Aerosol generating materials

Abstract

Aerosol generating materials This disclosure relates to an aerosol-generating material comprising a first surface and a second surface, and recesses on the first surface and / or the second surface. Methods for producing the aerosol-generating material and articles comprising the aerosol-generating material are also disclosed.

Description

[Technical Field]

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

[0002] Aerosol supply products generate aerosols during use, which are 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. Such aerosol supply 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 have a problem in that the aerosol-generating material is densely packed inside the product, which can make it relatively difficult for the user to inhale air through the aerosol-supplying product. As a result, the user may experience a worse sensory experience. [Overview of the Initiative]

[0004] According to a first aspect of the present invention, an aerosol-generating material is provided which includes a first surface and a second surface, as well as recesses on the first surface and / or on the second surface.

[0005] According to a second aspect of the present invention, an aerosol-generating material is provided comprising one or more elongated strips, each strip comprising a first surface and a second surface, and recesses on the first surface and / or the second surface.

[0006] According to a third aspect of the present invention, an aerosol-generating material is provided, comprising a sheet, the sheet comprising a first surface and a second surface, and recesses on the first surface and / or on the second surface.

[0007] In some embodiments, the recess has a shape selected from the group consisting of circular, semi-circular, crescent, square, triangular, Y-shaped, linear, rectangular, conical or star-shaped.

[0008] In some embodiments, the recess has a length and a width, and the average width is from about 0.01 to about 5 mm.

[0009] In some embodiments, the recess has a length and a width, and the length and the width have a length:width ratio of from about 1:0.25 to about 1:10.

[0010] In some embodiments, the length of the aerosol-generating material is at most about 34 mm.

[0011] In some embodiments, each recess is from about 0.00001 mm , , , , ,

[0016] , ,

[0015] ,

[0018] , ,

[0017] , ~ about 10 mm 3 in volume.

[0012] In some embodiments, the average volume density of the aerosol-generating material is from about 0.4 g / cm 3 ~ about 1 g / cm 3 .

[0013] In some embodiments, the aerosol-generating material comprises from about 100 to about 500 recesses per cm 2 .

[0014] In some embodiments, the thickness of the aerosol-generating material is from about 100 μm to 350 μm.

[0015] In some embodiments, the thickness of the aerosol-generating material is increased by about 10 to 40% compared to an equivalent material without recesses.

[0016] In some embodiments, the aerosol-generating material has a tensile strength of at least 3 N / 15 mm.

[0017] In some embodiments, the aerosol-generating material contains water.

[0018] In some embodiments, the aerosol-generating material contains 0% to about 15% by weight of water.

[0019] In some embodiments, the aerosol-generating material includes a plant-based material.

[0020] In some embodiments, the aerosol-generating material contains approximately 50 to approximately 80% by weight of plant-derived material.

[0021] In some embodiments, the aerosol-generating material includes at least one binder.

[0022] In some embodiments, the aerosol-generating material contains a binder content of 5 to about 40% by weight of the aerosol-generating material.

[0023] In some embodiments, the aerosol-generating material is in a form selected from the group consisting of sheets, shredded sheets, gathered sheets, rods, or strands.

[0024] According to a fourth aspect of the present invention, an article is provided for use in a non-combustible aerosol supply system including an aerosol generating unit containing an aerosol generating material according to any of the preceding claims.

[0025] In some embodiments, the article has a pressure drop of about 40 to about 120 mmWg between its upstream and downstream ends.

[0026] In some embodiments, the article includes an aerosol generating section, and the pressure drop in the aerosol generating section is 50 to about 500 mmWg.

[0027] A fifth aspect of the present invention provides a method for producing an aerosol generating material according to any one of claims 1 to 20, comprising the steps of: forming an aerosol generating material composition; imprinting depressions on the surface of the aerosol generating composition to form recesses on the surface; and drying the aerosol generating composition to form an aerosol generating material including the recesses.

[0028] In some embodiments, the aerosol-generating material is prepared by extruding the aerosol-generating composition.

[0029] A further aspect of the present invention provides an aerosol-generating material produced by the method of the fifth aspect.

[0030] Next, embodiments of the present invention will be described as merely examples with reference to the attached drawings. [Brief explanation of the drawing]

[0031] [Figure 1] This graph shows the effect of aerosol-generating materials containing recesses on the pressure drop of a material. [Figure 2] This is a magnified image of the first surface of an exemplary aerosol-generating material, including a recess. [Figure 3] This graph shows the effect of aerosol-generating materials containing recesses on the physical properties of the material. [Figure 4] This is a side cross-sectional view of an article for use with a non-flammable aerosol supply device. [Figure 5] Figure 4 is a perspective view of the item shown. [Figure 6] This is a simplified schematic diagram of an exemplary rolling press. [Figure 7] An exemplary process for preparing aerosol-generating materials is schematically shown. [Modes for carrying out the invention]

[0032] 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 pipe tobacco, hand-rolled tobacco, and homemade tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, tobacco substitutes, or other smokeable materials), Non-combustible aerosol supply systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of e-cigarettes, tobacco heating products, and aerosol-generating materials, An aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, and including, but not limited to, articles containing lozenges, gums, patches, inhalable powders, and oral products such as oral tobacco containing snuff or moist snuff, wherein at least one substance may or may not contain nicotine, and Includes.

