[0713] T16 material: 95 kg / m 3 It had a wet bulk density of [value missing].

[0714] Example 12 In this example, an aerosol-generating material containing a plant-based material made from rooibos was produced.

[0715] Three formulations were produced using the following combinations: [Table 37]

[0716] In the production of rooibos material, the following operating parameters were found to be optimal: [Table 38]

[0717] The aerosol-generating material obtained had the following properties: [Table 39]

[0718] Example 13 In this embodiment, the brittleness of the material was measured by examining the small particle content through sieving.

[0719] [Table 40]

[0720] Compared to materials containing tobacco (T4), aerosol-generating materials containing non-tobacco plant materials reflected a significantly lower content of small particles and fewer brittle strands.

[0721] Example 14 In Example 5, it was found that materials containing cellulose fibers had a higher fill value than materials containing other fibrous materials, and in Example 6, it was found that the use of different binders affected the fill value. In this example, the effects of the properties and content of tobacco plant materials and aerosol-forming materials on the fill value were investigated.

[0722] In addition to materials T20 to T28 described in detail in Examples 5 and 6, materials T18 and T19 were also investigated.

[0723] [Table 41]

[0724] The aerosol-generating material obtained had the following properties: [Table 42]

[0725] A strong correlation was found between the aerosol-forming material content of the initial formulation and the fill value of the resulting material. It was found that materials with lower levels of aerosol-forming material in the formulation produced materials with higher fill values.

[0726] On average, materials produced from formulations containing 5% aerosol-forming material had a 23% higher fill value than materials produced from formulations containing 15% aerosol-forming material.

[0727] Example 15 In this example, the quality of the material was evaluated.

[0728] A "quality score" was assigned to the material. The quality score is a single value obtained by combining values ​​obtained from individual evaluations of the material's thickness, lightness, resistance, surface smoothness, and volume. A higher quality score indicates better performance in continuous processing and use of the material.

[0729] [Table 43]

[0730] The factors found to have the most significant impact on material filling values ​​and / or quality scores were as follows: • Content of aerosol-forming material in the initial formulation (5% glycerol provided the highest fill value and quality score), • Content of fibers (especially cellulose fibers) in the formulation, • Properties of the binder used (CMC was found to provide the most significant combined positive effect on fill value and quality score).

[0731] It was found that both the filling value and quality score were maximized when the cutting speed (i.e., cone rotation (rpm)) and cutting pressure (i.e., hydraulic system pressure) were at substantially maximum levels, particularly 90-100% of the maximum value, e.g., 95%. The maximum cone rotation speed was found to be approximately 850 rpm, and the optimal cone rotation speed was found to be approximately 770-850 rpm, e.g., approximately 810 rpm. The maximum hydraulic system pressure was found to be approximately 150 bar, and the optimal pressure was found to be 135-150 bar, e.g., approximately 142 bar.

[0732] In contrast, both the filling value and quality score were found to be maximized when the material supply rate (i.e., the rotation speed of the supply screw (rpm)) was significantly lower than the maximum level, specifically at 30-50% of the maximum value, for example, 40%. The maximum rotation speed of the supply screw was approximately 30 rpm, and the optimal rotation speed of the supply screw was found to be approximately 9-15 rpm, for example, approximately 12 rpm.

[0733] Example 16 Based on the findings of Example 15, which used a tobacco-based formulation, materials containing non-tobacco plant materials were prepared, and the effects of the aerosol-forming materials and binders contained in the formulation, as well as processing parameters, on the fill value and quality score of the obtained materials were tested.

[0734] Materials containing a binder including CMC and a non-tobacco plant material including an aerosol-forming material containing 5% or 15% aerosol-forming material (AFM) were manufactured using processing parameters including 40% of the maximum feed rate (i.e., feed screw rotation at approximately 12 rpm), 95% of the maximum cutting pressure (i.e., hydraulic system pressure at approximately 142 bar), and 95% of the maximum cutting speed (i.e., conical rotation at approximately 810 rpm).

