Method for preparing aerosol-generating materials

Abstract

A process for preparing an aerosol-generating material, comprising the steps of: forming a first composition comprising a binder and optionally an aerosol-forming agent; forming a second composition comprising a non-tobacco plant material and a filler; combining the first and second compositions to form a mixture of the first and second compositions; and processing the mixture of the first and second compositions to form an aerosol-generating material, wherein optionally the first and / or second compositions contain active substances.

Description

[Technical Field]

[0001] This disclosure relates to a process for preparing an aerosol-generating material, an aerosol-generating material obtained or obtainable by this process, and an article containing the aerosol-generating material for use in conjunction with a non-combustible aerosol supply system. [Background technology]

[0002] Certain products generate aerosols during use, and these aerosols are inhaled by the user. For example, tobacco heating devices form aerosols by heating an aerosol-generating material, such as tobacco, rather than burning the base material. Such products generally include an aerosol-generating material that generates an aerosol when heated, and a mouthpiece through which the aerosol passes to reach the user's mouth. [Overview of the project]

[0003] According to the first aspect, A step of forming a first composition comprising a binder and optionally an aerosol-forming agent, A step of forming a second composition comprising a non-tobacco plant material and a filler, The steps include combining the first composition and the second composition to form a mixture of the first composition and the second composition, and The step of processing a mixture of the first composition and the second composition to form an aerosol generating material. A process is provided for preparing an aerosol-generating material, wherein the first composition and / or the second composition optionally contain an active substance.

[0004] In some embodiments, processing a mixture of a first composition and a second composition involves extruding the mixture to form a sheet of aerosol-generating material.

[0005] In some embodiments, processing a mixture of a first composition and a second composition involves extruding the mixture to form an extruded product.

[0006] In some embodiments, processing a mixture of the first composition and the second composition involves forming an extruded material into a sheet of aerosol-generating material.

[0007] In some embodiments, the extruded material is formed into a sheet of aerosol-generating material by rolling the extruded material using at least one roller to form a sheet of aerosol-generating material.

[0008] In some embodiments, the mixture of the first composition and the second composition and / or the sheet of aerosol-generating material contains water in an amount of about 40% to about 90%.

[0009] In some embodiments, the process includes drying a sheet of aerosol-generating material.

[0010] In some embodiments, the aerosol-forming agent is selected from the group consisting of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and mixtures thereof.

[0011] In some embodiments, the mixture of the first composition and the second composition has a volatile substance content of about 30% to about 90%.

[0012] In some embodiments, the aerosol-generating material has a volatile substance content lower than that of the mixture of the first composition and the second composition.

[0013] In some embodiments, the aerosol - generating material has a volatile content of from about 25% to about 35%.

[0014] In some embodiments, the plant - based material is selected from the list consisting of fennel, star anise, hemp, rooibos, and mixtures of any of these.

[0015] In some embodiments, the active substance is nicotine or a nicotine salt.

[0016] In some embodiments, the first composition and / or the second composition contains an acid.

[0017] In some embodiments, the acid is selected from the group consisting of nicotine benzoate, nicotine lactate, nicotine citrate, nicotine levulinate, and mixtures of any of these.

[0018] In some embodiments, the aerosol - generating material does not contain tobacco material.

[0019] In some embodiments, the non - tobacco plant - based material has a particle size distribution (D90) of from 250μm to about 400μm.

[0020] In some embodiments, the second composition contains a second binder. The first and second binders can be the same or different.

[0021] In some embodiments, the ratio of the first binder to the second binder is from 1:1 to about 1:10.

[0022] In some embodiments, the mixture of the first composition and the second composition contains a binder in an amount exceeding about 2% of the weight of the mixture of the first composition and the second composition.

[0023] In some embodiments, the mixture of the first composition and the second composition contains a first binder, a second binder, and a filler in a total amount of 5 to 40% of the weight of the mixture of the first composition and the second composition.

[0024] In some embodiments, the first composition is a liquid phase and the second composition is a solid phase.

[0025] In some embodiments, the mixture of the first composition and the second composition contains a filler in an amount greater than about 2% by weight of the mixture of the first composition and the second composition.

[0026] In some embodiments, the process includes shredding a sheet to form strands or strips of aerosol-generating material.

[0027] In some embodiments, drying is carried out at a temperature of less than approximately 100°C.

[0028] In some embodiments, a mixture of the first composition and the second composition is formed by homogenizing the first and second compositions.

[0029] In some embodiments, the aerosol-generating material is incorporated into an article for use with a non-combustible aerosol supply system.

[0030] According to a second embodiment, an aerosol-generating material is provided which can be obtained or obtained by the process of the first embodiment.

[0031] In some embodiments, the aerosol-generating material is in the form of a sheet or a shredded sheet.

[0032] In some embodiments, the sheet or shredded sheet has a burst strength of at least 150 g.

[0033] In some embodiments, the sheet or shredded sheet weighs approximately 170 g / m². 2~about 240g / m 2 It has a surface density.

[0034] In some embodiments, the sheet or shredded sheet has a tensile strength of approximately 4 N / 15 mm to approximately 20 N / 15 mm.

[0035] In some embodiments, the aerosol-generating material contains 0 to 15% by weight less glycerol and / or nicotine than the amount of glycerol and / or nicotine contained in the mixture of the first composition and the second composition.

[0036] According to a third embodiment, an article is provided for use in a non-combustible aerosol supply system, comprising an aerosol-generating material of the second embodiment or an aerosol-generating material prepared according to the process of the first embodiment.

[0037] In a further embodiment, a non-combustible aerosol supply system including an article according to a third embodiment is provided.

[0038] According to a fifth aspect, the use of an aerosol-generating material prepared according to the process of the second aspect or the process of the first aspect is provided in an article for use in a non-combustible aerosol supply system.

[0039] Next, embodiments of the present invention will be described as merely examples with reference to the attached drawings. [Brief explanation of the drawing]

[0040] [Figure 1] This shows the steps of the process used to manufacture aerosol-generating materials. [Figure 2] This is a side cross-sectional view of an article containing an aerosol-generating material. [Figure 3] Figure 2 is a perspective view of a non-combustion aerosol supply device for generating aerosols from aerosol-generating material of the article shown. [Modes for carrying out the invention]

[0041] The present invention relates to a process for preparing an aerosol-generating material. The process includes the steps of: forming a first composition comprising a binder and optionally an aerosol-forming agent; forming a second composition comprising a non-tobacco plant material and a filler; combining the first and second compositions to form a mixture of the first and second compositions; and processing the mixture of the first and second compositions to form an aerosol-generating material. The first and / or second compositions may contain an active substance. The first composition may contain water. Water may also be present in the non-tobacco plant material and / or the filler.

[0042] Aerosol-generating materials are materials that can generate aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of solids, liquids, or gels, and may or may not contain active substances and / or flavorings. Aerosol-generating materials may be incorporated into articles for use in aerosol-generating systems.

[0043] According to certain aspects of this disclosure, an aerosol-generating material prepared by a process described herein is provided. The aerosol-generating material is configured to generate an aerosol when heated.