[0033] According to this disclosure, a “combustion-type” aerosol supply system is a system in which the aerosol-generating materials (or components thereof) of the aerosol supply system are burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0034] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0035] In some embodiments, the disclosure relates to components for use in a combustion aerosol supply system, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components, such as capsules, threads or beads, or paper, such as plug wraps, chipping paper or cigarette paper.

[0036] The delivery systems described herein may be implemented as combustion-type aerosol delivery systems, non-combustible aerosol delivery systems, or aerosol-free delivery systems.

[0037] In a first aspect of the present invention, the aerosol-generating material includes a first surface and a second surface, and recesses on the first surface and / or on the second surface.

[0038] In a second aspect of the present invention, an aerosol-generating material is provided comprising one or more elongated strips, each strip comprising a first surface and a second surface, and recesses on the first surface and / or the second surface.

[0039] In a third aspect of the present invention, an aerosol-generating material is provided, comprising a sheet, the sheet comprising a first surface and a second surface, and recesses on the first surface and / or the second surface.

[0040] 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), which may or may not contain active substances and / or flavorings.

[0041] 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.

[0042] 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 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.

[0043] 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 contain a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating film is substantially tobacco-free.

[0044] 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.

[0045] 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.

[0046] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual 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.

[0047] The aerosol-generating film may be formed by combining a binder such as a gelling agent with one or more other components such as a solvent such as water, an aerosol-forming agent, and one or more substances to be delivered to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film.

[0048] 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.

[0049] 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.

[0050] The amorphous solid does not need to contain substantially any plant-based material. The amorphous solid does not need to contain substantially any tobacco.

[0051] The recesses on the first and / or second surfaces can facilitate or increase the airflow through the aerosol-generating portion of an article incorporating the aerosol-generating material. This can improve the flavor delivered to the user of the delivery system. It can also reduce the pressure drop in the aerosol-generating material during use.

[0052] The aerosol-generating material may be in the form of a sheet, shredded sheet, gathered sheet, rod, or strand. The aerosol-generating material may also include or be in the form of elongated strips. Each sheet, shredded sheet, strand, and / or strip may include a first surface and a second surface, and recesses on the first surface and / or the second surface. The form of the aerosol-generating material can be selected to provide the user with an appropriate flavor and experience. For example, in embodiments including tobacco, some forms of the aerosol-generating material may be selected to provide an experience similar to that of tobacco. The form of the aerosol-generating material also affects the surface area-to-volume ratio, and thereby the flavor delivered to the user.

[0053] In some embodiments, the first and second surfaces may be on opposite sides of a sheet, shredded sheet, or elongated strip.

[0054] In some embodiments, the recess covers a portion of the first and / or second surface. The recess can cover up to about 10%, 25%, 50%, 75%, 90%, or 100% of the first and / or second surface by surface area. In some embodiments, the portion or region having the recess covers all of the first and second surfaces of the aerosol-generating material.

[0055] In some embodiments, the recesses on the surface may be sparsely distributed, while in other embodiments, the recesses on the surface may be densely concentrated. In some embodiments, the number of recesses is 1 cm 2 The number of recesses is approximately 1 to 2000, 5 to 1000, and 10 to 100 per unit area. In some embodiments, the number of recesses is 1 cm 2 Each piece contains approximately 100 to 500 or 200 to 300 pieces. 2 The number of indentations per unit area affects the airflow, filling, filling level, and flavor delivery of the aerosol-generating material.

[0056] In some embodiments, portions of the first and / or second surface include recesses. These recesses may be of any suitable size or shape and may form a pattern on the surface. For example, portions may form a “striped” pattern on the surface of the aerosol-generating material, with portions containing recesses adjacent to portions that do not contain such recesses. This offers the advantage that the pattern of the recesses can be controlled, potentially influencing airflow, pressure drop, and flavor delivery to the user, as described herein. The portions may also form other patterns that may be visually appealing.

[0057] It has been found that a similar pressure drop in an article can be achieved by replacing part or all of a given volume of aerosol-generating material with a lower mass of aerosol-generating material having the recesses described herein. Moreover, the hardness of the aerosol-generating material may be maintained even with these lower masses.

[0058] The recess may be of any suitable size and / or volume, but may be selected to provide the advantages described herein. The height, width, and length disclosed herein may be average height, width, and length, respectively.

[0059] In some embodiments, the recess has a length and a width. As used herein, the term “length of the recess” may be measured as the longest distance across the recess. As used herein, the term “width of the recess” refers to the dimension in the direction perpendicular to the length. In some embodiments, the length and width have ratios of about 1:0.25 to about 1:10, about 1:0.5 to about 1:5, about 1:0.75 to about 1:2, or about 1:1. For example, in embodiments where the recess has a substantially circular or square shape, the length and width of the recess may be substantially the same, and the length and width have a ratio of about 1:1.

[0060] In some embodiments, the length of the recess is from about 0.01 to about 5 mm, from about 0.1 to about 1 mm, or from about 0.5 to about 0.8 mm. In some embodiments, the length of the recess is from about 0.1 mm to about twice the thickness of the sheet. For example, if the thickness of the sheet is 0.2 mm, the length of the recess may be at most 0.4 mm. In some embodiments, the length of the recess is about 0.5 mm.