[0735] The following shows the formulations of materials containing different non-tobacco plant materials, along with the resulting fill values ​​and quality scores.

[0736] [Table 44]

[0737] [Table 45]

[0738] [Table 46]

[0739] [Table 47]

[0740] [Table 48]

[0741] [Table 49]

[0742] It was found that using CMC as a binder increased the fill value by 23%. It was found that using CMC and a 5% aerosol-forming material increased the fill value by 52%.

[0743]

Table 50

[0744] Similar experiments were conducted using rooibos plant-based materials. When using a binder containing guar gum and starch, the filling value increased from 40.8 cm 3 / 10 g to 46 cm 3 / 10 g, and the quality score was also significantly improved.

[0745] When the level of the aerosol-forming material was reduced from 15% to 5%, the filling value further increased to 53 cm 3 / 10 g.

[0746] In summary, for all non-tobacco plant-based materials tested, filling values exceeding 40 cm 3 / 10 g were obtained. The use of CMC binder and / or reduced aerosol-forming material did not significantly affect the quality score of the materials, which was approximately 36 - 40 on average in both cases.

[0747] Materials with an average filling value of 42 cm 3 / 10 g were obtained from formulations containing non-tobacco plant-based materials and 15% aerosol-forming material. These materials were considered "high aerosol-forming materials".

[0748] Materials with an average filling value of 49 cm 3 [[ID=三十七]] / 10 g were obtained from formulations containing non-tobacco plant-based materials and 5% aerosol-forming material. These materials were considered "high filling value materials".

[0749] For reference, the filling value of equivalent reconstituted tobacco paper materials is typically in the range of 44 cm 3 / 10 g. Therefore, the disclosed process enables the production of aerosol-generating materials from non-tobacco plant-based materials having a filling value equal to or exceeding that of equivalent reconstituted paper materials.

[0750] Example 17 In the examples, the flavors and aromas produced by aerosol-generating materials containing non-tobacco plant materials were investigated.

[0751] The following formulations for the production of the disclosed aerosol-generating material are shown for the analysis of the aromatic and flavor compounds provided by the materials used. For comparison, an extruded sheet material was also produced using the formulations shown below (indicated as “Extruded Sheet”).

[0752] [Table 51]

[0753] [Table 52]

[0754] [Table 53]

[0755] [Table 54]

[0756] [Table 55]

[0757] The results of the analysis of flavor and aromatic compounds are shown below. The Odor Activity Value (OAV) was determined as shown. OAV represents the contribution of a single odor substance to the overall odor of the material. The main odor contributor of the material is the substance with the highest OAV, not the substance with the highest concentration. OAV is the value obtained by dividing the mass concentration of a substance by its odor threshold. Therefore, the lower the odor threshold of a substance, the more likely it is to contribute to the odor of the material. OAV is a dimensionless factor.

[0758] [Table 56]

[0759] The total aromatic potential was found to be similar between the T14 material and the extruded sheet when the material was heated. For both materials, the emission was primarily characterized in the woody sector arena.

[0760] [Table 57]

[0761] The total aromatic potential was found to be slightly higher in the extruded sheet than in the T8 material when the material was heated. For both materials, the release was primarily characterized by the green sector arena.

[0762] [Table 58]

[0763] The total aromatic potential was found to be similar between the T12 material and the extruded sheet when the material was heated. For both materials, the release was primarily characterized in the spicy sector arena.

[0764] [Table 59]

[0765] The total aromatic potential was found to be significantly higher in the T13 material than in the extruded sheet material when the material was heated. For both materials, the release was primarily characterized in the floral sector arena.

[0766] [Table 60]

[0767] The total aromatic potential was found to be similar between the T16 material and the extruded sheet when the material was heated. For both materials, the release was primarily characterized in the spicy and woody sectors.

