Aerosol generating materials

Abstract

A plant-based aerosol-generating material is provided, in the form of a sheet or shredded sheet, having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness, or visual appearance. Articles for use in a non-combustible aerosol supply system including an aerosol-generating section containing the aerosol-generating material, and methods for producing the aerosol-generating material are also provided.

Description

[Technical Field]

[0001] This disclosure relates to aerosol-generating materials, methods for producing aerosol-generating materials, and consumables containing aerosol-generating materials. [Background technology]

[0002] Aerosol-providing products generate an aerosol during use, which is inhaled by the user. For example, a cigarette heating device forms an aerosol by heating an aerosol-generating material, such as a cigarette, rather than burning the base material. Aerosol-providing products generally include an aerosol-generating section or region that generates an aerosol during use, and a mouthpiece through which the aerosol passes and reaches the user's mouth.

[0003] Such products suffer from the problem that the aerosol-generating material is heterogeneous, for example, in terms of density and thickness. Furthermore, methods commonly used to prepare sheets of such aerosol-generating material produce sheets or shredded sheets with rough surfaces that can adversely affect the airflow through the product. The surface of the sheet may also have varying roughness on each side, which can lead to even more inconsistent airflow. These characteristics provide users with inconsistent flavor delivery, and therefore, these properties of the aerosol-generating material need to be improved.

[0004] Aerosol-generating materials can be produced by extruding a mixture of the components of the aerosol-generating material. This offers the advantage of reduced water content and, consequently, the benefit of less drying required to prepare the aerosol-generating material (e.g., in terms of drying time or temperature). However, this method suffers from the problem of insufficient control over the homogeneity of the aerosol-generating material. [Overview of the project]

[0005] According to a first aspect of the present invention, there is provided an aerosol - generating material in the form of a sheet or shredded sheet having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness or visual appearance.

[0006] According to a second aspect of the present invention, there is provided an aerosol - generating material in the form of a sheet or shredded sheet having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness or visual appearance and comprising a plant - based material.

[0007] In some embodiments, the aerosol - generating material has an areal density of about 150 to about 210 g / m 2 ².

[0008] In some embodiments, the aerosol - generating material has a volume density of about 0.2 to about 1 g / cm 3 ³.

[0009] In some embodiments, the aerosol - generating material includes a first surface and a second surface, and the first surface and the second surface have substantially the same surface roughness.

[0010] In some embodiments, the first surface and the second surface have an average roughness (Ra) according to ISO 4287 of about 15 μm to about 20 μm.

[0011] In some embodiments, the aerosol - generating material has a thickness of about 0.15 mm to about 0.35 mm.

[0012] In some embodiments, the thickness does not vary by more than 10% across the area of the sheet.

[0013] In some embodiments, the air permeability of the aerosol - generating material is 5 to 40 seconds / 100 cm 3 ².

[0014] In some embodiments, the aerosol - generating material has a tensile strength of at least 3 N / 15 mm.

[0015] In some embodiments, the plant material is in the form of particles.

[0016] In some embodiments, the particles have a D90 of from about 320 to about 350 μm.

[0017] In some embodiments, the aerosol-forming material does not contain tobacco material.

[0018] In some embodiments, the plant material includes rooibos.

[0019] In some embodiments, the aerosol-forming material contains water.

[0020] In some embodiments, the aerosol-forming material has a water content of from about 6.5 to about 9.5 wt%.

[0021] In some embodiments, the aerosol-forming material has a plant material content of from about 50 to about 80 wt%.

[0022] In some embodiments, the aerosol-forming material includes at least one binder.

[0023] In some embodiments, the aerosol-forming material has a binder content of from about 10 to about 25 wt%.

[0024] According to a third aspect of the present invention, there is provided an article for use in a non-combustible aerosol supply system comprising an aerosol-forming section comprising the aerosol-forming material of the first or second aspect.

[0025] In some embodiments, the pressure drop across the article is from about 40 to about 120 mmWg.

[0026] In some embodiments, the pressure drop across the aerosol-forming section is from about 100 to about 500 mmWg.

[0027] In some embodiments, the aerosol-generating material is in the form of shredded sheets.

[0028] According to a fourth aspect of the present invention, a method for producing an aerosol generating material as described above, The steps include forming a first composition comprising a first binder and an aerosol-forming agent, The steps include forming a second composition comprising tobacco material, a filler, and optionally a second binder, The steps include combining the first composition and the second composition to form a mixture of the first composition and the second composition, Steps include extruding the mixture and The steps include rolling the extruded mixture using at least one roller to form an aerosol-generating material, A method is provided that includes this.

[0029] In some embodiments, the rolling step uses four rolling presses.

[0030] In some embodiments, the rollers are spaced approximately 0.5 mm apart.

[0031] Herein, embodiments of the present invention will be described merely as examples with reference to the accompanying drawings, where Sheet 1 refers to an aerosol-generating material in the form of a sheet produced using a band casting process, and Sheets 2 and 3 refer to the claimed aerosol-generating material in the form of a sheet. [Brief explanation of the drawing]

[0032] [Figure 1] This graph shows the thickness of the sheet along its respective area. [Figure 2] This graph shows the average surface roughness (Ra) of the first and second surfaces of Sheet 1 and Sheet 2. [Figure 3] This graph shows the average surface roughness (Rz) of the first and second surfaces of sheet 2 and sheet 2. [Figure 4]This graph shows the average surface roughness (RSm) of the first and second surfaces of Sheet 1 and Sheet 2. [Figure 5] This figure shows the air permeability data for Sheet 1 and Sheet 2. [Figure 6] This is a graph of data collected from a light intensity meter. [Figure 7] This is a table of the data shown in Figure 6. [Figure 8] This diagram schematically illustrates an exemplary process for producing aerosol-generating materials. [Figure 9] This is a perspective view of an article for use with a non-combustible aerosol supply device. [Figure 10] Figure 9 is a side cross-sectional view of the article shown. [Figure 11] This is a simplified schematic diagram of an exemplary rolling press. [Modes for carrying out the invention]

[0033] This invention relates to an aerosol-generating material having improved homogeneity. As used herein, the term homogeneous means substantially uniform composition or properties.

[0034] In a first aspect of the present invention, an aerosol-generating material is provided which includes a plant-based material and is in the form of a sheet or shredded sheet having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness, or visual appearance.

[0035] In some embodiments, the aerosol-generating material may be in the form of a sheet or a shredded sheet. The sheet or shredded sheet has a first surface and a second surface, the first surface and the second surface being opposite sides of the sheet.

[0036] 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 a solid, liquid, or semi-solid (such as a gel), and may or may not contain active substances and / or flavorings.

[0037] The aerosol-generating material may include one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0038] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or filler may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0039] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0040] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0041] The aerosol-generating film may be continuous. For example, the film may include a continuous sheet of material, or a continuous sheet of material. The sheet may be in the form of packaging material, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may include one or more strands or strips of the aerosol-generating material.

[0042] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more separate parts or regions of aerosol-generating material, such as dots, stripes, or lines, which can be supported on a support. In such embodiments, the support may be planar or non-planar.

[0043] An aerosol-generating film can be formed by combining a binder, such as a gelling agent, with a solvent such as water, an aerosol-forming agent, and one or more other components such as one or more substances to be delivered, forming a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form an aerosol-generating film.