[0061] The recesses may have any suitable volume, but may be selected to provide the advantages described herein. The length and width of the recesses may be selected to provide a suitable volume. In some embodiments, each of the recesses has a volume of from about 0.00001 to about 10 mm 3 In some embodiments, the recesses have a volume of from about 0.001 to about 10 mm 3 , from 0.01 to about 1 mm 3 , from 0.01 to about 0.5 mm 3 In some embodiments, the recesses have a volume of from about 0.001 to about 10 mm, from 0.01 to about 1 mm, or from 0.01 to about 0.5 mm.

[0062] The greater the height and width (and thus the volume) of the recesses, the greater the air flow and pressure drop in the aerosol - generating material. This provides a more comfortable user experience when the aerosol - generating material is used in an article within the delivery system. Additionally, the fill value of the aerosol - generating material is increased and thereby improved. For example, the recesses can reduce the density of the aerosol - generating material, which means that the same mass of material occupies a larger volume. This is advantageous for the transport of the material and its filling into articles. It is also advantageous for the delivery system itself to have a higher fill value.

[0063] The "fill value" (also known as the "filling value") is a measure of the ability of a material to occupy a particular volume at a given moisture content. The fill value is measured using a densitometer, and the volume occupied by a unit weight of the material or composition is measured. A material with a high fill value indicates that the weight of material required to produce a rod having a given circumference, volume, and length at an acceptable hardness / stiffness level is less than that of a material with a low fill value.

[0064] In some embodiments, the aerosol-generating material may have a filling value of about 3 to about 8 cc / g, about 4 to about 8 g / cc, or about 4.5 to about 5.5 cc / g.

[0065] The present invention enjoys the further advantage that the recess does not affect the hardness, elasticity, softness, or weight of the aerosol-generating material. This means that the aerosol-generating material can be used in known non-flammable aerosol-generating devices without significantly modifying the device to accommodate the aerosol-generating material.

[0066] Figure 1 shows data from tests using materials A and B. Material A contained a sheet of extruded aerosol-generating composition. Material B contained an exemplary embodiment of the aerosol-generating material described herein, which included a recess on a first surface. Materials A and B were in sheet form, with a thickness of 160 μm and a surface density of 172 g / m². 2 Material A and Material B have the same composition, including a particle size distribution of approximately 70 μm (D90), and are otherwise identical except for the recesses. Figure 1 shows that the hardness, softness, and elasticity, measured in percentages, remain substantially the same.

[0067] 1 cm on aerosol-generating material 3 The number of recesses per unit area can be selected to obtain an advantage. 1cm 3 The number of indentations per unit area is 1 cm. 2 The number of recesses per unit may be approximately 1 to 1000, 100 to 500, 200 to 300, 1 to 100, 1 to 50, or 1 to 20.

[0068] 1cm 3The number and volume of recesses per unit area are known to affect the thickness of the aerosol-generating material. A larger number and volume of recesses may result in a thicker aerosol-generating material. In some embodiments, the recesses increase the thickness of the aerosol-generating material by about 10–40%, about 20–30%, or about 25% compared to the thickness of the aerosol-generating material before the recesses are imprinted. For example, in embodiments where the aerosol-generating material is in the form of a sheet, shredded sheet, or elongated strip, the average thickness may be about 160–190 μm before the recesses are imprinted and increase to about 200 μm after the recesses are imprinted. In another example, in embodiments where the aerosol-generating material is in the form of a sheet, shredded sheet, or elongated strip, the average thickness may be about 250 μm before the recesses are imprinted and increase to about 310 μm after the recesses are imprinted. In some embodiments, a larger number and volume of recesses are associated with a thicker sheet.

[0069] In some embodiments, the thickness of the aerosol material is approximately 100 μm to 350 μm, approximately 160 μm to 250 μm, approximately 160 μm to 200 μm, approximately 160 μm to approximately 310 μm, or approximately 280 μm to approximately 310 μm. The thickness can be measured using a hand caliper based on measurements taken from a piece of material.

[0070] As the thickness of the aerosol-generating material increases, the density of the material is expected to decrease. This is because the material has a larger volume but the same mass or weight. This is advantageous because the aerosol-generating material is lighter, which is beneficial for the transportation and storage of the material, and also beneficial for consumers because the articles filled with the aerosol-generating material may be lighter.

[0071] In some embodiments, the sheet or shredded sheet of aerosol-generating material is approximately 100 g / m². 2 ~about 300g / m 2 , or approximately 150-210 g / m 2 It has a surface density of approximately 110 g / m². The sheet or shredded sheet has a surface density of approximately 110 g / m². 2 ~about 280g / m 2 , about 120g / m2 ~about 260g / m 2 , about 130g / m 2 ~about 240g / m 2 Or approximately 140g / m 2 ~about 220g / m 2 It may have a surface density of approximately 190 g / m². In some embodiments, the sheet or shredded sheet may have a surface density of approximately 190 g / m². 2 It has a surface density.

[0072] 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 surface 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 ~about 0.8g / cm 3 , or approximately 0.5 g / cm³ 3 ~about 0.7g / cm 3 That is the case.