[0768] Similar experiments were conducted using rooibos plant material. The total aromatic potential was found to be similar between the rooibos material produced by the disclosed method and the extruded sheets produced from similar formulations when the material was heated. For both materials, the release was primarily characterized in the woody sector arena. Regarding the secondary arena, creamy notes were observed only in the extruded sheets, and floral notes were observed only in the material produced by the disclosed method. Guaiacol and 2-methoxy-4-vinylphenol were observed at similar concentrations in the extruded sheets and the material produced by the disclosed method.

[0769] In summary, the aromatic potential of each material produced by the disclosed method is generally at least equivalent to the aromatic potential of the corresponding extruded sheet material.

[0770] The fact that different materials produced by the disclosed method, including different non-tobacco plant materials, generate aromas characterized primarily by different sectoral arenas, highlights the possibility of combining materials to provide novel and complex aroma profiles derived from natural sources.

[0771] Example 17 Test articles were prepared to test materials manufactured using the disclosed method in articles used with non-combustible aerosol supply devices.

[0772] The aerosol-generating material of the test article consisted of either a rooibos aerosol-generating material (formulation T37.4 (group A in Figure 5) or T37.6 (group B)) manufactured by the disclosed method, or a reconstituted paper sheet material (group C) manufactured from a similar formulation.

[0773] All aerosol-generating materials were infused with nicotine, acid, flavorings, menthol, and capsules to conform to commercially available materials. The materials were then used in a commercially available Glo Hyper device. The produced aerosols were tested and assigned intensity grades from 1 to 10 for the parameters shown in Figure 5 (from left to right: hot puff, ISS (first 3 puffs - best), initial flavor intensity (first 3 puffs - average), impact, irritation, aerosol body, visible aerosol, vegetable flavor intensity, flavor consistency, aerosol consistency, off-note, and draw-effort).

[0774] The test results are shown in Figure 5. Each group consisted of 11 repetitions. No significant differences were observed between the groups.

[0775] Overall, 45% of consumers preferred items from Group A, 22% preferred items from Group B, and 33% preferred items from Group C.

[0776] The results indicate that aerosol-generating materials may be manufactured from non-tobacco plant materials that provide properties similar to those of extruded sheet materials when in use.

[0777] To address various problems and advance the technology, the entirety of this disclosure illustrates various embodiments in which the claimed invention can be carried out and which can provide a superior aerosol-generating material. The advantages and features of this disclosure are merely representative samples of embodiments and are not exhaustive and / or exclusive. They are presented solely to aid in and teach the understanding of the claimed features. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be considered as limitations to the disclosure as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be utilized and modified without departing from the scope and / or spirit of this disclosure. Various embodiments may suitably include, consist of, or essentially consist of, various combinations of disclosed elements, components, features, parts, steps, means, etc. In addition, this disclosure includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A method for producing an aerosol generating material, A step of supplying an initial material containing at least 20% by mass of particulate non-tobacco plant material, The steps include: processing the initial material by subjecting it to increased mechanical pressure to produce an aerosol-generating material; It includes, and further, The steps include: applying an additive selected from an aerosol-forming material, an active substance, and a binder to the initial material before or during the increased mechanical pressure applied to the initial material, and The step of applying an additive selected from an aerosol-forming material, an active substance, and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure. A method for producing an aerosol-generating material, comprising at least one of the following.

2. The method according to claim 1, wherein the initial material comprises less than 60% by mass of tobacco material.

3. The method according to claim 1 or 2, wherein the initial material contains more than 30% by mass of the particulate non-tobacco plant material.

4. The method according to any one of claims 1 to 3, wherein the aerosol generating material does not contain the tobacco material.

5. The particulate non-tobacco plant material includes the following: Asteraceae family, Fabaceae family, Myrtaceae family, Apiaceae family, Camellia taliensis, Solanaceae family, Brassicaceae family, Caricaceae family, Asclepiadaceae family, Equisetaceae family, and Oleaceae family. The method according to any one of claims 1 to 4, wherein the material is derived from a species that is a member of the Lamiaceae family and tisanes.