[0044] The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent.

[0045] The aerosol-generating material may include or may be an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which is an amorphous solid. The amorphous solid may be a monolithic solid. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid 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.

[0046] In some embodiments, the aerosol-generating material includes a plant-derived material. In some embodiments, the plant-derived material includes or consists of one or more plant-derived substances, or their components, derivatives, or extracts. In some embodiments, the aerosol-generating material does not include a plant-derived material.

[0047] As used herein, the term “plant material” includes any material derived from a plant or plant material, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. In some embodiments, the plant material is plant-derived material or plant material cut into smaller pieces, for example, the plant-derived material or plant material may be milled, crushed, diced, sliced, or otherwise divided to reduce the size of the pieces. In some embodiments, the plant material is plant-derived material or plant material in the form of particles, as described herein.

[0048] Alternatively, the material may include naturally occurring or synthetically obtained active compounds found in plant matter. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, or the like.

[0049] 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 (green or black), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and saffron. These include lavender, 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. The mint may be selected from the following mint varieties: Mentha Arventis, Mentha cv, Egyptian mint (Mentha niliaca), Mentha piperita, Mentha piperita citrata cv, Candy mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Kentucky Colonel mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), Green mint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0050] In some embodiments, the plant material is selected from eucalyptus, star anise, cocoa, hemp, and fennel.

[0051] In some embodiments, the plant material may contain one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes. The plant material may also be CBD or a derivative thereof.

[0052] The plant-based material may also be a non-tobacco plant-based material. “Non-tobacco plant-based material” refers to any plant-based material other than tobacco. The use of non-tobacco plant-based materials can improve the sensory properties of aerosols produced by aerosol-generating materials manufactured by the process. For example, when rooibos, fennel, star anise, and / or mint are used as aerosol-generating materials, the non-tobacco plant-based materials can produce a particularly neutral aroma profile. The relatively neutral aroma profile of non-tobacco plant-based materials can lead to the formation of a relatively neutral aerosol. Furthermore, when one or more of these plant-based 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, 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.

[0053] In some embodiments, the plant-based material is rooibos. This offers the advantage that rooibos provides a suitable texture and density while being nicotine-free. Rooibos is also preferably caffeine-free.

[0054] By combining one or more non-tobacco plant materials with an active substance, the sensory properties resulting from the active substance (such as nicotine or menthol) may be more easily perceived by the user compared to tobacco-based aerosol-generating materials. As a result, 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, in order to achieve a product with consistent aerosol properties, it is desirable to ensure that both the non-tobacco plant material and the active substance are homogeneously mixed throughout the aerosol-generating material.

[0055] The aerosol-generating materials produced by the processes described herein exhibit homogeneous properties, and therefore, the aerosols produced by these materials are relatively consistent.

[0056] In some embodiments, the plant material is tobacco material. Therefore, in some embodiments, the aerosol-generating material contains tobacco. In some embodiments, the aerosol-generating material does not contain tobacco. In some embodiments, the aerosol-generating material does not contain tobacco material and is substantially tobacco-free.

[0057] As used herein, the term “tobacco material” refers to material derived from the Nicotiana species plant. The selection of the Nicotiana species plant is not limited, and the type of tobacco or tobacco used may vary. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco leaves, tobacco stems, recombined tobacco, and / or tobacco extracts. As used herein, “tobacco leaves” means cut lamina tobacco.

[0058] In some embodiments, the tobacco material is selected from iron-tube dried tobacco or Virginia tobacco, Burley tobacco, sun-dried tobacco, Maryland tobacco, dark-fired tobacco, dark-colored air-dried tobacco, light-colored air-dried tobacco, Indian air-dried tobacco, Red Russian tobacco and Rustica tobacco, and mixtures thereof, as well as various other rare or specialty tobaccos, green tobacco or dried tobacco. Tobacco material produced by any other type of tobacco processing that can alter the taste of tobacco, such as fermented tobacco or genetic modification or crossbreeding techniques, is also within the scope of this disclosure. For example, it is conceivable that tobacco plants may be genetically engineered or crossbred to increase or decrease the production of components, characteristics or attributes.

[0059] In some embodiments, the tobacco material is sun-dried tobacco selected from Indian Kurnool tobacco and Oriental tobacco, including Izmir tobacco, Basma tobacco, Samsun tobacco, Katerini tobacco, Prelip tobacco, Komotini tobacco, Xanthi tobacco and Yambol tobacco. In some embodiments, the tobacco material is dark-colored air-dried tobacco selected from Passanda tobacco, Cubano tobacco, Jatin tobacco and Besuki tobacco. In some embodiments, the tobacco material is light-colored air-dried tobacco selected from North Wisconsin tobacco and Galpao tobacco.

[0060] In some embodiments, the tobacco material is selected from Brazilian tobaccos, including Mata Fina tobacco and Bahia tobacco. In some embodiments, the tobacco material is selected from Criollo tobacco, Piloto Cubano tobacco, Olor tobacco, Green River tobacco, Isabela DAC tobacco, White Pata tobacco, Eluru tobacco, Jatim tobacco, Madura tobacco, Kasturi tobacco, Connecticut Seed tobacco, Broad Leaf tobacco, Connecticut tobacco, Pennsylvania tobacco, Italian dry-air-dried tobacco, Paraguayan dry-air-dried tobacco, and One Sucker tobacco.

[0061] The tobacco material may include, or consist of, reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, bandcast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco such as tobacco lamina or granules.

[0062] In some embodiments, the aerosol-generating material may contain two or more plant-based materials. This offers the advantage of allowing consumers to taste different plant-based materials.

[0063] In some embodiments, the aerosol-generating material comprises at least about 10% by weight of plant material. In some embodiments, the aerosol-generating material comprises at least 40% by weight, at least about 50% by weight, at least about 60% by weight, at least about 75% by weight, at least about 95% by weight, or at least about 99% by weight of plant material. In some embodiments, the aerosol-generating material is substantially composed of plant material.

[0064] In some embodiments, the aerosol-generating material contains up to about 10% by weight of plant-derived material. In some embodiments, the aerosol-generating material does not contain plant-derived material.

[0065] In some embodiments, the aerosol-generating material includes up to about 60% by weight, up to about 75% by weight, up to about 80% by weight, up to about 95% by weight, and up to about 99% by weight of plant-based material.

[0066] For example, the plant material may be present in an amount of approximately 50%, 60%, 70%, 80%, or 90% by weight of the aerosol-generating material. The plant material may be present in an amount of approximately 50 to approximately 80% by weight of the aerosol-generating material.

[0067] The plant-based material content may be selected to provide the user with a positive flavor and to give the aerosol-generating material an appropriate texture. The plant-based material content affects the elastic and tensile strength of the aerosol-generating material, the first aerosol-generating material and / or the second aerosol-generating material.

[0068] The plant material may be particulate or granular. In some embodiments, the plant material may be a powder or pulverized. 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. The plant material particles offer the benefit that the particle size distribution and resulting physical properties of the sheet described herein can be more easily controlled.

[0069] In embodiments where the plant material is a particulate plant material, each particle of the particulate plant 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 the same particle of tobacco or any other point on the particle surface. The maximum dimension of the particles of the particulate plant material may be measured using scanning electron microscopy (SEM).