[0073] In some embodiments, the recess is a perforation. A perforation is when the recess forms a hole that penetrates the aerosol-generating material. This has the advantage of further increasing the airflow through the aerosol-generating material, thereby reducing pressure drop and suction resistance. Such perforations also further increase airflow and flavor delivery to the user.

[0074] In some embodiments, the aerosol-generating material comprises a mixture of both perforations and recesses on the first and / or second surface. The aerosol-generating material may contain perforations at a maximum of about 10%, about 20%, about 30%, about 40%, or about 50% compared to recesses on the first and / or second surface.

[0075] The perforations may have a diameter of approximately 0.01 to 1 mm. The perforations may also have a diameter of approximately 1 to 300 μm, approximately 10 to 100 μm, approximately 50 to 150 μm, or approximately 70 to 100 μm.

[0076] The present invention enjoys the advantage of an increased surface area-to-volume ratio compared to aerosol-generating materials without recesses. The surface area-to-volume ratio also increases with the amount, size, and shape of the recesses. This results in the advantage that a higher surface area-to-volume ratio leads to stronger and more sustained flavor delivery from the aerosol-generating material to the user.

[0077] The amount and size of recesses are known to affect the tensile strength of aerosol-generating materials. For example, too many recesses or recesses that are too large can reduce the tensile strength of the aerosol-generating material and potentially cause the material's structure to be lost. On the other hand, the amount and size of recesses must be sufficient to obtain the desired benefits. In some embodiments, the tensile strength of the aerosol-generating material is increased to accommodate a greater amount and / or larger size of recesses. For example, the amount of binder or filler can be adjusted as described herein.

[0078] In some embodiments, the aerosol-generating material has a tensile strength of about 1 to about 30 N / 15 mm, about 5 to about 20, about 8 to about 15, or about 9 to about 13 N / 15 mm. In some embodiments, the aerosol-generating material has a tensile strength greater than about 5 N / 15 mm. In some embodiments, the aerosol-generating material has a tensile strength of at least 3 N / 15 mm or at least 4 N / 15 mm.

[0079] In some embodiments in which the first and second surfaces include recesses, the number, density, size, or shape of the recesses may vary. This provides the advantage of being able to control the airflow when the aerosol-generating material is placed in the consumable.

[0080] On the other hand, in some embodiments, the recesses are of an appropriate size and shape to allow the aerosol-generating material to interlock. This is particularly advantageous in embodiments where the aerosol-generating material is in the form of shredded sheets and elongated strips. In such embodiments, a surface without recesses can be aligned with the recesses to allow the aerosol-generating material to interlock. This increases the filling of the aerosol-generating material and reduces airflow and pressure drop. The size, shape, and pattern of the recesses may also be selected to prevent the aerosol-generating material from interlocking.

[0081] 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 . A higher packing density may increase the pressure drop.

[0082] Packing density affects flavor delivery. As more aerosol-generating material is packed into the consumable, a stronger flavor may be delivered to the user. On the other hand, higher packing density reduces airflow, increasing pressure drop and user suction resistance.

[0083] The recesses may be of any suitable shape. In some embodiments, the shape is selected from the group consisting of circular, semicircular, crescent, square, triangular, Y-shaped, linear, rectangular, conical, or star-shaped. The shape can be selected to provide suitable airflow, pressure drop, and flavor delivery characteristics while maintaining appropriate tensile strength. For example, circular shapes have been found to provide particularly suitable parameters, including improved airflow and air permeability. They can be arranged closely together without gaps, which makes it possible to make the recesses more densely packed on the surface.

[0084] Figure 2 shows a magnified image of the first surface of an exemplary aerosol-generating material including a recess. In this exemplary embodiment, the shape of the recess is circular.

[0085] In some embodiments, the aerosol-generating material is formed from an aerosol-generating composition, which is then extruded. Aerosol-generating materials prepared in this way possess specific elastic properties that make them particularly suitable for imprinting recesses into the material. More specifically, such aerosol-generating materials retain their recesses for longer periods. In contrast, aerosol-generating materials formed using the band casting method have lower elasticity and retain their shape for a shorter period.

[0086] The duration for which the aerosol-generating material retains its recesses is also influenced by the content and particle size of water, binders, fillers, and plant materials in the aerosol-generating composition and / or aerosol-generating material. These can be selected to provide an aerosol-generating composition suitable for imprinting recesses, as well as to deliver a pleasant flavor to the user.

[0087] In some embodiments of the present invention, the aerosol-generating composition and / or aerosol-generating material comprises a binder. 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 comprises 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 comprises alginate and / or pectin or carrageenan. In some embodiments, the binder comprises CMC.

[0088] In some embodiments, the aerosol-generating composition and / or aerosol-generating material contains a binder content of 5 to about 40% by weight. In some embodiments, the aerosol-generating material and / or aerosol-generating composition may contain a binder content of about 5 to about 30% by weight, about 5 to about 20% by weight, about 5 to about 15% by weight, or about 5 to about 10% by weight.

[0089] In some embodiments, the aerosol-generating composition and / or 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.

[0090] 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 particulate plant-derived material or plant material.