6. The method according to any one of claims 1 to 5, wherein the particulate non-tobacco plant material is selected from Matricaria species such as chamomile; Pimpinella anisum species such as anise; Foeniculum vulgare species such as fennel; jasmine; lavender; clove; eucalyptus; and Aspalathus linearis species such as rooibos.

7. The method according to any one of claims 1 to 6, wherein the particulate non-tobacco plant material comprises mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and / or clove material.

8. The method according to any one of claims 1 to 7, wherein the initial material further comprises non-tobacco cellulose fibers.

9. The method according to claim 8, further comprising the step of supplying the initial material by combining the plant material with the non-tobacco cellulose fibers, wherein the initial material comprises at least 50% by mass of the particulate non-tobacco plant material.

10. To produce the aerosol-generating material by bonding the particulate non-tobacco plant material to the non-tobacco cellulose fibers, A step of setting the initial material to a predetermined water content, A step of subjecting the initial material to a temperature increase, and The process of subjecting the initial material to increased pressure. The method according to claim 8 or 9, further comprising the step of processing the initial material by means of the method.

11. The method according to any one of claims 8 to 10, wherein the particulate non-tobacco plant material and the non-tobacco cellulose fibers are each predetermined in size, and their sizes substantially overlap or have corresponding particle size distributions.

12. A method for producing an aerosol generating material, A step of supplying an initial material comprising particulate tobacco plant material and non-tobacco cellulose fibers, wherein the initial material comprises at least 20% by mass of particulate tobacco plant material, The steps include: processing the initial material by subjecting it to increased mechanical pressure to produce the aerosol generating material; It includes, and further, The steps include: applying an additive selected from an aerosol-forming material, an active substance, and a binder to the initial material before or during the increased mechanical pressure applied to the initial material, and The step of applying an additive selected from an aerosol-forming material, an active substance, and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure. A method for producing an aerosol-generating material, comprising at least one of the following.

13. To produce the aerosol-generating material by bonding the particulate tobacco plant material to the non-tobacco cellulose fibers, A step of setting the initial material to a predetermined water content, A step of subjecting the initial material to a temperature increase, and The process of subjecting the initial material to increased pressure. The method according to claim 12, further comprising the step of processing the initial material by means of the method.

14. The method according to any one of claims 8 to 13, wherein the initial material and / or the aerosol generating material comprises at least 5% by mass of non-tobacco cellulose fibers.

15. The method according to any one of claims 8 to 14, wherein the non-tobacco cellulose fibers include wood pulp or consist of wood pulp.

16. The method according to any one of claims 8 to 15, wherein the initial material comprises 5 to 20% by mass of non-tobacco cellulose fibers.

17. The method according to any one of claims 8 to 16, wherein the non-tobacco cellulose fibers are pre-sized and have Dp90 values ​​of 130 micrometers to 200 micrometers, Dp50 values ​​of 50 micrometers to 100 micrometers, and Dp10 values ​​of 10 micrometers to 50 micrometers.

18. The method according to any one of claims 1 to 17, wherein the initial material and / or the aerosol generating material comprises 10 to 25% by mass of the aerosol forming material.

19. The method according to claim 18, wherein the initial material and / or the aerosol generating material comprises 15 to 20% by mass of the aerosol forming material.

20. The method according to any one of claims 1 to 19, wherein the aerosol-forming material comprises glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

21. The method according to any one of claims 1 to 20, wherein the initial material and / or the aerosol generating material comprises the binder in an amount of up to 25% by mass.

22. The method according to any one of claims 1 to 21, wherein the binder comprises carboxymethylcellulose (CMC), starch, guar gum, xanthan gum, acacia gum and / or hydroxypropylcellulose (HPC).