[0044] The second composition includes non-tobacco plant materials. “Non-tobacco plant materials” are plant materials other than tobacco. The use of non-tobacco plant materials can improve the sensory properties of the aerosol produced by the aerosol-producing material created by the process. Non-tobacco plant materials, such as rooibos, fennel, star anise, and / or mint, can produce a particularly neutral aroma profile when used in the aerosol-producing material. The relatively neutral aroma profile of non-tobacco plant materials can lead to the formation of a relatively neutral aerosol. Furthermore, when one or more of these plant substances are used in combination with an active substance such as nicotine, the sensory properties resulting from the active substance can be more easily perceived by the user. For example, aroma can be enhanced when paired with flavors such as menthol, spearmint, and / or peppermint, berry fruits, citrus fruits, and / or tropical fruits, or any combination of these flavors.

[0045] The water content of the aerosol-generating materials described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as is known to those skilled in the art.

[0046] Unless otherwise specified, the terms “volatile components,” “volatile substances,” “total volatile,” “volatile substance content,” and “total volatiles” used herein refer to volatile compounds including water. The volatile substance content of a material can be measured as the mass loss when the sample is dried in a forced-draft oven at a temperature adjusted to 110°C ± 1°C for 3 hours ± 0.5 minutes. After drying, the sample is cooled to room temperature in a desiccator for approximately 30 minutes.

[0047] Figure 1 shows how aerosol-generating materials can be manufactured according to several embodiments. A first composition comprising a binder, an optional active ingredient, water, and an aerosol-forming agent is formed and mixed with a second composition comprising a non-tobacco plant material, a filler, and optionally a second binder. In a subsequent step, the first and second compositions are mixed and extruded. Subsequently, the extruded mixture of the first and second compositions can be dried to form a sheet of aerosol-generating material. In an optional step, the extruded mixture of the first and second compositions may be rolled to form a sheet before drying the sheet. The sheet may then be shredded to produce an aerosol-generating material, which may then be incorporated into consumables for a non-combustible aerosol delivery system. The sheet may be shredded to form multiple strands or strips of aerosol-generating material. Multiple strands or strips of aerosol-generating material may have the same or similar physical properties as the strands or strips of aerosol-generating material described in International Publication No. 2021 / 255453.

[0048] The first composition, also known as the "wet mixture," may contain an aerosol-forming agent or humectant, an active substance, water, and a binder. The wet mixture may be in the form of a suspension. The first composition may also contain other liquids or suspensions disclosed herein. The first composition may be in liquid phase.

[0049] The first composition may include an aerosol-forming agent. The aerosol-forming agent includes one or more components capable of forming an aerosol. The aerosol-forming agent includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol-forming agent is glycerin, glycerol, or propylene glycol.

[0050] The first composition contains a binder. The binder is configured to bind components of the first composition. When combined with the second composition, the binder binds to components of the first and second compositions to form an aerosol-generating material. The first composition may contain two or more binders. In such embodiments, the binders in the first composition may be the same or different.

[0051] The binder may be selected from one or more compounds chosen from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder includes alginate and / or pectin or carrageenan. In some embodiments, the binder includes CMC.

[0052] The second composition, also referred to herein as the “dry mixture,” comprises a non-tobacco plant material, a filler, and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be a solid phase.

[0053] As used herein, the term “plant material” 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 naturally present in the plant material. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, etc. In a preferred embodiment, the plant material is solid.

[0054] Examples of plant-based substances include 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, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and saffron. These include lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, Korean ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Mentha Arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens. In some preferred embodiments, the plant material is selected from the group consisting of fennel, star anise, rooibos, and mixtures thereof.

[0055] In some embodiments, the second composition includes tobacco material. The aerosol-generating material produced by the process may also include tobacco material. As used herein, the term “tobacco material” refers to any material including tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, extended tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of crushed tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco leaves, reconstituted tobacco, and / or tobacco extracts.

[0056] The plant material may be granular or granular. In some embodiments, the plant material is a powder. The plant material may be formed by grinding a solid plant material to create a ground plant material. Alternatively or additionally, the plant material may include strips, strands, or fibers of the plant material. For example, the plant material may include particles, granules, fibers, strips, and / or strands of the plant material. In some embodiments, the plant material consists of particles or granules of the plant material. In some embodiments, the plant material is in a granular or ground form to aid in the formation of a fabric-like material when the first and second compositions are combined.

[0057] In embodiments where the plant material is granular, each particle of the plant tobacco material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight-line distance from the surface of a particle of the plant material or any point on the particle surface to any other point on the same particle of the plant material or on the particle surface. The maximum dimension of a particle of granular tobacco material can be measured using scanning electron microscopy (SEM).

[0058] In some embodiments, the maximum size of each particle of the plant material is approximately 800 μm. In some embodiments, the maximum size of each particle of the plant material is approximately 2000 μm. In some embodiments, the maximum size of each particle of the plant material is approximately 200 μm to approximately 800 μm.

[0059] A collection of plant-derived particles may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of at least about 50 μm, at least about 60, at least about 70 μm, at least about 80 μm, at least about 90, at least about 100 μm, at least about 110 μm, at least about 120 μm, and at least about 130 μm. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of about 720 μm or less, about 740 μm or less, about 760 μm or less, about 780 μm or less, about 800 μm or less, about 820 μm or less, about 840 μm or less, and about 860 μm or less. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of about 600 μm. Particle size distribution can be measured using particle size and shape analyzers such as Camsizer, and the particle size distribution of plant-based materials can be determined using sieve analysis.

[0060] The particle size distribution (D90) of plant-based materials can be controlled so that the aerosol-generating material, and the sheets, shredded sheets, or products made from the aerosol-generating material, achieve a desired surface density. The surface density of the material is expressed in GSM (grams per square meter or g / m²). 2 ) can be measured in . For example, a lower particle size distribution (D90) is associated with a higher surface density. When aerosol-generating materials are incorporated into articles for use in non-combustible aerosol supply systems, this higher surface density can reduce the fill value of plant materials. A specific example of this is a particle size distribution (D90) of 320, which is approximately 190-200 g / m³. 2 This is expected to result in a surface density.

[0061] Lower surface density may be associated with better taste and sensory properties of aerosol-generating materials and sheets, shredded sheets, or products created from aerosol-generating materials. While we do not wish to be bound by theory, superior taste and sensory properties may be attributable to improved heat transfer through the material. Lower surface density facilitates heat transfer through aerosol-generating materials, which is thought to improve the sensory characteristics of the material by facilitating aerosol formation. Because the process for creating aerosol-generating materials produced by the process of this disclosure involves less drying than conventional processes, less volatile components (many of which are considered desirable) are lost. Taste and aroma are better preserved, which is therefore associated with better sensory properties. Furthermore, the process requires less energy to remove volatile compounds.

[0062] However, surface density cannot be made too low, because surface density is associated with insufficient sensory characteristics due to a decrease in the amount of tobacco in the material that consumers perceive as providing positive sensory characteristics. Furthermore, materials with higher surface density can contain more tobacco material, and therefore, reducing surface density can reduce the amount of tobacco material required, which can lead to further economic benefits.