[0070] In some embodiments, the maximum size of each particle of the plant material is approximately 500 μm, 450 μm, 400 μm, or 350 μm. In some embodiments, the maximum size of each particle of the plant material is at least approximately 320 μm, 350 μm, 400 μm, or 500 μm. In some embodiments, the maximum size of each particle of the plant material is approximately 320-350 μm.

[0071] In some embodiments, the aerosol-generating material may include a portion of plant material particles having a maximum size of approximately 80 μm. In some embodiments, the portion of particles constitutes 10% of the total composition of plant material in the aerosol-generating material. Embodiments in which the aerosol-generating material includes a portion of up to 10% of plant material particles having a maximum size of approximately 80 μm have been found to enjoy the benefit of increased tensile strength. D90 may be selected based on the density of the aerosol-generating material. For example, a lower density may result in a lower D90.

[0072] The inventors have found that a small particle size distribution (PSD) is associated with a low surface roughness of the sheet or shredded sheet, as described herein. However, a smaller PSD may be manipulated and flattened with rollers to produce a more homogeneous and smoother surface.

[0073] Furthermore, the inventors have found that the particle size of the plant material affects the tensile strength. Smaller PSDs are associated with higher tensile strength and denser aerosol-generating materials. D90 may be selected to optimize the tensile strength of the aerosol-generating material. The tensile strength of the material may be influenced by the amount (weight %) and / or type of plant material. Therefore, the inventors have found that D90 may be selected to still change the amount and / or type of plant material while maintaining the desired tensile strength of the aerosol-generating material.

[0074] The inventors have found that by controlling the particle size distribution (D90), a desired area density can be achieved for aerosol-generating materials and for sheets, shredded sheets, or products manufactured therefrom. The area density of the material may be measured in GSM (grams per square meter, i.e., g / m2). For example, a lower particle size distribution (D90) is associated with a higher area density. When the aerosol-generating material is incorporated into articles for use in non-combustible aerosol supply systems, this higher area density can reduce the fill value of the plant-based material.

[0075] A collection of plant material particles may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, a collection of plant material particles may have a particle size distribution (D90) of at least about 200 μm, at least about 250 μm, at least about 300 μm, or at least about 320 μm. In some embodiments, a collection of plant material particles may have a particle size distribution (D90) of up to about 500 μm, up to about 450 μm, up to about 400 μm, or up to about 350 μm. In some embodiments, a collection of plant material particles may have a particle size distribution (D90) of about 320-350 μm. To measure the particle size distribution, a particle size and shape analyzer such as a Camsizer may be used, or sieve analysis may be used to determine the particle size distribution of the plant material particles.

[0076] In some embodiments, the sheet or shredded sheet has a homogeneous or substantially homogeneous thickness. As used herein, the term thickness is defined by the distance between a first surface and a second surface of the sheet or shredded sheet.

[0077] In some embodiments, the term homogeneous thickness may refer to a consistent thickness across a region of the aerosol-generating material. In some embodiments, the thickness may not vary by more than about 10% across a region of the sheet. In some embodiments, the thickness may not vary by more than about 20% across a region of the sheet, more than about 15%, 10%, 8%, or 5%. In some embodiments, the region of the sheet or shredded sheet is at least a portion of the sheet or shredded sheet. In some embodiments, the portion of the sheet may be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 99% of the region of the sheet or shredded sheet.

[0078] In some embodiments, the thickness of the aerosol-generating material is about 0.15 to about 0.35 mm. In some embodiments, the thickness of the aerosol-generating material is about 0.18 to about 0.32 mm, about 0.2 to about 0.3 mm, or about 0.24 to about 0.28 mm. The sheet thickness may be determined using the Guobiao standard method outlined in GB / T 451.3 Paper and cardboard - Measurement of thickness. In some embodiments, the thickness of the sheet or shredded sheet may be determined according to ISO 534 - Paper and cardboard for determination of thickness, density and specific volume. In some embodiments, the thickness of the sheet or shredded sheet may be determined according to ISO 3402 - Tobacco and tobacco products for atmospheres for conditioning and testing.

[0079] The thickness may be selected to provide appropriate malleability and tensile strength.

[0080] The inventors have established that if the sheet or shredded sheet of the aerosol-generating material is too thick, the heating efficiency may be impaired. This can negatively affect power consumption during use, for example, the power consumption for releasing flavor from the aerosol-generating material. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle, and very thin materials are more difficult to cast and are brittle, which can impair aerosol formation during use.

[0081] The improved uniformity of the sheet thickness offers the advantage of consistent sheet or shredded sheet thickness, resulting in improved consistency in flavor delivery. The sheet or shredded sheet thickness is also more consistent during the manufacturing of the article, allowing the final product to be machined more quickly and inexpensively.

[0082] While we do not wish to be bound by a single theory, when a material is rolled, its thickness can be easily controlled by changing the distance between the rollers. Furthermore, two or more rolling presses may be used to gradually reduce the thickness and to firmly control the thickness of the sheet or shredded sheet.

[0083] The homogeneity of rolled or shredded sheets is improved compared to other methods for producing aerosol-generating materials. For example, a known method for producing aerosol-generating materials, commonly known as "band casting," involves preparing a slurry, forming the slurry into layers, flattening it using a blade, and drying it. The use of rollers provides consistent flattening of the material, while the use of blades is known to provide a textured or rough surface. The thickness of materials produced by this method is also inconsistent.

[0084] Figure 1 shows a graph illustrating the sheet thickness along the length of the sheet. The material is passed through a micrometer and the thickness is repeatedly measured. Sheet 1 is a sheet of aerosol-generating material manufactured using the "band casting method," and Sheet 2 is a sheet of the claimed aerosol-generating material. It is clear that the thickness of Sheet 2 is more homogeneous and consistent than that of Sheet 1. The best-fit line (linear regression fit) of the data for Sheet 2 has a lower slope than that of Sheet 1. This indicates improved consistency and lower variability in the sheet thickness over time across the measured area of ​​the sheet.

[0085] The thickness of the sheet or shredded sheet is also thought to affect the area density and mass-to-volume ratio of the sheet or shredded sheet. That is, increasing the thickness of the sheet or shredded sheet may decrease the area density of the sheet or shredded sheet. Conversely, decreasing the thickness of the sheet or shredded sheet may increase the area density of the sheet or shredded sheet. Therefore, the more uniform the thickness, the more uniform the density. To avoid misunderstanding, when area density is referred to herein, it refers to the average area density calculated for a given strip, strand, piece, or sheet of aerosol-generating material, which is calculated by measuring the surface area and weight of a given strip, strand, piece, or sheet of aerosol-generating material.

[0086] Approximately 150g / m 2 ~about 200g / m 2 Along with area density, sheets or shredded sheets having a thickness of at least about 0.15 mm to about 0.35 mm have been observed to be less likely to tear, break, or otherwise deform during the manufacture of the sheets or shredded sheets. A thickness of at least about 100 μm can have a positive effect on the overall structural integrity and strength of the sheets or shredded sheets. For example, sheets or shredded sheets having a thickness of at least about 100 μm may have good tensile strength and therefore the material may be relatively easy to process. Preferably, the inventors have found that homogeneous tensile strength reduces the likelihood of breakage or deformation at specific locations of lower thickness or density.

[0087] In some embodiments, the sheet or shredded sheet has a uniform or substantially uniform areal density, bulk density, and / or volume density.