23. The method according to any one of claims 1 to 22, wherein the active substance is selected from nutritional supplements, nootropics, and psychostimulants.

24. The method according to any one of claims 1 to 23, wherein the active substance comprises nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof, or components, derivatives, or extracts of tobacco, cannabis, or one or more other plants.

25. The method according to any one of claims 1 to 24, wherein the active substance comprises nicotine or a nicotine salt.

26. The method according to claim 25, wherein the initial material and / or the aerosol generating material contains nicotine in an amount of up to 3% by weight.

27. The method according to any one of claims 1 to 26, wherein the initial material and / or the aerosol generating material further comprises an acid.

28. The method according to claim 27, wherein the initial material and / or the aerosol generating material contains an acid in an amount of about 0.1% to about 5% by weight.

29. The method according to claim 27 or 28, wherein the acid comprises one or more acids selected from lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and 2-methylvaleric acid.

30. The method according to any one of claims 1 to 29, wherein the aerosol generating material has a Dp90 value of 1.2 mm to 6.0 mm, a Dp50 value of 1.1 mm to 2.4 mm, and a Dp10 value of 0.2 mm to 1.5 mm.

31. The aerosol generating material is 25 cm ３ The method according to any one of claims 1 to 30, wherein the filling value exceeds 10 g.

32. The method according to any one of claims 1 to 31, wherein the step of processing the initial material includes transporting the initial material through a conveyor that increases mechanical pressure, the conveyor operating at a throughput of 25 to 75 kg / hour.

33. The method according to any one of claims 1 to 32, wherein the step of processing the initial material includes using a water flow rate of less than 12 L / hour.

34. The method according to any one of claims 1 to 33, wherein the step of processing the initial material includes pressurizing the initial material to a pressure in the range of 15 to 35 bars.

35. The method according to any one of claims 1 to 34, comprising the step of supplying the processed material through a shear gap, wherein the shear gap is positioned between shear surfaces, and a rotatable shear member is included in one of the shear surfaces, and the method comprises the step of rotating the shear member at an angular velocity of 500 to 850 rpm.

36. The method according to any one of claims 1 to 35, comprising the step of applying the aerosol-forming material and the active substance to the initial material before or during the application of the increased mechanical pressure to the initial material.

37. The method according to any one of claims 1 to 36, comprising the step of applying the aerosol-forming material and the active substance to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

38. The method according to any one of claims 1 to 37, wherein the aerosol generating material is a discontinuous aerosol generating material.

39. At least 20% by mass of particulate plant material, Non-tobacco cellulose fibers, below: Aerosol-forming materials, Active substances, and Binder At least one additive selected from and Aerosol-generating materials, including those mentioned above.

40. The aerosol generating material according to claim 39, wherein the particulate plant material includes particulate tobacco material or particulate non-tobacco material or a combination thereof.

41. an aerosol-generating material obtained or obtainable by the method described in any one of claims 1 to 38.

42. The aerosol generating material according to any one of claims 39 to 41, wherein the aerosol generating material is a discontinuous aerosol generating material.

43. A component for a delivery system comprising the aerosol-generating material described in any one of claims 39 to 41.

44. The component according to claim 43, for use in an aerosol supply system.

45. A product comprising the component described in claim 43 or claim 44.

46. An article for use in an aerosol supply system, or for use as an aerosol supply system, comprising the components described in claim 43 or claim 44.

47. An article comprising an aerosol-generating material manufactured according to the method described in any one of claims 1 to 38.

48. Use of an aerosol-generating material according to any one of claims 39 to 41 in an article for use in an aerosol supply system.

49. An article for use in an aerosol supply system, or for use as an aerosol supply system, comprising an aerosol generating material according to any one of claims 39 to 41.

50. A system comprising an aerosol generating material according to any one of claims 39 to 41, and a device configured to heat the aerosol generating material and generate an aerosol from the aerosol generating material.

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