[0063] The particle size distribution (D90) of an aerosol-generating material, and sheets, shredded sheets, or products made from such materials, can be controlled to achieve a desired tensile strength. For example, a higher particle size distribution (D90) is associated with lower tensile strength. While we do not wish to be bound by logic, a higher particle size distribution means less material is bonded together. This can make the aerosol-generating material, and sheets, shredded sheets, or products made from such materials, weaker, and therefore have lower tensile strength. A particle size distribution (D90) of 160–450 μm, particularly 300–350 μm, can achieve optimal tensile strength.

[0064] A balance can be achieved between the optimal surface density and tensile strength of aerosol-generating materials and sheets, shredded sheets, or products made from aerosol-generating materials. This balance can be achieved by selecting the particle size distribution (D90). The particle size distribution (D90) needs to be low enough to achieve sufficient tensile strength, but high enough to provide a surface density that gives the user positive sensory characteristics and enables easier removal of volatile compounds.

[0065] For example, the particle size distribution (D90) may be chosen to achieve a sufficiently small surface density to realize positive sensory characteristics, while also providing a sufficiently high tensile strength to remain within the operating limits of the manufacturing machine.

[0066] A particle size distribution (D90) of at least approximately 100 μm is considered to contribute to the tensile strength of the aerosol-generating material. The inventors have found that a particle size distribution (D90) of less than 100 μm results in an aerosol-generating material with good tensile strength. However, the density can be increased by including such fine particles of tobacco material in the aerosol-generating material. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol supply system, this higher density may reduce the fill value of the tobacco material. Preferably, the inventors have found that a satisfactory balance between tensile strength and appropriate surface density (and therefore fill value) can be achieved when the particle size distribution (D90) is at least 100 μm. In some embodiments, the particle size distribution (D90) is between 100 and 800 μm.

[0067] In some embodiments, the particle size distribution (D90) is 160 to 450 μm. In some embodiments, the particle size distribution (D90) is 200 to 450 μm.

[0068] A particle size distribution of at least approximately 180 μm (D90) is considered to contribute to the appropriate tensile strength of the aerosol-generating material. A particle size distribution of at least approximately 200 μm (D90) results in an aerosol-generating material with good tensile strength. By including finer particles of tobacco material in the aerosol-generating material, the surface density can be increased.

[0069] The selection of particle size distribution (D90) can lead to appropriate tensile strength and surface density of the aerosol-generating material, or improvements to the aerosol-generating material created by the "band casting" technique.

[0070] The second composition includes a filler. The filler may be a non-tobacco component, i.e., a component that does not contain any tobacco-derived components or elements. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and a suitable inorganic adsorbent, such as molecular sieves. The filler may be a non-tobacco fiber such as wood fiber or pulp or wheat fiber. The filler may be a cellulose-containing material or a cellulose derivative. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is a cellulosic material, cellulose, or CMC. In some embodiments, the filler is essentially composed of cellulose or consists of cellulose.

[0071] In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. While we do not wish to be bound by theory, it is thought that including a fibrous filler can increase the tensile strength of the resulting aerosol-generating material. The use of cellulose as a filler may have a particularly favorable effect on the burst strength of the aerosol-generating material.

[0072] Fillers can also contribute to the texture of the aerosol-generating material. For example, fibrous fillers such as cellulose can result in an aerosol-generating material having relatively rough first and second surfaces. Conversely, non-fibrous granular fillers such as powdered chalk can result in an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material includes a combination of different filler materials. Fillers can help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0073] By incorporating a relatively large amount of binder relative to the aerosol-forming agent into the first composition, a highly viscous mixture can be obtained, potentially making it difficult to blend the first composition with the second composition. This problem can be solved by reducing the amount of binder in the first composition and adding a second binder (which may be the same as or different from the first binder) to the second composition.

[0074] Therefore, the second composition may contain an optional second binder. In some embodiments of the present invention, the first and second binders are the same. In some embodiments of the present invention, the first and second binders are different. The binder may be selected from one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder includes alginate and / or pectin or carrageenan. In some embodiments, the binder includes CMC.

[0075] As described above, by incorporating the second binder into the second composition, the amount of the first binder in the first composition can be reduced, thus lowering the viscosity of the first composition and facilitating the formation of a mixture of the first and second compositions. The binder may at least partially cover the surface of the tobacco material. If the plant material is in granular form, the binder may at least partially cover the surface of the particles of the plant material, binding the particles together.

[0076] The total volatile matter content of the second composition may be about 5% to 40% or about 10% to 20% by weight of the second composition.

[0077] The first and second compositions described herein can be mixed to obtain a mixture of the first and second compositions. The mixture of the first and second compositions may be formed by homogenizing the first and second compositions. The mixture of the first and second compositions may be in the form of a “dough.” Water may be included in the first composition. Including water in the first composition helps to ensure uniform dispersion of the binder throughout the mixture. Water can also help hydrate the binder.

[0078] As mentioned above, non-tobacco plant materials have a relatively neutral aroma profile. By combining one or more of these plant substances with an active ingredient, the sensory properties resulting from the active ingredient (such as nicotine or menthol) may be more easily perceived by the user compared to tobacco-based aerosol-generating materials. Consequently, when the aerosol-generating material is heated to produce an aerosol, any variation in the consistency of the aerosol-generating material may be more detectable by the user. Therefore, to achieve a product with consistent aerosol properties, it is desirable to ensure that both the non-tobacco plant substance and the active ingredient are uniformly mixed throughout the aerosol-generating material.

[0079] The aerosol-generating material produced by the process described herein exhibits uniform properties, and therefore the aerosol produced by the aerosol-generating material is relatively consistent. A homogeneous aerosol-generating material is formed by separately forming a first composition containing a binder and optionally an aerosol-forming agent from a second composition containing a non-tobacco plant material and a filler, and then combining the first and second compositions to form a mixture of the first and second compositions, in which the non-tobacco plant material, filler, binder, and optionally active ingredients are uniformly distributed throughout the aerosol-generating material.

[0080] In some embodiments, it may be necessary to add a small amount of water to the mixture, or it may not be necessary to add any water at all, in order to achieve a homogeneous dough suitable for subsequent processing steps. For example, the dough may then be extruded through a die, and the homogeneous dough may pass through the die without the addition of further water or even small amounts of water.

[0081] In some embodiments, the first composition contains water. Including water in the first composition helps to hydrate the binder and form a homogeneous mixture.

[0082] Mixing a first binder, an optional active ingredient, an optional aerosol-forming agent, a non-tobacco plant material, a filler, and an optional second binder in a single step (i.e., without forming the first and second compositions separately and then combining them) may result in a viscous mixture that is difficult to process and handle. Forming the first and second compositions separately and then combining these compositions makes the resulting “dough”-like mixture easier to process.

[0083] Non-tobacco plant material may be present in an amount of about 10% to about 90% of the weight of the mixture of the first and second compositions. For example, the plant material may be present in an amount of about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the weight of the mixture of the first and second compositions. In some embodiments, the non-tobacco plant material may be present in an amount of about 10% to 80% or about 20% to 50% of the weight of the mixture of the first and second compositions. The non-tobacco plant material may be present in an amount of about 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, or 40%.

[0084] The filler component may be present in an amount of 0-20% of the weight of the mixture of the first and second compositions, or in an amount of 1-10% of the weight of the mixture of the first and second compositions. For example, the filler may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or more than 10% of the weight of the mixture of the first and second compositions. In some embodiments, the filler component is present in an amount of 5-10% of the weight of the mixture of the first and second compositions. By including 5-10% filler, the burst strength can be improved and the brittleness of the aerosol-generating material can be reduced.