[0088] In some embodiments, the term uniform density may refer to a consistent areal density and / or volume density across a region of the aerosol-forming material. In some embodiments, the areal density and / or volume density may not vary by more than 10% across the region of the sheet. In some embodiments, the areal density and / or volume density may not vary by more than 8% or more than 5% across the region of the sheet. In some embodiments, the region of the sheet or shredded sheet is at least a portion of the sheet or shredded sheet. In some embodiments, a portion of the sheet may be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 99% of the region of the sheet or shredded sheet.

[0089] Preferably, the claimed aerosol-forming material has a uniform volume density or areal density. This results in a consistent distribution of the components of the aerosol-forming material. This means that the uniform density contributes to the provision of a consistent flavor delivery to the user.

[0090] In some embodiments, the sheet or shredded sheet of the aerosol-forming material is from about 100 g / m 2 to about 300 g / m 2 , or from about 150 to about 210 g / m 2 in areal density. The sheet or shredded sheet may have an areal density from about 110 g / m 2 to about 280 g / m 2 , from about 120 g / m 2 to about 260 g / m 2 , from about 130 g / m 2 to about 420 g / m 2 , or from about 140 g / m 2 to about 220 g / m 2 In some embodiments, the sheet or shredded sheet is about 130 g / m 2~Approx. 290g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 160g / m 2 ~about 210g / m 2 It has a surface density of .

[0091] The average volume density or basis weight of a sheet or shredded sheet of aerosol-generating material may be calculated from the sheet thickness and the sheet area density. In some embodiments, the average volume density or basis weight is approximately 0.4 g / cm³. 3 , about 0.6g / cm 3 , or approximately 0.7 g / cm³ 3 It may be larger. In some embodiments, the average volume density is about 0.4 g / cm³. 3 ~Approx. 1g / cm 3 Approximately 0.4 g / cm³ 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~about 0.8g / cm 3 , about 0.6g / cm 3 ~about 0.8g / cm 3 , or approximately 0.7 g / cm³ 3 ~about 0.8g / cm 3 In some embodiments, the average volume density is approximately 0.72 g / cm³. 3 ~about 0.80g / cm 3 And,

[0092] Aerosol-generating materials have a lower density compared to other aerosol-generating materials. As a result of this lower density, the rods are lighter and therefore easier to handle and store.

[0093] The tensile strength of a sheet or shredded sheet may be related to its thickness and area density. Thicker sheets or shredded sheets may have higher tensile strength than thinner sheets or shredded sheets. Sheets or shredded sheets with higher density may have higher tensile strength.

[0094] The sheet or shredded sheet may have a tensile strength of at least 3N / 15mm.

[0095] The inventors have found that 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. The sheet or shredded sheet may have a tensile strength of at least 4 N / 15 mm. This is preferable because common machines used for processing aerosol-generating materials are often limited to use with materials of at least 4 N / 15 mm.

[0096] In some embodiments, the sheet or shredded sheet may have a tensile strength of up to 20 N / 15 mm.

[0097] The sheet or shredded sheet may have more consistent tensile strength across the sheet or shredded sheet. This reduces the likelihood of the sheet or shredded sheet breaking when handled, for example, during manufacturing, packaging, or storage. If the tensile strength is too low, the aerosol-generating material may be relatively brittle. This is particularly preferable when the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol supply device. As a result of homogeneous density, and therefore tensile strength, the strip can maintain the integrity of the strip when the aerosol-generating material is formed into an article or when an aerosol generator is inserted into the aerosol-generating material, thus improving the ease with which the aerosol generator can be inserted into the material.

[0098] 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.

[0099] In some embodiments, the sheet or shredded sheet has a uniform roughness. In some embodiments, the term uniform roughness refers to an average surface roughness calculated, for example, by measuring the average surface height and depth across the surface of the sheet or shredded sheet. In some embodiments, the term uniform roughness refers to a lower average surface roughness. In some embodiments, the above-mentioned area of ​​the sheet or shredded sheet is at least a portion of the sheet or shredded sheet. In some embodiments, the portion of the sheet may be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 99% of the area of ​​the sheet or shredded sheet.

[0100] In some embodiments, the aerosol-generating material is in the form of a sheet or shredded sheet including a first surface and a second surface, and the first and second surfaces have substantially the same surface roughness. Furthermore, the surface roughness is homogeneous across the entire surface of the sheet.

[0101] Surface roughness may be measured by multiple methods. Average roughness (Ra), average maximum profile height (Rz), and average profile irregularity interval (RSm) may be measured according to ISO standard 4287. Figures 2 to 4 show graphs of the average Ra, Rz, and RSm of the first and second surfaces of Sheet 1 (aerosol-generating material in sheet form, fabricated using a band casting process) and Sheet 2 (claimed aerosol-generating material in sheet form).

[0102] Figure 2 shows that the difference in Ra between the first and second surfaces of sheet 1 is much larger than that of sheet 2. In other words, the first and second surfaces of sheet 2 are more homogeneous and have more similar roughness than the first and second surfaces of sheet 1. Furthermore, the Ra of both the first and second surfaces is lower than that of the first surface of sheet 1 (i.e., they are not rough and are smooth).

[0103] Similarly, Figures 3 and 4 show the same trend for Rz and RSm, respectively.

[0104] In some embodiments, the first surface and / or the second surface have an average roughness (Ra) of about 10 μm to about 30 μm according to ISO standard 4287. In some embodiments, the first surface and / or the second surface have an average roughness (Ra) of about 15 μm to about 20 μm according to ISO standard 4287.

[0105] Surface roughness may be generated from the surface of a roller that transfers the surface texture to the surface(s) of the aerosol-generating material.

[0106] The inventors have also found that the area density of a sheet or shredded sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the area density, the roughness of the first and / or second surfaces can be adjusted. For example, increasing the area density reduces the particle size distribution and makes the surface smoother. This can reduce the roughness of the first and second surfaces. Decreasing the area density increases the roughness of the first and second surfaces.

[0107] As the surface roughness becomes more uniform, the sheet or shredded sheet exhibits less variation in thickness and becomes smoother across at least one surface. The inventors have found that this reduces turbulent airflow on at least one surface compared to aerosol-generating materials not manufactured by the method described herein, thereby improving airflow, and consequently flavor delivery and user experience.

[0108] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (for example, relatively smooth).

[0109] In some embodiments, both the first and second surfaces are relatively smooth. This further improves airflow because both sides of the sheet or shredded sheet disturb the airflow in a more similar manner. This improves the consistency of the aerosol generated from the material, providing the user with improved flavor delivery.

[0110] Sheets or shredded sheets further benefit from the fact that the less rough the surface, the easier they are to fit together within an article. While not wishing to be bound by specific reasons, it is generally believed that the less rough the surface, the more easily the surfaces slide against each other and interlock within an article. This improves the packing density of the aerosol-generating material. These improvements are particularly evident compared to other aerosol-generating materials where the first and second surfaces are not homogeneous. For example, the band-casting method for producing aerosol-generating materials results in a material having a first surface that is rougher than the other second surface. This is because a blade is used to flatten the slurry on the mesh before drying. Therefore, the claimed aerosol-generating material enjoys these advantages over such band-cast materials.