[0091] In some embodiments, the plant material comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, wherein the plant substance is tobacco. In some embodiments, the aerosol-generating composition does not contain tobacco. In embodiments, the aerosol-generating composition may contain plant materials that do not contain tobacco, or plant materials that do not consist of tobacco. In such embodiments, the plant material may be selected to be a plant material other than tobacco, for consumer preference or for regulatory reasons. The plant material may be selected to provide a pleasant or desirable flavor to consumers.

[0092] In some embodiments, the plant material comprises or is derived from one or more plants or their components, derivatives, or extracts, and the plant material is selected from eucalyptus, star anise, cocoa, and hemp. In some embodiments, the plant material is selected from rooibos and fennel. Rooibos and tobacco may be preferred plant materials.

[0093] Alternatively, the material may include naturally occurring active compounds found in plant matter, obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, or the like.

[0094] 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, 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 uniformly mixed throughout the aerosol-generating material.

[0095] 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.

[0096] The aerosol-generating composition and / or aerosol-generating material may not contain substantially any plant-derived material. In particular, in some embodiments, the aerosol-generating composition and / or aerosol-generating material is substantially tobacco-free.

[0097] As used herein, the term “tobacco material” refers to any material including tobacco or its derivatives or substitutes. Tobacco material may be any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, extended tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of crushed tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco leaves, reconstituted tobacco, and / or tobacco extracts.

[0098] In some embodiments, the aerosol-generating composition and / or aerosol-generating material contains at least about 10% by weight of plant material. In some embodiments, the aerosol-generating material contains 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. The plant material content may be selected to provide the user with a positive flavor and to provide the aerosol-generating material with a suitable texture. The plant material content affects the elastic and tensile strength of the aerosol-generating material.

[0099] In some embodiments, the aerosol-generating composition and / or 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.

[0100] In some embodiments, the aerosol-generating composition and / or aerosol-generating material comprises 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-derived material.

[0101] For example, the plant material may be present in an amount of about 50%, 60%, 70%, 80%, or 90% by weight of the aerosol-generating composition and / or aerosol-generating material. The plant material may be present in an amount of about 50 to about 80% by weight of the aerosol-generating composition and / or aerosol-generating material.

[0102] The plant material may be in granular or granular form. In some embodiments, the plant material may be a powder or ground. Alternatively or additionally, the plant material may include tobacco strips, strands, or fibers. For example, the plant material may include particles, granules, fibers, strips, and / or strands of plant material. In some embodiments, the plant material consists of particles or granules of plant material. In some embodiments, the plant material is in granular or ground form to aid in the formation of a fabric-like material when the first and second compositions are combined.

[0103] 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 plant particle or any point on the particle surface to the same plant particle 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).

[0104] In some embodiments, the maximum size of each particle of the plant material is approximately 800 μm. In some embodiments, the maximum size of each particle of the plant material is approximately 2000 μm. In some embodiments, the maximum size of each particle of the plant material is approximately 200 μm to approximately 800 μm.

[0105] A collection of plant-derived particles may have a particle size distribution (D90) of at least about 70 μm. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of at least about 50 μm, at least about 60, at least about 70 μm, at least about 80 μm, at least about 90, at least about 100 μm, at least about 110 μm, at least about 120 μm, and at least about 130 μm. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of up to about 720 μm, up to about 740 μm, up to about 760 μm, up to about 780 μm, up to about 800 μm, up to about 820 μm, up to about 840 μm, and up to about 860 μm. In some embodiments, a collection of plant-derived particles may have a particle size distribution (D90) of about 600 μm. Particle size distribution can be measured using particle size and shape analyzers such as Camsizer, and the particle size distribution of plant materials can be determined using sieve analysis.

[0106] It has been found that the particle size distribution (D90) can be controlled to achieve a desired tensile strength in aerosol-generating materials. For example, a higher particle size distribution (D90) is associated with lower tensile strength. While we do not wish to be bound by this reason, a lower particle size distribution means that more material is bonded together. This allows for a stronger aerosol-generating material, and therefore a higher tensile strength. Thus, D90 can be used to optimize the tensile strength of aerosol-generating materials. This is particularly important because a larger and greater amount of recesses in the aerosol-generating material can reduce the tensile strength.

[0107] In some embodiments, the aerosol-generating material includes a filler. In some embodiments, the aerosol-generating material has a filler content of about 0% to about 20% by weight, about 1 to about 15% by weight, about 3 to about 10% by weight, or about 4 to about 6% by weight.

[0108] The filler is generally a non-plant component, i.e., a component that does not contain tobacco-derived inclusions 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 non-tobacco fibers such as wood fibers or pulp or wheat fibers. 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.

[0109] In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. While we do not wish to be bound by theory, it is thought that including a fibrous filler can increase the tensile strength of the aerosol-generating material formed. This is advantageous because it can balance the decrease in tensile strength caused by the depressions.

[0110] Fillers can also contribute to the texture of the aerosol-generating material. For example, fibrous fillers such as cellulose can result in an aerosol-generating material having relatively rough first and second surfaces. Conversely, non-fibrous granular fillers such as powdered chalk can result in an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material includes a combination of different filler materials. Fillers can help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0111] In some embodiments, the aerosol-generating material contains water. The aerosol-generating material may contain water in an amount of less than about 20% by weight, less than about 15% by weight, less than about 10% by weight, or less than about 5% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material contains water in an amount of about 0% to about 15% by weight or about 5% to about 15% by weight of the aerosol-generating material. The amount of water affects the texture and tensile strength of the material and can be selected to obtain properties appropriate for its usability.