[0085] The aerosol-forming agent may be present in an amount of about 10% to about 25% of the weight of the mixture of the first and second compositions, or in an amount of 1% to about 10% of the weight of the mixture of the first and second compositions. For example, the aerosol-forming agent may be present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% of the weight of the mixture of the first and second compositions. In some embodiments, the aerosol-forming agent is present in an amount of about 15%, 16%, 17%, 18%, or 19% of the weight of the mixture of the first and second compositions.

[0086] The binder may be present in an amount of about 1% to about 20% of the weight of the mixture of the first and second compositions, or in an amount of 1% to about 10% of the weight of the mixture of the first and second compositions. For example, the binder may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% of the weight of the mixture of the first and second compositions. In some embodiments, the binder may be present in an amount greater than about 2% of the weight of the mixture of the first and second compositions. In some embodiments, the binder may be present in an amount of about 5% or up to about 5% of the weight of the mixture of the first and second compositions. The amount of binder in the first composition, the second composition, and the mixture of the first and second compositions is important because it changes the consistency of the compositions and mixtures. Too much binder may make the viscosity of the composition / mixture too high, making it impossible to process, for example, with pumps and machines.

[0087] In embodiments of the present invention in which first and second binders are prepared, the ratio of the first binder to the second binder may be 1:1 to 1:10. This ratio is preferably selected to achieve proper bonding of the mixture and / or aerosol-generating materials without maintaining the physical properties of the sheet and without adversely altering the texture of the composition. The ratio between the first binder and the second binder may be about 1:10, 2:8, 3:7, 4:6, 5:5, 10:1, 8:2, 7:3, and 6:4, respectively. In some embodiments, the ratio between the first binder and the second binder is 4:6, respectively, to maintain the physical properties of the sheet or the shredded sheet. Including all the binders in the first composition may result in the first composition becoming too viscous, making it impossible to process, for example, with pumps and machines. Adding binders to both the first and second compositions makes the compositions easier to process.

[0088] The incorporation of a first binder, an optional second binder, and a filler in a total amount of about 1% to about 15% by weight of the mixture of the first and second compositions may have beneficial effects on the burst strength, strength, and flexibility of the aerosol-generating material. The mixture of the first and second compositions may contain about 2%, about 5%, about 8%, about 10%, about 12%, or about 15% of the first binder, the optional second binder, and the filler in total, on a dry weight basis (dwb). In some embodiments, the mixture of the first and second compositions contains 5% of the first binder, an optional second binder, and 5% of the filler. This incorporation of the first binder, the optional second binder, and the filler can reduce the tackiness of the aerosol-generating material, increase its burst strength, and improve its flexibility.

[0089] In certain embodiments, both the first and optional second binders are CMC, and the total amount of the binder is 5%. The filler is cellulose, and the total amount of cellulose is 8.2%. Therefore, in such embodiments, the mixture of the first composition and the second composition contains 5% CMC and 8.2% cellulose.

[0090] In some embodiments, both the first and optional second binders are CMC, and the total amount of the binder is 10%. The filler is cellulose, and the total amount of cellulose is 14%. Thus, in such embodiments, the mixture of the first composition and the second composition contains 10% CMC and 14% cellulose.

[0091] The presence of binders and fillers in these amounts can have particularly beneficial effects on the physical properties of aerosol-generating materials, including improvements in strength and flexibility. Cellulose fillers improve the burst strength and reduce brittleness of aerosol-generating materials.

[0092] The bursting strength of the aerosol-generating material produced by the process described herein can be measured using a calibrated Texture Analyser (50 kg load cell, 20 mm probe height calibration, 1 g contact force) and Exponent software from Stable Micro Systems. The bursting strength is measured using a 5 mm stainless steel ball probe at 3 cm. 2 This can be determined using the aerosol-generating material sheet. The bursting strength can be reported in units of force (g).

[0093] The aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the aerosol-generating material may have a burst strength of at least 150 g.

[0094] If the burst strength is too low, the aerosol-generating material may be relatively brittle. As discussed herein, the aerosol-generating material may be formed in the form of a sheet or a shredded sheet. As a result, breakage of the sheet or shredded sheet may occur during the process of manufacturing the aerosol-generating material. For example, if a sheet is shredded by a cutting process to form a shredded sheet, the sheet may pulverize or break into pieces or fragments when cut. The incorporation of a first binder, an optional second binder, and fillers may help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0095] The total volatile matter content (oven volatile matter) of the mixture of the first and second compositions may exceed 20% by weight of the mixture of the first and second compositions. The volatile matter content may exceed about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, or 60% by weight of the mixture of the first and second compositions. In some embodiments, about 20% to about 60% of water is added to the mixture of the first and second compositions. In some embodiments, about 30% to 60% or 40% to 60% of water is added.

[0096] The total volatile matter content of the mixture of the first composition and the second composition may be about % by weight. The total volatile matter content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, or 80% by weight of the mixture of the first composition and the second composition.

[0097] The water content of the mixture of the first and second compositions may exceed 20% of the weight of the mixture of the first and second compositions. The water content may exceed about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, or 60% of the weight of the mixture of the first and second compositions. In some embodiments, about 20% to about 60% of water is added to the mixture of the first and second compositions. In some embodiments, about 30% to 60% or 40% to 60% of water is added.

[0098] The total water content of the mixture of the first composition and the second composition may be about 40-90% by weight. The total water content may be about 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% by weight of the mixture of the first composition and the second composition.

[0099] The present invention enjoys the further advantage of requiring less water than other conventional compositions to produce a dough-like mixture of the first and second compositions. Therefore, this has the advantage that the mixture of the first and second compositions can be easily mixed without the need to add additional water or chemicals to form a homogeneous mixture suitable for extrusion. A further benefit of the reduced amount of water required is improved reliability of the manufacturing process. As a result, the manufacturing process is also repeatable, which also has cost-saving implications. Therefore, the total water content of the mixture of the first and second compositions is relatively low.

[0100] As a result of this lower water content, less water needs to be removed during the processing stage. For example, the "band casting" process uses a slurry with a target water content of about 75% to about 80%. This slurry must then be dried to a target water content of about 13%, thus requiring a loss of about 67% water. In the invention disclosed herein, a minimum amount of water is incorporated into the mixture of the first and second compositions. For example, the water loss from the resulting dough to the final product may be only about 47%. Thus, water loss can be significantly less in the process described herein compared to methods of forming aerosol-generating materials containing a slurry, such as the band casting process. Preferably, less energy is consumed because less water needs to be removed during the processing stage. This is more environmentally friendly, faster, and cost-effective. Furthermore, less drying is required, resulting in better retention of flavor and aroma.

[0101] The aerosol-generating material produced by the processes disclosed herein has a volatile matter content of approximately 5% to 30%. This makes it possible to cut the aerosol-generating material into strips relatively easily. If the volatile matter content, particularly the water content, is too high, the aerosol-generating material may break during the cutting process, which is undesirable. If the volatile matter content is too low, the material may become too brittle and crumble during the cutting process.