[0111] The aerosol-generating material is present in the aerosol-generating section at a concentration of approximately 400 mg / cm³. 3 ~about 900mg / cm 3 It may have a packing density of 400 mg / cm³. A higher packing density may make it difficult to insert the aerosol generator of the aerosol supply device into the aerosol generating material and may increase the pressure drop. 3 If the density is below a certain level, the rigidity of the article may decrease. Furthermore, if the packing density is too low, the aerosol-generating material may not effectively grip the aerosol generator of the aerosol supply.

[0112] The smoothness of the first and second surfaces can be influenced by many factors, including the surface density of the first and second surfaces and the properties of the components constituting the aerosol-generating material, such as the particle size of plant-based materials. Furthermore, rollers used in the production of aerosol-generating materials flatten and smooth the surface of the material.

[0113] In some embodiments, the sheet or shredded sheet has uniform permeability or air permeability.

[0114] As used herein, permeability refers to the flow of air, aerosol, or mixture of air and aerosol that can be produced by an aerosol-generating material when the aerosol-generating material is heated by an aerosol generator. As used herein, the term air permeability refers to the time required for a known amount of air, aerosol, or mixture of air and aerosol to pass through a known area of ​​a sheet. Thus, lower air permeability is associated with lower permeability of the aerosol-generating material.

[0115] In some embodiments, homogeneous permeability or air permeability refers to more consistent permeability or air permeability across a sheet or shredded sheet of aerosol-generating material or a region of the sheet or shredded sheet. In some embodiments, the region of the sheet or shredded sheet is at least a portion of the sheet or shredded sheet. In some embodiments, the portion of the sheet may be at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 99% of the region of the sheet or shredded sheet.

[0116] In some embodiments, the permeability of the aerosol-generating material is approximately 60, 50, 45, 40, or 3 seconds / 100cm. 3 In some embodiments, the permeability of the aerosol-generating material is at least about 5, at least about 10, at least about 15, or at least about 20 seconds / 100cm. 3 In some embodiments, the permeability of the aerosol-generating material is 5-40 seconds / 100cm. 3 The air permeability may be measured using a Gurley Precision Instruments densometer and / or a Gurley Precision Instruments porosity test plate.

[0117] Aerosol-generating materials benefit from lower air permeability. Lower air permeability is associated with higher permeability of aerosol-generating materials. Lower air permeability has a positive effect on aerosol generation because more air or aerosols pass through the material in a given time. This makes it possible to generate and deliver more aerosols to the user.

[0118] Furthermore, lower air permeability or higher permeability is associated with improved pressure drop, and therefore an improved user experience. Moreover, more homogeneous air permeability or permeability is associated with improved pressure drop across areas of the material, providing a more consistent user experience and consistent flavor delivery.

[0119] The inventors believe that a lower material density is related to improved air permeability. While they do not wish to be constrained by a single reason, they believe that lower density results in lower porosity, which in turn allows more air or aerosols to pass through the material.

[0120] Figure 5 shows the permeability data for Sheet 1 (aerosol-generating material in sheet form, fabricated using a band casting process) and Sheet 2 (claimed aerosol-generating material in sheet form). This is 100 cm 3 This shows the time required for air to pass through a known area of ​​the sheet. Sheet 2 requires less time for air to pass through than Sheet 1. This demonstrates the improved air permeability of the claimed aerosol-generating material.

[0121] In some embodiments, the visual appearance of the sheet is homogeneous. For example, the sheet may have a more uniform appearance, texture, or coloration over a region of its surface or across its surface. In some embodiments, the first surface may have a similar appearance to the second surface of the sheet. For example, the first and second surfaces may have similar appearances, textures, or coloration to each other. Furthermore, the visual appearance may be homogeneous over one surface or over the entire area of ​​each surface.

[0122] For example, a sheet manufactured using rollers has a homogeneous texture. Another sheet formed using, for example, the band casting method, has different surface roughness on the first and second surfaces.

[0123] This offers the advantage of improving the appearance of the sheet and enhancing the perception of material quality.

[0124] Figure 6 is a graph of data collected from the light intensity meter. The light intensity meter measures the amount of light that can pass through the material on the strip cutting machine before the material is cut or sliced.

[0125] Figure 7 shows a table of the data from Figure 6. Sheet 1 is a sheet of aerosol-generating material manufactured using the "band casting method," and Sheets 2 and 3 are sheets of the claimed aerosol-generating material. The standard deviation of the light intensity data for Sheets 2 and 3 is lower than that of Sheet 1. This indicates that the data variance is smaller and that Sheets 2 and 3 are more homogeneous than Sheet 1.

[0126] Figures 6 and 7 also show the light transmittance of the sheets. Light transmittance is related to the thickness and density of the sheets. Figure 6 shows that sheets 2 and 3 (containing the claimed aerosol-generating material) have more consistent and homogeneous light transmittance, and therefore more consistent thickness and density, compared to sheet 1 (band-cast sheet).

[0127] In another aspect of the present invention, an article is provided for use in conjunction with a non-combustible aerosol supply system, comprising an aerosol-generating material.

[0128] Articles or consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Articles may 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. Consumables may also comprise an aerosol generator, such as a heater, which generates heat during use to produce an aerosol in the aerosol-generating material. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0129] 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, expanded tobacco, recombined tobacco, tobacco substitutes, or other smokeable materials), 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 electronic cigarettes, tobacco heating products, and aerosol-generating materials, and An aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or by another method that does not form an aerosol, including but not limited to oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco containing snus or wet snuff, wherein at least one substance may or may not contain nicotine. Includes.

[0130] 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.

[0131] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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, a power source or a heat source. In some embodiments, the heat 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 transfer material located near the heat source.

[0138] 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.

[0139] 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.

[0140] In some embodiments, the aerosol-generating material is provided in the aerosol-generating section. In some embodiments, the aerosol-generating material is in the form of shredded sheets.

[0141] The present invention offers the advantage that an aerosol-generating material provides an improved pressure drop across an aerosol-generating section. Preferably, compared to other aerosol-generating materials, the aerosol-generating material according to this disclosure may have a lower mass at the same pressure drop when incorporated into an aerosol product. While we do not wish to be bound by any particular theory, a lower surface roughness may increase the airflow around the aerosol-generating material, thereby increasing the pressure drop across the aerosol-generating material and / or the section containing the material. The pressure drop is also related to improved permeability of the material.

[0142] In some embodiments, the pressure drop across the aerosol generation section is about 100 to about 500 mmWg. In some embodiments, the pressure drop across the aerosol generation section is about 100 to about 200 mmWg, about 200 to about 400 mmWg, or about 300 to about 350 mmWg.

[0143] In some embodiments, the pressure drop across the article is approximately 40 to 120 mmWg, approximately 50 to 100 mmWg, and approximately 60 to 90 mmWg.

[0144] During use, the article may exhibit a pressure drop of approximately 15 to 40 mmH2O. In some embodiments, the aerosol-generating section exhibits a pressure drop of approximately 15 to 30 mmH2O across the aerosol-generating section.

[0145] In some embodiments, the aerosol generation section has a maximum size of approximately 34 mm, 28 mm, 25 mm, 20 mm, 16 mm, and 12 mm.

[0146] In some embodiments, the article is approximately 34 mm, 28 mm, 25 mm, 20 mm, 16 mm, 12 mm, or 10 mm in maximum size.

[0147] In an exemplary embodiment, Figure 9 is a perspective view of Article 1 for use in an aerosol delivery system. Figure 10 is a side cross-sectional view of Article 1.