[0112] 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.

[0113] In some embodiments, the aerosol-generating material contains flavor. In some embodiments, the aerosol-generating material may contain a flavor content of about 0 to about 20% by weight. The aerosol-generating material may have a flavor content of about 0 to about 20%, about 5 to about 20%, about 5 to about 15%, or about 8 to about 12%. The flavor content can be selected to deliver an appropriate flavor to the consumer without adversely affecting other properties of the material.

[0114] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.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, rye). 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-ylang 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, maji It may also contain other additives such as chollum, 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-derived substances, or breath fresheners.Flavors and flavorings may be imitation ingredients, synthetic ingredients, natural ingredients, or blends thereof. Flavors and flavorings may be in any suitable form, such as a liquid such as oil, a solid such as powder, or a gas.

[0115] 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.

[0116] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensory effects that are normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the aroma or taste nerves, and may include components that produce heating, cooling, tingling, or numbing effects. A suitable thermal agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0117] In some embodiments, the aerosol-generating material delivers a substance to the user. In some embodiments, this substance delivered to the user includes an active substance.

[0118] As used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, nutritional supplements, nootropics, and psychotropic substances. The active substance may be naturally occurring or obtained by synthesis. Examples of active substances include nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances. The active substance may be CBD or its derivatives.

[0119] In one embodiment, the active substance is a legally permissible recreational drug.

[0120] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0121] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0122] In some embodiments of the present invention, the aerosol-generating material does not contain tobacco. In such embodiments, the aerosol-generating material may include plant material or plant-derived substance or other substance delivered to the user.

[0123] In another aspect of the present invention, an article is provided for use in a non-combustible aerosol supply system comprising an aerosol generating unit containing an aerosol generating material.

[0124] Consumables or articles are articles containing or consisting of aerosol-generating materials, some or all of which are intended to be consumed during use by the user. An article 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. An article may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0125] The present invention offers the advantage that the aerosol-generating material provides an improved pressure drop across the aerosol-generating portion. Advantageously, the aerosol-generating material of the present invention may have a smaller mass for the same pressure drop compared to other aerosol-generating materials. Therefore, the aerosol-generating material may have a smaller mass while maintaining an appropriate pressure drop. This results in lighter weight of the article during use and storage. While we do not wish to be bound by any particular theory, the recess increases the airflow around the aerosol-generating material, thereby increasing the pressure drop in the aerosol-generating material and / or the portion containing the material.

[0126] In some embodiments, the pressure drop in the article is about 40 to about 120 mmWg, about 50 to about 90 mmWg, about 60 to about 80 mmWg, or about 30 to about 50 mmWg. The pressure drop can be measured between the upstream and downstream ends of the article. In some embodiments, the pressure drop in the article is greater than 35, about 40, about 50, about 60, or about 70 mmWg.

[0127] In some embodiments, the pressure drop in the aerosol generation section is approximately 100 to 500 mmWg, 150 to 300 mmWg, 180 to 250 mmWg, or 200 to 220 mmWg. In some embodiments, the pressure drop in the aerosol generation section is approximately 350 to 600 mmWg, 400 to 5800 mmWg, or 500 to 550 mmWg.

[0128] Figure 3 shows data from tests using materials A and B. Material A contained a sheet of extruded aerosol-generating composition. Material B contained an exemplary embodiment of the aerosol-generating material described herein, which included a recess on the first surface. Materials A and B were in sheet form, with a thickness of 160 μm and a surface density of 172 g / m². 2 Material A and Material B have the same composition, including a particle size distribution of approximately 70 μm (D90), and are otherwise identical except for the recesses. Figure 3 shows that when the material contains recesses, the pressure drop in the aerosol generation area is greater.

[0129] In some embodiments of the present invention, an article for use with a non-flammable aerosol supply system comprises an aerosol-generating material. In some embodiments, the article comprises two or more aerosol-generating materials. In such embodiments, the aerosol-generating material may have different recesses (or compositions) after the airflow passes through the article. This affects the flavor and pressure drop in the article delivered to the user.

[0130] Referring to Figures 4 and 5, Article 1 comprises a mouthpiece 2 and an aerosol generating unit 3 connected to the mouthpiece 2. In this example, the aerosol generating unit 3 contains an aerosol generating material. Article 1 comprises a downstream end 2b and an upstream end 2a located away from the downstream end 2b.

[0131] In some embodiments, the aerosol generating material described herein is supplied to the aerosol generating unit.

[0132] The pressure drop in the aerosol-generating section of an article containing an aerosol-generating material may be in the range of approximately 0.3 to 5 mmWG per 1 mm of length of the aerosol-generating section. The pressure drop may be in the range of 0.5 mmWG to 2 mmWG per 1 mm of length of the aerosol-generating section. For example, the pressure drop may be in the range of 0.5 to 1 mmWG / mm with respect to the length of the aerosol-generating section, in the range of 1 to 1.5 mmWG / mm with respect to the length, or in the range of 1.5 to 2 mmWG / mm with respect to the length.