[0102] The present invention enjoys the additional advantage that less of certain volatile components, particularly nicotine and glycerol, are lost during the drying of the mixture of the first and second compositions. While we do not wish to be bound by logic, the mixture of the first and second compositions contains a relatively low water content and therefore requires less drying than slurries known to those skilled in the art. For example, the desired volatile substance content of the aerosol-generating material can be achieved using lower temperatures and shorter drying times. This also reduces the loss of certain valuable volatile components, resulting in improved flavor, taste, and texture characteristics of the aerosol produced in the final product.

[0103] In exemplary embodiments, a mixture of the first and second compositions comprises about 66% plant material (rooibos), about 17% aerosol-forming agent (glycerol), about 8.2% filler (cellulose), and about 5% binder (CMC). The inventors have found that this mixture of the first and second compositions realizes the advantages disclosed herein.

[0104] Once formed and mixed, the mixture of the first composition and the second composition may be extruded from the aerosol-generating material using any extrusion technique or apparatus known in the art.

[0105] Extrusion involves supplying a precursor composition through an orifice to create an extruded aggregate. The process of applying pressure to the precursor composition in combination with shear force results in an aggregated structure that may take the form of a sheet.

[0106] Extrusion can be carried out using one of the main classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. Forming a sheet structure by extrusion has the advantage that this process combines mixing, conditioning, homogenization, and molding of a mixture of a first composition and a second composition.

[0107] Other materials, such as bases, diluents, solid aerosol-forming agents, solid flavor modifiers, leavening agents, and other additives known in the art, can also be added during the extrusion process. This has the advantage that the additives are uniformly distributed throughout the aggregated structure that is formed.

[0108] The resulting extruded mixture of the first and second compositions can be dried using any suitable drying technique known in the art. For example, microwave, infrared, air, and oven drying are suitable techniques for drying aerosol-generating materials. The temperature of the drying step may be less than 100°C, and in some embodiments of the present invention, less than 90°C. The drying temperature used may be up to about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C.

[0109] The resulting extruded mixture of the first and second compositions can be processed by forming a layer of the mixture on a surface, and then the mixture can be dried to remove at least some of the water to form a sheet of aerosol-generating material.

[0110] Water may be removed by evaporating it from the mixture extruded at ambient temperature and pressure (e.g., 25°C and 101kPa). Alternatively, water may be removed by applying heat to the extruded mixture (e.g., by heating it to above about 25°C) and / or by reducing the atmospheric pressure surrounding the extruded mixture of the first and second compositions (e.g., below 101kPa).

[0111] The low drying temperature used is preferable because it reduces the loss of volatile components such as nicotine, glycerol, and flavors that contribute to the flavor, taste, and texture of the final product. In some embodiments of the present invention, there is a loss of less than 10%, less than 8%, less than 5%, less than 4%, less than 2%, or less than 1% of the total nicotine and glycerol. In some embodiments, the loss of total volatile substances is less than 5%. In some embodiments of the present invention, there is a loss of less than 10%, less than 8%, less than 5%, less than 4%, less than 2%, or less than 1% of the total glycerol and nicotine. In some embodiments, there is a loss of less than 5% of the total glycerol and nicotine. Therefore, the aerosol-generating material has a lower total volatile substance content than a mixture of the first and second compositions.

[0112] The aerosol-generating material may contain total volatile matter in amounts less than about 40%, less than about 30%, less than about 20%, less than about 15%, less than about 10%, or less than about 5% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material contains total volatile matter in amounts of about 0% to about 40%, about 10% to about 35%, or about 20% to about 30% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material may have a total volatile matter content of about 25% to about 35% by weight.

[0113] The aerosol-generating material may contain water. The aerosol-generating material may contain water in an amount of less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the weight of the aerosol-generating material. In some embodiments, the aerosol-generating material contains water in an amount of about 0% to about 15% or about 5% to about 15% of the weight of the aerosol-generating material. In some embodiments, the aerosol-generating material contains water in an amount of about 5% to about 15% of the weight of the aerosol-generating material. Therefore, the aerosol-generating material has a lower water content than a mixture of the first composition and the second composition.

[0114] In some embodiments, the water loss from the mixture of the first and second compositions and the aerosol-generating material is 5-60%. In some embodiments of the present invention, there is a water loss of about 10%, about 15%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60%. In some embodiments, there is a water loss of about 40-55%.

[0115] A sheet or shredded sheet of aerosol-generating material may contain water and an aerosol-forming agent in a total amount of less than about 30% of the weight of the sheet or shredded sheet of aerosol-generating material, or less than about 25% of the weight of the aerosol-generating material. Incorporating water and an aerosol-forming agent into a sheet or shredded sheet of aerosol-generating material in an amount of less than about 30% of the weight of the sheet or shredded sheet is considered to suitably reduce the stickiness of the sheet. This can improve the ease with which the aerosol-generating material can be handled during processing. For example, it may be easier to wind up a sheet of aerosol-generating material to form a bobbin of material, and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness may also reduce the tendency of the strands or strips of shredded material to aggregate or stick to each other, thus potentially further improving processing efficiency and the quality of the final product.

[0116] The extruded mixture of the first composition and the second composition can pass through one or a series of rollers to form a sheet of aerosol-generating material having a desired thickness.

[0117] In some embodiments, the distance between rollers differs in different rolling presses. For example, the distance between rollers may be gradually reduced to gradually flatten the material and control its thickness.

[0118] In some embodiments, the rollers are smooth. This offers the advantage of resulting in a sheet with reduced roughness and improved smoothness. In embodiments where two or more rolling presses are used, repeated rolling of the material can further improve smoothness and reduce roughness.

[0119] In embodiments where the rolling press comprises two rollers, both the first and second surfaces of the sheet can benefit from improved smoothness and reduced roughness. This provides the additional advantage that the first and second surfaces of the sheet or shredded sheet may be more consistent and have similar smoothness.

[0120] By reducing the thickness of the extruded mixture, the drying time can be shortened. The sheet can then be dried. After drying, the sheet of aerosol-generating material can be cut into strips or strands of aerosol-generating material. The sheet of aerosol-generating material can be fed into a shredding device by a single thickness. This can be achieved, for example, by preparing a bobbin of sheet material that can be continuously fed into the shredding device. Alternatively, individual portions of the aerosol-generating material in sheet form, such as sheets known to those skilled in the art as flags, may be fed into the shredding device. The strips or strands of aerosol-generating material can be collected and formed into articles for use in a non-combustible aerosol supply system. Optionally, the aerosol-generating material may be corrugated before being collected and formed into articles. Optionally, the aerosol-generating material may be subjected to a second cutting step, such as a cross-cut shredding process, to obtain a specified cut length.

[0121] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth), or they may be uneven or irregular. For example, the first and / or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second surfaces are relatively rough.

[0122] The smoothness of the first and second surfaces may be influenced by several factors, including the surface density of the sheet or shredded sheet, the properties of the components constituting the aerosol-generating material, or whether the surface of the material has been manipulated, such as being embossed, notched, or otherwise modified to impart a pattern or texture.