[0148] Article 1 comprises a mouthpiece 2 and an aerosol generating section 3 connected to the mouthpiece 2. In this example, the aerosol generating section 3 contains an aerosol generating material. The aerosol generating material may be in the form of a sheet or shredded sheet within the article. Article 1 comprises a downstream end 2b and an upstream end 2a away from the downstream end 2b.

[0149] In this example, the aerosol-generating material is enclosed by packaging material 5. In this example, packaging material 5 is a non-permeable packaging material. Packaging material 5 also encloses the plug 4. In some embodiments, the packaging material is paper, but it may be made of an alternative material such as aluminum.

[0150] The mouthpiece 2 includes a cooling section 6, also called a cooling element, positioned adjacent to the source of the aerosol-generating material 3 immediately downstream. In this example, the cooling section 6 is in contact with the source of the aerosol-generating material. The mouthpiece 2 also, in this example, includes at the mouthpiece end of article 1 a body 7 of the material downstream of the cooling section 6 and a hollow tubular element 8 downstream of the body 7 of the material.

[0151] Another aspect of the present invention provides a method for producing an aerosol-generating material, comprising the steps of: forming a first composition comprising a first binder and an aerosol-forming agent; forming a second composition comprising a plant material, a filler, and optionally a second binder; combining the first composition and the second composition to form a mixture of the first composition and the second composition; extruding the mixture; and rolling the extruded mixture using at least one roller to form an aerosol-generating material.

[0152] Aerosol-generating materials may be manufactured by any suitable method, but the method described herein offers certain advantages.

[0153] Figure 8 shows an exemplary embodiment of a method for producing an aerosol-generating material. A first composition comprising a binder and an aerosol-forming agent, and a second composition comprising a plant material, a filler, and optionally a second binder are formed and mixed. In a subsequent step, the first and second compositions are mixed and extruded. Subsequently, the extruded mixture of the first and second compositions may be rolled and then dried to form a sheet of aerosol-generating material. The sheet may then be shredded to produce an aerosol-generating material, which may then be incorporated into a consumable for a non-combustible aerosol delivery system. Optionally, the sheet is shredded.

[0154] In some embodiments, the first composition, also known as the “wetting mixture,” comprises an aerosol-forming agent or wetting agent and a binder. The first composition may also comprise other liquids or suspensions disclosed herein.

[0155] In some embodiments, the first composition may include an aerosol-forming agent. The aerosol-forming agent comprises one or more components capable of forming an aerosol. The aerosol-forming agent comprises one or more of the following: 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.

[0156] In some embodiments, the first composition may include a first binder. The binder is arranged 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.

[0157] 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.

[0158] The binder may be selected to provide specific properties to the first composition or the second composition, a mixture of the first composition and the second composition, and / or the aerosol-generating material.

[0159] The viscosity of a binder may depend on the type, concentration, and temperature of the binder. Generally, viscosity decreases as temperature increases and increases as concentration increases. The binder may contain, or consist of, low-viscosity, medium-viscosity, or high-viscosity binders. For example, low-viscosity binders are generally used in "dilute" aqueous solutions. A medium-viscosity binder may be used to prepare a syrup-like solution. A high-viscosity binder may be used to prepare a cream or lotion-like mixture.

[0160] High-viscosity binders have a viscosity of approximately 7,000 to 10,000 centipoise (cPs). For example, a high-viscosity binder may have a viscosity of 9,620 cPs. Medium-viscosity binders have a viscosity of approximately 3,000 to 7,000 cPs. Low-viscosity binders have a viscosity of approximately 0 to 3,000 cPs. For example, a low-viscosity binder may have a viscosity of approximately 2,315 cPs.

[0161] The binder may contain or consist of CMC. The choice of binder, particularly its viscosity, has unexpectedly been found to provide specific consistency and texture for the material. For example, higher viscosity facilitates mechanical processing, improves machine operability, and facilitates the formation of sheets or shredded sheets. For instance, the material may have lower tackiness and lower breakability. This can also improve the texture of aerosol-generating materials. This advantage is particularly evident in embodiments where the binder contains or consists of CMC.

[0162] In a specific example, the binder is a CMC such as Gumix K-1500 F with a viscosity of 9620 cPs. This is a high-viscosity binder, and an improved texture has been observed. In another specific example, the binder is a CMC such as Gumix K-500 with a viscosity of 2315 cPs.

[0163] In some embodiments, the first composition may contain a nicotine component.

[0164] "Nicotine component" means any suitable form of nicotine (e.g., free base or salt) to provide oral absorption of at least a portion of the nicotine present. Typically, the nicotine component is selected from the group consisting of nicotine free bases and nicotine salts. In some embodiments, the nicotine component is nicotine in the form of a free base, which can be readily adsorbed to, for example, a microcrystalline cellulose material to form a microcrystalline cellulose-nicotine carrier composite. See, for example, the discussion of nicotine in the form of a free base in Hansson's U.S. Patent Application Publication No. 2004 / 0191322, incorporated herein by reference.

[0165] In some embodiments, at least a portion of the nicotine component can be used in the form of a salt. Nicotine salts may be provided using the types of components and techniques described by Cox et al., U.S. Patent No. 2,033,909 and Perfetti, Beitrage Tabakforschung Int., 12:43-54 (1983), which are incorporated herein by reference.

[0166] Furthermore, nicotine salts are available from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Typically, the nicotine component is selected from the group consisting of free nicotine base, nicotine salts such as hydrochloride, dihydrochloride, monotartrate, bisartrate, sulfate, salicylate, and zinc nicotine chloride.

[0167] Nicotine salts can be formed using a pH modifier that may be included in the first composition. The pH modifier may include a pH adjuster or buffer. Examples of pH modifiers that can be used include, but are not limited to, metal hydroxides (e.g., alkali metal hydroxides such as sodium hydroxide and potassium hydroxide) and other alkali metal buffers such as metal carbonates (e.g., potassium carbonate or sodium carbonate), or metal bicarbonates such as sodium bicarbonate, organic acids or non-organic acids including benzoic acid, lactic acid, ascorbic acid, and acetic acid. In some embodiments, the pH modifier is selected from the group consisting of benzoic acid, lactic acid, ascorbic acid, and acetic acid.

[0168] Non-limiting examples of suitable buffers include alkali metal acetates, glycinates, phosphates, glycerophosphates, citrates, carbonates, bicarbonates, borates, or mixtures thereof.

[0169] In some embodiments, at least a portion of the nicotine may be in the form of a nicotine resin composite, where the nicotine is bonded to an ion exchange resin such as nicotine polarilex, which is nicotine bonded to polymethacrylic acid, such as Amberlite IRP64, Purolite C115HMR, or Doshion P551. See, for example, U.S. Patent No. 3,901,248 by Lichtneckert et al., incorporated herein by reference. Another example is a nicotine polyacrylic carbomer composite, such as Carbopol 974P. In some embodiments, the nicotine may exist in the form of a nicotine polyacrylic composite.

[0170] In some embodiments, the first compositions, aerosol-generating materials and / or compositions of the present disclosure may be characterized as being nicotine-free (for example, any embodiment disclosed herein may be completely or substantially nicotine-free). "Substantially nicotine-free" means that nicotine is not intentionally added in amounts exceeding trace amounts that may naturally occur in, for example, plant materials. For example, certain embodiments may be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001% by weight, or even 0% by weight of nicotine, calculated as free base.