[0133] The total pressure drop in an article may be, for example, in the range of 60 mmWG to 120 mmWG, or in the range of 70 mmWG to 110 mmWG.

[0134] It has been found that recesses are associated with an increase in pressure drop. That is, aerosol-generating materials can increase the pressure drop compared to articles containing aerosol-generating materials without recesses. This means that the mass of the aerosol-generating material can be reduced while maintaining a favorable pressure drop.

[0135] This improves pressure drop during use, which can increase the intensity and persistence of the resulting flavor. Furthermore, the pressure drop is related to suction resistance, which can potentially improve the consumer experience.

[0136] 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 in the aerosol generating section.

[0137] Another aspect of the present invention provides a method for producing an aerosol-generating material by imprinting depressions on the surface of the aerosol-generating material to form recesses.

[0138] 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. In some embodiments, the packaging material is paper, but it may be made of an alternative material such as aluminum.

[0139] 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 3. The mouthpiece 2 also, in this example, includes 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 at the mouthpiece end of the article 1.

[0140] The aerosol-generating material may be imprinted using any suitable means. Such means include, for example, rollers, presses, and stamps. Such a device may have a recessed shape embossed on at least one surface, and is used to imprint the shape onto the surface of the aerosol-generating material. In some embodiments in which the first and second surfaces include recesses, a single device can be used to imprint the recesses on the surfaces simultaneously. This has the advantage of imprinting the recesses in a shorter amount of time.

[0141] An exemplary rolling press is schematically shown in Figure 6. The rolling press 102 comprises two rollers 106. The rollers 106 are provided with a space 103 through which the material 101 moves, thereby imprinting recesses on the material.

[0142] The advantage of using rollers is that it is a continuous process, where the aerosol-generating material is fed to the rollers or rolling press, and a recess can be imprinted.

[0143] The rolling process also provides an aerosol-generating material with a certain thickness. This, along with the volume and shape of the recesses, affects the airflow and pressure drop.

[0144] In some embodiments, the aerosol-generating material is prepared from an aerosol-generating composition, which includes combining a first composition and a second composition to form a mixture of the first and second compositions, and processing the mixture of the first and second compositions to form the aerosol-generating material.

[0145] 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. The first composition may be a liquid phase.

[0146] The second composition, also known as the “dry mixture,” comprises tobacco material, fillers, 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.

[0147] The amount of binder in the first composition, the second composition, and the mixture of the first and second compositions is important because it changes the consistency of the compositions and mixtures. Too much binder may make the composition / mixture too viscous, making it impossible to process, for example, with pumps and machines.

[0148] The first and second compositions described herein can be mixed to obtain a mixture of the first and second compositions. The mixture of the first and second compositions may be formed by homogenizing the first and second compositions. The mixture of the first and second compositions may be in the form of a “dough”.

[0149] In some embodiments, the mixture is extruded before the recesses are imprinted to form an aerosol-generating composition. For example, the aerosol-generating composition may be extruded into the form of a sheet and then fed to a roller to imprint recesses on the first and / or second surfaces of the sheet to produce the described aerosol-generating material.

[0150] Extrusion involves supplying an aerosol-generating composition through an orifice to produce extruded aggregates. The process of applying pressure to the precursor composition in combination with shear force results in aggregated structures that may take the form of sheets.

[0151] Extrusion can be carried out using one of the main classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. Forming a sheet structure by extrusion has the advantage that this process combines mixing, conditioning, homogenization, and molding of a mixture of a first composition and a second composition.

[0152] In some embodiments, the method for producing the aerosol-generating material includes casting (e.g., band casting) or a papermaking process.

[0153] Other materials, such as bases, diluents, solid aerosol-forming agents, solid flavor modifiers, leavening agents, and other additives known in the art, can also be added during the extrusion process. This has the advantage that the additives are uniformly distributed throughout the aggregated structure that is formed.

[0154] In some embodiments, the aerosol-generating composition is extruded simultaneously, imprinting recesses. This offers the advantages of faster processing and a reduction in the amount of equipment required.

[0155] In some embodiments, the aerosol-generating material may be dried. For example, any suitable apparatus using air, infrared radiation, or microwaves can be used.

[0156] In some embodiments, the aerosol-generating material may be collected. This is a process of collecting the material together by passing it through a conical or funnel-shaped device.

[0157] In some embodiments, the aerosol-generating material is cut or sliced ​​to shorten its length.

[0158] In some embodiments, the aerosol-generating material may have a maximum length of about 34 mm. In some embodiments, the aerosol-generating material may have a maximum length of about 34, about 24, about 20, about 16, about 12, or about 10 mm. In some embodiments, the aerosol-generating material may have a minimum length of about 34, about 24, about 20, about 16, about 12, or about 10 mm. The length may be selected to fit the article and provide appropriate flavor delivery to the user.