[0123] The sheet or shredded sheet of the aerosol-generating material has a thickness of at least about 100 μm. The sheet or shredded sheet may have a thickness of at least about 100 μm, 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm, 280 μm, 290 μm, or 300 μm. In some embodiments, the sheet or shredded sheet has a thickness of approximately 100 μm to approximately 300 μm, approximately 151 μm to approximately 299 μm, approximately 152 μm to approximately 298 μm, approximately 153 μm to approximately 297 μm, approximately 154 μm to approximately 296 μm, approximately 155 μm to approximately 295 μm, approximately 156 μm to approximately 294 μm, approximately 157 μm to approximately 293 μm, approximately 158 μm to approximately 292 μm, approximately 159 μm to approximately 291 μm, or approximately 160 μm to approximately 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of approximately 170 μm to approximately 280 μm, approximately 180 to approximately 270 μm, approximately 190 to approximately 260 μm, approximately 200 μm to approximately 250 μm, or approximately 210 μm to approximately 240 μm. In some embodiments, the thickness of the sheet or shredded sheet is approximately 230 μm to 270 μm or approximately 240 μm to 260 μm.

[0124] The thickness of the sheet or shredded sheet may vary between the first and second surfaces. In some embodiments, individual strips or pieces of the aerosol-generating material have a minimum thickness of about 100 μm across the area of ​​the strip or piece. In some cases, individual strips or pieces of the sheet or shredded sheet of the aerosol-generating material have a minimum thickness of about 0.05 mm or about 0.1 mm across the area of ​​the strip or piece. In some cases, individual strips, strands, or pieces of the sheet or shredded sheet of the aerosol-generating material have a maximum thickness of about 1.0 mm across the area of ​​the strip or piece. In some cases, individual strips or pieces of the aerosol-generating material have a maximum thickness of about 0.5 mm or about 0.3 mm across the area of ​​the strip or piece.

[0125] The sheet thickness can be determined using ISO 534:2011 "Paper and board - Determination of Thickness".

[0126] If the sheet or shredded sheet of aerosol-generating material is too thick, heating efficiency may be impaired. This can negatively affect power consumption during use, for example, the power consumed for flavor release from the aerosol-generating material. Conversely, if the sheet or shredded sheet of aerosol-generating material is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to mold, are more brittle, and may impair aerosol formation during use.

[0127] If the sheet or shredded sheet of aerosol-generating material is too thin (e.g., less than 100 μm), it is assumed that it may be necessary to increase the cutting width of the shredded sheet in order to achieve adequate packing of the sheet or shredded sheet when incorporated into an article. Increasing the cutting width of the shredded sheet may increase the pressure drop, which is undesirable.

[0128] having a thickness of at least about 100 μm and a basis weight of about 100 g / m 2 ~ about 240 or 250 g / m 2 of the aerosol-forming material is assumed to be less likely to break, tear or otherwise deform during its manufacture. Further, an aerosol-forming material having a basis weight of about 100 g / m 2 ~ about 240 or 250 g / m 2 is less likely to break, tear or otherwise deform during its manufacture. A thickness of at least about 100 μm can have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, it can have good tensile strength, so processing can be relatively easy. In some embodiments, the basis weight is from about 170 to about 240 or about 250 g / m 2 . In some embodiments, the basis weight is about 180 g / m 2 .

[0129] The thickness of the sheet or shredded sheet is also thought to affect its basis weight. That is, increasing the thickness of the sheet or shredded sheet can increase the basis weight of the sheet or shredded sheet.

[0130] Conversely, decreasing the thickness of the sheet or shredded sheet can decrease the basis weight of the sheet or shredded sheet. To avoid misunderstanding, when referring to basis weight in this specification, this reference refers to the average basis weight calculated for a given strip, strand, piece or sheet of the aerosol-forming material, and the basis weight calculated by measuring the surface area and weight of a given strip, strand, piece or sheet of the aerosol-forming material.

[0131] The sheet or shredded sheet of the aerosol-forming material has a basis weight of from about 100 g / m 2 ~ about 250 g / m 2 . The sheet or shredded sheet has a basis weight of from about 110 g / m 2 ~ about 240 g / m 2 , from about 120 g / m 2 ~ about 230 g / m 2, about 130g / m 2 ~about 220g / m 2 Or approximately 140g / m 2 ~about 210g / m 2 It may have a surface density of approximately 130 g / m². In some embodiments, the sheet or shredded sheet may have a surface density of approximately 130 g / m². 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 It has a surface density of approximately 180 g / m². In some embodiments, the sheet or shredded sheet has a surface density of approximately 180 g / m². 2 It has a surface density.

[0132] Approximately 100g / m 2 ~about 250g / m 2 The surface density is thought to contribute to the strength and flexibility of the sheet or shredded sheet. Furthermore, a rod containing shredded sheets of aerosol-generating material having a surface density of approximately 180 gsm and a minimum thickness of 220-230 μm can be packed such that the aerosol-generating material remains in place within the rod, while maintaining a desired weight (e.g., approximately 300 mg) of tobacco material within the rod, and delivering acceptable sensory stimuli (e.g., taste and smell) when heated in a non-combustible aerosol supply device.

[0133] The flexibility of a sheet or shredded sheet is considered to depend, at least in part, on the thickness and surface density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the higher the surface density of the sheet, the lower the flexibility of the sheet or shredded sheet. The combinations of thickness and surface density of the aerosol-generating materials described herein are considered to result in relatively flexible sheets or shredded sheets. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol supply device, this flexibility can offer various advantages. For example, strands or strips can be easily deformed and bent when an aerosol generator is inserted into the aerosol-generating material, thus facilitating the insertion of the aerosol generator (e.g., a heater) into the material and improving the retention of the aerosol generator by the aerosol-generating material.

[0134] The surface density of a sheet or shredded sheet of aerosol-generating material can affect the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the surface density, the roughness of the first and / or second surfaces can be adjusted.

[0135] The sheet or shredded sheet may have a tensile strength of at least 3 N / 15 mm. The tensile strength may be at least about 4 N / 15 mm.

[0136] If a sheet or shredded sheet has a tensile strength of less than 3 N / 15 mm, the sheet or shredded sheet may tear, break, or otherwise deform during its manufacture and / or subsequent incorporation into articles for use in non-combustible aerosol supply systems. Tensile strength may be measured using ISO 1924:2008.

[0137] A sheet or shredded sheet of aerosol-generating material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g. In some embodiments, the burst strength of a sheet or shredded sheet of aerosol-generating material is at least 150 g. As disclosed and discussed above, burst strength affects the strength of the material.

[0138] The total volatile matter content may be about 5%, 10%, 15%, 20%, 25%, 30%, or 40% by weight. A sheet or shredded sheet of aerosol-generating material may have a total volatile matter content of about 5-15% by weight. As disclosed herein, the present invention preferably retains the amount of volatile compounds. This improves the flavor, taste, and texture characteristics of the aerosol produced in the final product.

[0139] The aerosol-generating material includes a substance delivered to the user. The delivered substance includes an active substance, also referred to herein as an active material.

[0140] The composition of an aerosol contributes to the user experience and satisfaction. One attribute that contributes to the user experience and satisfaction is the presence of active substances in the aerosol, particularly the nicotine content of the aerosol. Another attribute that contributes to the user experience and satisfaction is the perceived harshness of the aerosol. Therefore, it is important to control the nicotine content and harshness of the aerosol.