[0171] In some embodiments, water is added to the first composition to form a suitable consistency. The first composition may be a liquid, gel, slurry, or suspension phase. Water is added to provide a consistency suitable for mixing, extrusion, and rolling processes.

[0172] In some embodiments, the water content of the first mixture is about 20-60%, about 25-50%, about 30-40%, about 28-33%, or about 33-37%. In some embodiments, the water content of the first mixture is about 28%. In some embodiments, the water content of the first mixture is about 33%. In some embodiments, the water content of the first mixture is about 37%.

[0173] The second composition, also known as the “dry mixture,” comprises a 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.

[0174] In some embodiments, the second composition includes a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain any tobacco-derived ingredients or components. 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 also 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.

[0175] In some embodiments, the filler is inert and non-reactive. In some embodiments, the filler is tasteless and does not contribute to the flavor or sensory properties of the generated aerosol. This offers the advantage that the amount and type of filler can be selected so as to alter the physical properties of the aerosol-generating material but not affect the aerosol's flavor profile or user experience.

[0176] 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 may increase the tensile strength of the resulting aerosol-generating material. The use of cellulose as a filler has been found to have a particularly favorable effect on the burst strength of the aerosol-generating material.

[0177] Fillers can also contribute to the texture of the aerosol-generating material. For example, fibrous fillers such as cellulose can provide an aerosol-generating material having relatively rough first and second surfaces. Conversely, non-fibrous particulate fillers such as powdered chalk can provide 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.

[0178] In some embodiments, the second composition may include 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.

[0179] The filler component may be present in an amount of 0 to 20% by weight of the aerosol-generating material, or in an amount of 1 to 10% by weight of the aerosol-generating material. For example, the filler may be present in an amount exceeding about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the aerosol-generating material. The filler may also be present in an amount of about 20%, 15%, 10%, 5%, or less than about 2% by weight of the aerosol-generating material.

[0180] In some embodiments, the inventors have found that including 5% filler improves burst strength and reduces the brittleness of the aerosol-generating material; therefore, the filler component is present in an amount of 5% by weight of the aerosol-generating material.

[0181] The aerosol-forming agent may be present in an amount of about 10% to about 25% by weight of the aerosol-generating material, or in an amount of 1% to about 10% by weight of the aerosol-generating material. For example, the aerosol-forming agent may be present in an amount of about 10%, 12%, 15%, 18%, 20%, or 25% by weight of the aerosol-generating material. In some embodiments, the aerosol-forming agent is present in an amount of about 15% by weight of the aerosol-generating material.

[0182] The binder may be present in an amount of about 1 to about 40% by weight of the aerosol-generating material, or in an amount of 10 to about 25% by weight of the aerosol-generating material. For example, the binder may be present in an amount greater than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the aerosol-generating material. The binder may be present in an amount of about 40%, 35%, 30%, 25%, or less than 20% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material has a binder content of about 10 to about 25% by weight.

[0183] The amount of binder in aerosol-generating materials is important because it changes the consistency of the material and mixture. Too much binder can increase the viscosity of the material too much, making it impossible to process, for example, with pumps and machinery.

[0184] The first and second compositions described herein may be mixed to provide 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.” Preferably, in order to provide a homogeneous dough suitable for subsequent processing steps, it is necessary to add a minimum amount of added water to the mixture, or to add no water at all. For example, the dough may then be extruded through a die, through which the homogeneous dough may pass well with or without the addition of further water.

[0185] Once formed and mixed, the mixture of the first composition and the second composition can be extruded from the aerosol-generating material using any extrusion technique or apparatus known in the art.

[0186] Extrusion involves supplying a precursor composition through an orifice to produce extruded aggregates. 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.

[0187] Extrusion may be carried out using one of the main types 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 the first and second compositions.

[0188] Other materials, such as bases, diluents, solid aerosol-forming agents, solid flavor modifiers, leavening agents, and other additives known in the art, may also be added during the extrusion process. This has the advantage that the additives are uniformly distributed throughout the formed aggregate structure.

[0189] The resulting extruded mixture may then be rolled using a rolling press. As used herein, the rolling press is a device comprising at least one roller. In embodiments where the rolling press comprises one roller, the material may be pressed between the roller and another substantially flat surface. Preferably, the rolling press comprises two rollers that can move the material, thereby flattening the material. The space between the rollers may define the thickness of the aerosol-generating material.

[0190] One of the drawbacks associated with the use of extrusion to form aerosol-generating materials is the difficulty in controlling the density of the aerosol-generating material. For example, the mixture may expand after extrusion. The rolling process offers the advantage of planarizing the material to control its density and thickness. Furthermore, the rolling process provides the improved homogeneity properties described herein.

[0191] While mixing and extrusion processes enhance the homogeneity of the composition within the material, the rolling process has a further synergistic effect that improves the homogeneity of the material's physical properties.

[0192] The inventors have found that the process of producing aerosol-generating material can be made continuous by controlling the amount of material entering the rolling press by extruding the mixture before the rolling process. In some embodiments, the extruded material is in the form of pellets, which are then fed into at least one rolling press. Thus, the rate at which the material enters the rolling process can be easily controlled.

[0193] In some embodiments, the extruded mixture may be processed by two or more rolling presses so that the extruded mixture is rolled two or more times. In some embodiments, the extruded mixture is rolled at least one, two, three, or four times. In some embodiments, the extruded mixture is rolled up to one, two, three, or four times.

[0194] The greater the number of rollers used to flatten the mixture, the more homogeneous the material produced will be, resulting in the homogeneity-related advantages described herein.

[0195] The rolling process also provides improved control over thickness. For example, the material may be continuously rolled using two or more rolling presses to achieve the desired thickness. This can be compared to the band casting method, where the thickness of the resulting material is determined by the rate at which the slurry is added to the apparatus and the rate at which the blades flatten the slurry.

[0196] An exemplary rolling press is schematically shown in Figure 9. The rolling press 102 comprises two rollers 106. The rollers 106 have a space 103 through which the material 101 moves and flattens the material. Thus, the thickness of the material is determined by the distance between the rollers in the space 103.

[0197] The space 103 may be adapted to produce a sheet having the required thickness. In embodiments where two or more rollers are used, the space 103 may gradually decrease in each successive roller. This results in a process that slowly flattens and reduces the thickness of the material to the required thickness. This increases the homogeneity of the sheet and reduces the stress on the material as it moves through the rolling process.

[0198] In some embodiments, the rollers are spaced about 0.5, 0.45, 0.4, 0.35, 0.3, 0.2, 0.25, 0.2, or 0.15 mm apart. In some embodiments, the rollers are spaced up to about 0.5, 0.45, 0.4, 0.35, 0.3, 0.2, 0.25, 0.2, or 0.15 mm apart.

[0199] 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 the thickness of the material.

[0200] In some embodiments, the rollers are smooth. This offers the advantage of providing a sheet with reduced roughness and improved smoothness. In embodiments where two or more rolling presses are used, the use of repeated rolling on the material can further increase smoothness and reduce roughness.

[0201] In embodiments where the rolling press(s) have two rollers, both the first and second surfaces of the sheet may 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.