[0159] In some embodiments, the aerosol-generating material may have a maximum width of about 2 mm. In some embodiments, the aerosol-generating material may have a maximum width of about 2 mm, about 1.4 mm, or about 1 mm. In such embodiments, the aerosol-generating material may be in the form of a sheet, shredded sheet, strand and / or strip. As used herein, the term “width of the aerosol-generating material” refers to a dimension in the direction perpendicular to the length. Aerosol-generating materials with a smaller width are associated with being more brittle, and therefore, aerosol-generating materials with a larger width are stronger. This can also negatively affect the uniformity of the pressure drop in the material. On the other hand, the material must have an appropriate width that is suitable for the article and easy to handle. It should also be noted that if the width of the aerosol-generating material is wide, the shape of the recess may be distorted, for example, it may have less roundness or circularity.

[0160] The width of the aerosol-generating material can be selected to match the pattern of the recesses, thereby allowing for optimal placement of the recesses on the material. The width of the aerosol-generating material may also be selected to suit the width and / or height of the recesses. Therefore, the width of the aerosol-generating material is 1 cm. 3 It can be selected to suit the number of recesses in the contact area.

[0161] In some embodiments, a method for producing an aerosol-generating material includes a combination of steps: extrusion, drying, collection, and / or cutting.

[0162] Figure 7 shows how an aerosol-generating material can be manufactured. 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 the next step, the first and second compositions are mixed and extruded to form a sheet of aerosol-generating material. Subsequently, recesses may be imprinted on the extruded mixture of the first and second compositions, and optionally dried. The sheet can then be cut and incorporated into articles for a non-flammable aerosol delivery system.

[0163] In some embodiments, the aerosol-generating material is imprinted immediately before an optional cutting step. This offers the advantage of minimizing deformation of the recesses. For example, since the imprinting step is in a later stage of the manufacturing process of the aerosol-generating material, the material requires little to no additional processing after the recesses have been imprinted.

[0164] 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 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 appropriately include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, processes, 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 comprising a first surface and a second surface, and a recess on the first surface and / or the second surface.

2. An aerosol-generating material comprising one or more elongated strips, each strip comprising a first surface and a second surface, and recesses on the first surface and / or the second surface.

3. an aerosol-generating material comprising a sheet, wherein the sheet comprises a first surface and a second surface, and recesses on the first surface and / or the second surface.

4. The aerosol generating material according to any one of claims 1 to 3, wherein the recess has a shape selected from the group consisting of a circle, a semicircle, a crescent shape, a square, a triangle, a Y-shape, a line, a rectangle, a cone, or a star shape.

5. The aerosol generating material according to any one of claims 1 to 4, wherein the recess includes a length and a width, and the average width of the recess is about 0.01 to about 5 mm.

6. The aerosol generating material according to any one of claims 1 to 5, wherein the recess has a length and a width, and the ratio of the length and the width is about 1:0.25 to about 1:

10.

7. The aerosol generating material according to claim 5 or 6, wherein the length of the aerosol generating material is a maximum of approximately 34 mm.

8. Each recess is approximately 0.00001 to 10 mm in size. ３ An aerosol generating material according to any one of claims 1 to 7, having a volume of the above.

9. The average volume density of the aerosol-generating material is approximately 0.4 g / cm³. ３ ~Approx. 1g / cm ３ The aerosol generating material according to any one of claims 1 to 8.

10. The aerosol generating material is cm ２ An aerosol generating material according to any one of claims 1 to 9, comprising approximately 100 to approximately 500 recesses per unit.

11. The aerosol generating material according to any one of claims 1 to 10, wherein the thickness of the aerosol generating material is approximately 100 μm to 350 μm.

12. The aerosol generating material according to any one of claims 1 to 11, wherein the thickness of the aerosol generating material is increased by about 10 to 40% compared to an equivalent material without the recess.

13. The aerosol generating material according to any one of claims 1 to 12, wherein the aerosol generating material has a tensile strength of at least 3 N / 15 mm.

14. The aerosol generating material according to any one of claims 1 to 13, wherein the aerosol generating material contains water, and optionally the aerosol water content is a maximum of about 15% by weight of the aerosol generating material.

15. The aerosol generating material according to any one of claims 1 to 14, wherein the aerosol generating material includes a plant material.

16. The aerosol generating material according to claim 15, wherein the aerosol generating material contains approximately 50 to approximately 80% by weight of plant-derived material.

17. The aerosol generating material according to any one of claims 1 to 16, wherein the aerosol generating material comprises at least one binder.

18. The aerosol generating material according to claim 17, wherein the aerosol generating material contains a binder content of 5 to about 40% by weight of the aerosol generating material.

19. The aerosol generating material according to any one of claims 1 to 18, wherein the aerosol generating material is in a form selected from the group consisting of a sheet, a shredded sheet, a gathered sheet, a rod, or a strand.

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

21. The article according to claim 20, wherein the article has a pressure drop of about 40 to about 120 mmWG between its upstream and downstream ends.

22. The article according to claim 20 or 21, wherein the article comprises an aerosol generating section, and the pressure drop in the aerosol generating section is 50 to about 500 mmWg.

23. A method for producing an aerosol-generating material according to any one of claims 1 to 19, comprising the steps of: forming an aerosol-generating material composition; imprinting depressions on the surface of the aerosol-generating composition to form recesses on the surface; and drying the aerosol-generating composition to form an aerosol-generating material including the recesses.

24. The method according to claim 23, wherein the aerosol generating material is prepared by extruding the aerosol generating composition.

25. An aerosol-generating material manufactured by the method described in either claim 23 or 24.

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