[0141] As mentioned above, non-tobacco plant materials, when present, can create a neutral flavor profile that enhances the sensory attributes of the active ingredient. As a result, the harshness of the aerosol may also increase.

[0142] In some cases, aerosol-generating materials containing nicotine and organic acids have been found to produce aerosols with a desirablely perceived harshness. Aerosol-generating materials containing pure nicotine, such as free base nicotine, produce relatively harsh aerosols. The addition of organic acids reduced the perceived harshness to a desirable level. Alternatively, aerosol-generating materials containing nicotine salts may produce aerosols with a desirablely perceived harshness.

[0143] For example, aerosol-generating materials containing non-tobacco plant materials, nicotine, and acid, or aerosol-generating materials containing non-tobacco plant materials and nicotine salts may exhibit a relatively smoother and enhanced flavor profile compared to aerosol-generating materials containing tobacco and nicotine or nicotine salts.

[0144] The first composition and / or the second composition may contain an active substance. It may be preferable to add the active substance to the first composition. This has the advantage that the active substance is uniformly distributed at least throughout the first composition.

[0145] The active substances used herein may be physiologically active materials, and are materials intended to achieve or enhance a physiological response. Active substances may be selected from, for example, nutritional supplements, nootropics, and psychotropic substances. Active substances may be naturally occurring or obtained by synthesis. Examples of active substances include 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 from tobacco, cannabis, or other plant substances.

[0146] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0147] 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.

[0148] As described herein, the active substance may include or be derived from one or more plant substances or their components, derivatives, or extracts.

[0149] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substance being tobacco.

[0150] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0151] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0152] In some embodiments, the process involves adding an acid to either the first or second composition. The acid may be selected from the group consisting of levulinic acid, lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is benzoic acid. In some embodiments, the acid is levulinic acid.

[0153] 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.

[0154] In some embodiments, the active ingredient includes a flavoring. The flavoring may be added at any stage in the preparation of the aerosol-generating material.

[0155] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to produce a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.Flavorings and flavorings include naturally occurring flavoring materials, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (for example, tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon). Lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine Ingredients include: ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint 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, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, and dami. Other additives may include bell peppers, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-based substances, or breath fresheners.Flavors and flavorings may be imitation ingredients, synthetic ingredients, natural ingredients, or blends thereof. Flavors and flavorings may be in any suitable form, such as a liquid such as oil, a solid such as powder, or a gas.

[0156] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0157] In some embodiments, the active ingredient may include a sensory stimulant, which is intended to achieve somatosensory effects that are normally chemically induced and 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 heating, cooling, tingling, or numbing effects. A suitable thermal agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol (WS-3).

[0158] In some embodiments, active ingredients may be added after the shredding operation. For example, a flavoring nozzle may be provided in the machine to deposit flavorings onto the surface of the aerosol-generating material strip.

[0159] In some embodiments, the additive can be incorporated into the second composition, a mixture of the first and second compositions, or an aerosol-generating material before or after the extrusion, drying, or shredding steps. In some embodiments, the additive comprises the delivered substance.

[0160] The active ingredients may be selected to enhance the underlying properties of the aerosol-generating material. For example, as described herein, it may be preferable that the aerosol-generating material be tobacco-free. In such examples, for instance, when rooibos, fennel, star anise, and / or mint are used in the aerosol-generating material, the botanical materials can achieve a particularly neutral aroma profile. When one or more of these botanical substances are used, the aroma can be enhanced when paired with flavors such as menthol, spearmint, and / or peppermint, berry fruits, citrus fruits, and / or tropical fruits, or any combination of these flavors.

[0161] In some embodiments, the first composition, the second composition, or a mixture of the first and second compositions may contain one or more functional materials. The one or more other functional materials may include one or more pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0162] In some embodiments, the delivered substance may be an aerosol-generating material, such as those described herein, or a material not intended to be aerosolized. If necessary, any of the materials may include one or more active components, one or more flavorings, one or more aerosol-forming agents, and / or one or more other functional materials.

[0163] In some aspects of this disclosure, a consumable comprising an aerosol-generating material described herein is provided. The consumable is an article comprising the aerosol-generating material, which is intended to be consumed in part or in whole during use by the user. The consumable may also comprise 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. The consumable may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor. The consumable may be in any shape or size suitable for a smoking device. In some embodiments of the present invention, the consumable is in the form of a rod.

[0164] In one embodiment, the aerosol generating material is provided in an aerosol generating device such as a tobacco heating product (THP) or a hybrid e-cigarette product.

[0165] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user. Combustion aerosol supply systems for cigarettes, cigarillos, cigars, and tobacco for pipes, hand-rolled cigarettes, or homemade cigarettes (whether based on tobacco, tobacco derivatives, extended tobacco, reconstituted tobacco, tobacco substitutes, or other smokeable materials), The invention includes a non-combustion aerosol supply system that releases compounds from aerosol-generating materials without burning them, such as in e-cigarettes, tobacco heating products, and hybrid systems, for generating aerosols using a combination of aerosol-generating materials.

[0166] According to this disclosure, a “combustion-type” aerosol supply system is a system in which the aerosol-generating materials (or components thereof) of the aerosol supply system are burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0167] 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.

[0168] In some embodiments, the present disclosure relates to components for use in a combustion aerosol supply system, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components, such as capsules, threads or beads, or paper, such as plug wraps, chipping paper or cigarette paper.

[0169] 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.

[0170] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0171] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping 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.

[0172] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a cigarette heating system.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] In some embodiments, a non-combustible aerosol supply system, for example, a non-combustible aerosol supply device, may include a power supply and a controller. The power supply may be, for example, an electric power supply or a heat-generating power supply. In some embodiments, the heat-generating power supply includes a carbon substrate that can be supplied with energy to distribute power in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power supply.

[0177] In some embodiments, the non-combustion aerosol supply system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0178] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer component, aerosol generator, aerosol generating area, housing, packaging material, filter, suction nozzle and / or aerosol modifier.

[0179] In some embodiments, the delivered substance may be an aerosol-generating material or a material not intended for aerosolization. Optionally, either material may include one or more active components, one or more flavorings, one or more aerosol-forming agents, and / or one or more other functional materials.

[0180] As disclosed herein, a non-combustible aerosol supply system may include an aerosol-generating material, which is illustrated in Figures 2 and 3.

[0181] Figure 2 is a side cross-sectional view of a consumable or article 1 for use in an aerosol delivery system. Article 1 includes a mouthpiece segment 2 and an aerosol generating segment 3.

[0182] The aerosol-generating segment 3 is in the form of a cylindrical rod and contains an aerosol-generating material 4. The aerosol-generating material may be any of the materials discussed herein.

[0183] Although described above in rod form, the aerosol-generating segment 3 may be provided in other forms, such as a plug, pouch, or packet of material within an article.

[0184] In the illustrated embodiment, the suction nozzle segment 2 includes a material body 5 such as a fibrous or filamentous tow.

[0185] The rod-shaped consumable 1 further comprises a packaging material 6, such as paper packaging material, that surrounds the mouthpiece segment 2 and the aerosol generating segment 3.