[0202] After the rolling process, the aerosol-generating material is in the form of a sheet. The resulting sheet may be dried using any suitable drying technique known in the art. For example, microwave drying, infrared drying, air drying, and oven drying are suitable techniques for drying the aerosol-generating material. 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.

[0203] The length of the drying step may be up to approximately 5, 10, 30, 45, 60, 90, 120, or 360 minutes.

[0204] In some embodiments, the aerosol-generating material includes water.

[0205] In some embodiments, the aerosol-generating material has a water content of about 0 to about 15% by weight, about 5 to about 10%, or about 6.5 to about 9.5% by weight.

[0206] 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.

[0207] In some embodiments, the sheet may be shredded or sliced ​​to form shredded sheets. The sheet has a first surface and a second surface, the second surface being on an opposing surface of the sheet.

[0208] The shredded sheet may include one or more strips of the aerosol-generating material. In some embodiments, the shredded sheet includes multiple (e.g., two or more) strips of the aerosol-generating material.

[0209] If the shredded sheet contains multiple strips of material, the dimensions of each strip may be the same, similar, or different. For example, the shredded sheet may include a first assembly of strips and a second assembly of strips, where the dimensions of the strips in the first assembly are different from those of the strips in the second assembly. For example, the multiple strips may include a first assembly of strips having a first size and a second assembly of strips having a second size different from the first size.

[0210] A sheet, shredded sheet, or strip of material formed by shredding may be cut in the width direction, for example, by a cross-cut shredding method, to define the cutting width as well as the cutting length of the aerosol-generating material strip.

[0211] In some embodiments, the cutting length of the sheet or shredded sheet of aerosol-generating material is preferably at least 5 mm, for example, at least 10 mm, or at least 20 mm. The cutting length may be less than 60 mm, less than 50 mm, or less than 40 mm. The cutting length may be about 20 mm to about 25 mm.

[0212] In some embodiments, a plurality of strips of aerosol-generating material are provided, and at least one of the plurality of strips of aerosol-generating material has a length greater than about 10 mm. Alternatively or additionally, at least one of the plurality of strips of aerosol-generating material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the plurality of strips of aerosol-generating material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0213] 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.

[0214] In some embodiments, the delivered substance includes an active substance.

[0215] 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.

[0216] In one embodiment, the active substance is a legally permissible recreational drug.

[0217] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0218] In some embodiments, the delivered substance includes flavorings.

[0219] 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, to the extent permitted by local regulations.Flavors and flavorings are derived from naturally occurring flavoring materials, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., 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, etc.). Lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, pimento, 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, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, It may also contain other additives such as 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 matter, 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.

[0220] 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.

[0221] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensation that is usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and may include agents that produce heating, cooling, tingling, or numbing sensations. 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, eucolyptol, WS-3.

[0222] example Table 1 shows the components of exemplary aerosol-generating materials 1-7. There was a 30% moisture loss during the drying stage. The D90 was 320-350 μm for all materials.

[0223] [Table 1]

[0224] Table 2 shows the components of exemplary aerosol-generating materials 1-7. These examples have the advantage that all components are 100% plant-based. This results in a more environmentally friendly product, which is desirable for users. There was a 30% moisture loss during the drying stage. The D90 was 320-350 μm for all materials.

[0225] [Table 2]

[0226] Table 3 shows the physical properties of exemplary sheets of aerosol-generating material. Preferably, the sheets of aerosol-generating material are also consistent with each other.

[0227] [Table 3]

[0228] Table 4 shows the physical properties of exemplary articles containing aerosol-generating materials. The pressure drop (PD) may be measured over the entire article. In embodiments where the article has vents, the measured pressure drop may be called the open pressure drop. Preferably, the articles are also consistent with each other.

[0229] [Table 4]

[0230] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used or modified without departing from the scope of the claimed invention. Various embodiments of the invention may, may consist of, or may essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An aerosol-generating material in the form of a sheet or shredded sheet having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness, or visual appearance.

2. An aerosol-generating material comprising a plant-derived material, wherein the aerosol-generating material is in the form of a sheet or shredded sheet having one or more homogeneous properties selected from the group consisting of thickness, permeability, density, surface roughness, or visual appearance.

3. Approximately 150 to approximately 210g / m ２ The aerosol generating material according to claim 1 or 2, having the area density.

4. Approximately 0.2 to approximately 1g / cm ３ An aerosol generating material according to any one of claims 1 to 3, having a volume density of .

5. The aerosol-generating material according to any one of claims 1 to 4, comprising a first surface and a second surface, wherein the first surface and the second surface have substantially the same surface roughness.

6. The aerosol generating material according to claim 5, wherein the first surface and the second surface have an average roughness (Ra) of about 15 μm to about 20 μm according to ISO standard 4287.

7. An aerosol generating material according to any one of claims 1 to 6, having a thickness of approximately 0.15 mm to approximately 0.35 mm.

8. The aerosol generating material according to claim 7, wherein the thickness does not change by more than 10% across the area of ​​the sheet.

9. The permeability of the aerosol-generating material is 5 to 40 s / 100 cm. ３ An aerosol generating material according to any one of claims 1 to 8, which is between [the specified range].

10. An aerosol-generating material according to any one of claims 1 to 9, having a tensile strength of at least 3 N / 15 mm.

11. The aerosol generating material according to any one of claims 2 to 10, wherein the plant material is in the form of particles.

12. The aerosol-generating composition material according to claim 11, wherein the particles have a D90 of about 320 to about 350 μm.

13. An aerosol generating material according to any one of claims 1 to 12, which does not contain tobacco material.

14. The aerosol generating material according to any one of claims 2 to 13, wherein the plant material includes rooibos.

15. An aerosol generating material according to any one of claims 1 to 14, comprising water.

16. The aerosol generating material according to claim 15, having a water content of approximately 6.5 to approximately 9.5% by weight.

17. An aerosol generating material according to any one of claims 1 to 16, having a plant-derived material content of approximately 50 to approximately 80% by weight.

18. An aerosol-generating material according to any one of claims 1 to 17, comprising at least one binder.

19. The aerosol generating material according to claim 18, having a binder content of approximately 5 to approximately 25% by weight.

20. An article for use in a non-combustible aerosol supply system, which includes an aerosol generating section containing an aerosol generating material according to any one of claims 1 to 19.

21. The article according to claim 20, wherein the pressure drop across the article is approximately 40 to approximately 120 mmWg.

22. The article according to claim 20, wherein the pressure drop across the aerosol generation section is approximately 100 to approximately 500 mmWg.

23. The article according to any one of claims 20 to 22, wherein the aerosol generating material is in the form of shredded sheets.

24. A method for producing an aerosol generating material according to any one of claims 1 to 23, The steps include forming a first composition comprising a first binder and an aerosol-forming agent, The steps include forming a second composition comprising tobacco material, a filler, and optionally a second binder, The steps include: combining the first composition and the second composition to form a mixture of the first composition and the second composition; The step of extruding the mixture, The steps include rolling the extrusion mixture using at least one roller to form the aerosol-generating material, Methods that include...

25. The method according to claim 24, wherein the rolling step uses four rolling presses.

26. The aerosol-generating material according to any one of claims 1 to 19, in the form of a sheet or a shredded sheet, comprising a first surface and a second surface, wherein the first surface and the second surface have substantially the same surface roughness.

27. The aerosol generating material according to claim 26, comprising a plant-derived material.

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