[0186] Figure 3 shows an example of a non-combustible aerosol supply device 100 for generating aerosols from aerosol-generating media / materials such as aerosol-generating materials of the consumables 110 described herein. Schematically, the device 100 may be used to heat a replaceable article 110, including an aerosol-generating medium, such as article 1 shown in Figure 2 or elsewhere described herein, to generate an aerosol or other inhalable medium to be inhaled by the user of the device 100. The device 100 and the replaceable article 110 together form a system.

[0187] Device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and accommodates various components of device 100. Device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by a heating assembly. During use, the article 110 may be fully or partially inserted into the heating assembly, where it may be heated by one or more components of the heating assembly.

[0188] The device 100 in this example includes a first end member 106, the first end member 106 having a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Figure 3, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, the user can slide the lid 108 in the direction of arrow "B".

[0189] Device 100 may also include a user-operable control element 112, such as a button or switch, which operates device 100 when pressed. For example, a user can turn on device 100 by operating the switch 112.

[0190] Device 100 may also include electrical components such as a socket / port 114 that can receive a cable for charging the device 100's battery. For example, the socket 114 may be a charging port, such as a USB charging port.

[0191] In some embodiments, the consumable 110 may include an aerosol modifier. The aerosol modifier is a substance typically located downstream of the aerosol generation region, configured to modify the resulting aerosol by, for example, altering the taste, flavor, acidity, or other characteristics of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0192] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more 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.

[0193] In some embodiments, the device may also include an aerosol generator. 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 aerosol-generating 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, pressure increase, or electrostatic energy. [Examples]

[0194] Referring to Table 1, aerosol-generating materials can be prepared by forming a first composition ("liquid phase") comprising a binder, an active substance (optional), an acid (optional), an aerosol-forming agent, and water, and a second composition ("dry phase") comprising a plant material and a filler, and by combining the first and second compositions. The mixture is then extruded and rolled between a pair of rollers to form a sheet, and the sheet is dried at less than 100°C to form a dry sheet of the aerosol-generating material. The compositions of each material are provided in Table 1.

[0195] [Table 1]

[0196] Four mixtures (mixtures A1 to A4) were prepared based on mixture A. The amount of water in mixture A was modified by increasing the amount of water added to the first composition. The relative amounts of water and other components (plant-based materials, aerosol-forming agents, fillers, and binders) are shown in Table 2.

[0197] [Table 2]

[0198] Mixture A1 was too dry and had the consistency of loamy soil, making it difficult to extrude and form into a sheet. Mixture A2 was too sticky and could not be extruded and formed into a sheet. Mixture A3 could be processed, but its relatively high stickiness made it difficult to handle. Mixture A4 had lower stickiness and could be processed to form a sheet.

Claims

1. A step of forming a first composition comprising a binder and optionally an aerosol-forming agent, A step of forming a second composition comprising a non-tobacco plant material and a filler, The steps of combining the first composition and the second composition to form a mixture of the first composition and the second composition, The step of processing the mixture of the first composition and the second composition to form an aerosol generating material. A method for preparing an aerosol-generating material, wherein the first and / or second composition optionally contains an active substance.

2. The method according to claim 1 or 2, wherein the step of processing the mixture of the first composition and the second composition includes the step of extruding the mixture to form a sheet of the aerosol-generating material.

3. The method according to claim 2, wherein the step of processing the mixture of the first composition and the second composition includes the step of extruding the mixture to form an extruded product.

4. The method according to claim 3, wherein the step of processing the mixture of the first composition and the second composition includes the step of forming the extruded material into a sheet of the aerosol-generating material.

5. The method according to claim 4, wherein the extruded material is formed on the sheet of aerosol-generating material by rolling the extruded material using at least one roller to form a sheet of aerosol-generating material.

6. The method according to any one of claims 2 to 5, wherein the mixture of the first composition and the second composition and / or the sheet of the aerosol generating material contains water in an amount of about 40% to about 90%.

7. The method according to any one of claims 2 to 6, comprising the step of drying the sheet of the aerosol generating material.

8. The method according to any one of claims 1 to 7, wherein the aerosol-forming agent is selected from the group consisting of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, propylene carbonate, and a mixture of any of these.

9. The method according to any one of claims 1 to 8, wherein the mixture of the first composition and the second composition has a volatile substance content of about 30% to about 90%.

10. The method according to any one of claims 1 to 9, wherein the aerosol generating material has a volatile substance content lower than the volatile substance content of the mixture of the first composition and the second composition.

11. The method according to any one of claims 1 to 10, wherein the aerosol generating material has a volatile substance content of about 25% to about 35%.

12. The method according to any one of claims 1 to 11, wherein the plant material is selected from the list consisting of fennel, star anise, hemp, rooibos, and mixtures thereof, and optionally the active ingredient is nicotine or a nicotine salt.

13. The method according to any one of claims 1 to 12, wherein the first composition and / or the second composition comprises an acid, and optionally the acid is selected from the group consisting of nicotine benzoate, nicotine lactate, nicotine citrate, nicotine levulinate, and mixtures thereof.

14. The method according to any one of claims 1 to 13, wherein the aerosol generating material does not contain tobacco material.

15. The method according to any one of claims 1 to 14, wherein the non-tobacco plant material has a particle size distribution (D90) of 250 μm to about 400 μm.

16. The method according to any one of claims 1 to 15, wherein the second composition comprises a second binder, the first and second binders are the same or different, optionally the ratio of the first binder to the second binder is 1:1 to about 1:10, and optionally the mixture of the first composition and the second composition comprises the first binder, the second binder and the filler in a total amount of 5 to 40% of the weight of the mixture of the first composition and the second composition.

17. The method according to any one of claims 1 to 16, wherein the mixture of the first composition and the second composition contains the binder in an amount exceeding about 2% by weight of the mixture of the first composition and the second composition.

18. The method according to any one of claims 1 to 17, wherein the first composition is in a liquid phase and the second composition is in a solid phase.

19. The method according to any one of claims 1 to 18, wherein the mixture of the first composition and the second composition contains the filler in an amount exceeding about 2% by weight of the mixture of the first composition and the second composition.

20. The method according to any one of claims 1 to 19, comprising the step of shredding the sheet to form strands or strips of the aerosol-generating material.

21. The method according to any one of claims 1 to 20, wherein the drying step is performed at a temperature of less than approximately 100°C.

22. The method according to any one of claims 1 to 21, wherein the mixture of the first composition and the second composition is formed by homogenizing the first composition and the second composition.

23. The method according to any one of claims 1 to 22, wherein the aerosol generating material is incorporated into an article for use in conjunction with a non-combustible aerosol supply system.

24. An aerosol-generating material obtained or obtainable by the method described in any one of claims 1 to 23, wherein the aerosol-generating material is optionally in the form of a sheet or a shredded sheet, optionally the sheet or shredded sheet having a burst strength of at least 150 g, and optionally the sheet or shredded sheet having a burst strength of about 170 g / m² ２ ~Approx. 240g / m ２ An aerosol-generating material having a surface density, optionally the sheet or the shredded sheet having a tensile strength of about 4 N / 15 mm to about 20 N / 15 mm, and optionally the aerosol-generating material containing 0 to 15% by weight less glycerol and / or nicotine than the amount of glycerol and / or nicotine contained in the mixture of the first composition and the second composition.

25. An article for use in a non-combustion aerosol supply system, comprising the aerosol generating material described in claim 24.

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