A novel aerosol-generating substrate containing Illicium spp.

Abstract

The aerosol-generating article (1000) (4000a, 4000b) (5000) comprises an aerosol-generating substrate (1020), the aerosol-generating substrate comprising a homogenized star anise material, the homogenized star anise material including star anise particles, an aerosol former, and a binder, the aerosol-generating substrate (1020) (4020a, 4020b) (5020) comprising, on a dry weight basis, at least 70 micrograms of (£)-anethole per gram of substrate, at least 50 micrograms of epoxyanethole per gram of substrate, and at least 130 micrograms of benzyl isoeugenol ether per gram of substrate.

Description

[Technical field]

[0001] The present invention relates to aerosol-generating substrates comprising homogenized plant material formed from star anise particles, and to aerosol-generating articles incorporating such aerosol-generating substrates. The present invention further relates to aerosols derived from aerosol-generating substrates comprising star anise particles. [Background technology]

[0002] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than combusted, are known in the art. Typically, in such articles, an aerosol is generated by transferring heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the substrate by heat transfer from the heat source and are entrained in the air drawn through the article. As the released compounds cool, they condense to form an aerosol.

[0003] Some aerosol-generating articles include flavorings that are delivered to the consumer during use of the article to provide the consumer with a different sensory experience, for example to enhance the flavor of the aerosol. Flavorings can be used to deliver a taste (flavor), an odor (smell), or both taste and odor to the user inhaling the aerosol. It is known to provide heated aerosol-generating articles that include flavorings.

[0004] It is also known to provide flavorants to conventional combustible cigarettes, which are smoked by lighting the end of the cigarette opposite the mouthpiece so that the tobacco rod burns to generate inhalable smoke. Typically, one or more flavorants are mixed with the tobacco in the tobacco rod to provide additional flavor to the mainstream smoke as the tobacco is burned. Such flavorants may be provided, for example, as essential oils.

[0005] Aerosols from conventional cigarettes contain many components that interact with receptors located in the mouth, providing a sensation of "body," or a relatively strong mouthfeel. "Mouthfeel," as used herein, refers to the physical sensation in the mouth caused by a food, beverage, or aerosol, and is distinct from taste. Mouthfeel, along with taste and odor, is a fundamental sensory attribute that determines the overall flavor of a food or aerosol.

[0006] There are difficulties in replicating the consumer experience provided by traditional combustible cigarettes with aerosol-generating articles in which the aerosol-generating substrate is heated rather than combusted, due in part to the cooler temperatures reached during heating of such aerosol-generating articles, which release a different profile of volatile compounds.

[0007] It is desirable to provide novel aerosol-generating substrates for heated aerosol-generating articles that provide aerosols with improved flavor and body. Such aerosol-generating substrates are particularly desirable if they can provide aerosols with a sensory experience comparable to that provided by conventional combustible cigarettes. Also, such aerosol-generating substrates are particularly desirable if they can provide aerosols with reduced levels of undesirable aerosol compounds compared to existing aerosol-generating substrates, such as those that contain only tobacco.

[0008] It would be further desirable to provide such an aerosol-generating substrate that can be easily incorporated into an aerosol-generating article and that can be manufactured using existing rapid methods and equipment. Summary of the Invention

[0009] The present disclosure relates to an aerosol-generating article comprising an aerosol-generating substrate, the aerosol-generating substrate being formed of a homogenized plant material comprising star anise particles, referred to as a "homogenized star anise material." The homogenized star anise material may further comprise an aerosol former. The homogenized star anise material may further comprise a binder. The aerosol-generating substrate may comprise at least about 70 micrograms of (E)-anethole per gram substrate, on a dry weight basis. The aerosol-generating substrate may comprise at least about 50 micrograms of epoxyanethole per gram substrate, on a dry weight basis. The aerosol-generating substrate may comprise at least about 130 micrograms of benzyl isoeugenol ether per gram substrate, on a dry weight basis.

[0010] According to the present invention, there is provided an aerosol-generating article comprising an aerosol-generating substrate, the aerosol-generating substrate comprising homogenized plant material including star anise particles. According to the present invention, the aerosol-generating substrate comprises at least about 70 micrograms of (E)-anethole per gram substrate on a dry weight basis, at least about 50 micrograms of epoxyanethole per gram substrate on a dry weight basis, and at least about 130 micrograms of benzyl isoeugenol ether per gram substrate on a dry weight basis.

[0011] According to the present invention, there is provided an aerosol-generating article comprising an aerosol-generating substrate, the aerosol-generating substrate being formed of a homogenized star anise material comprising star anise particles. According to the present invention, the homogenized star anise material comprises star anise particles, an aerosol former, and a binder. The aerosol-generating substrate comprises at least about 70 micrograms of (E)-anethole per gram substrate on a dry weight basis, at least about 50 micrograms of epoxyanethole per gram substrate on a dry weight basis, and at least about 130 micrograms of benzyl isoeugenol ether per gram substrate on a dry weight basis.

[0012] Upon heating of the aerosol-generating substrate of the aerosol-generating article according to the present invention by Test Method A described below, an aerosol is preferably generated that contains at least about 20 micrograms of (E)-anethole per gram substrate, on a dry weight basis, at least about 10 micrograms of epoxyanethole per gram substrate, on a dry weight basis, and at least about 3.5 micrograms of benzyl isoeugenol ether per gram substrate, on a dry weight basis. According to the present invention, the amount of (E)-anethole per gram substrate is no more than about 5 times the amount of epoxyanethole per gram substrate, and the amount of (E)-anethole per gram substrate is no more than about 10 times the amount of benzyl isoeugenol ether per gram substrate.

[0013] Upon heating the aerosol-generating substrate according to Test Method A, the aerosol generated from the aerosol-generating substrate comprises (E)-anethole in an amount of at least about 0.4 micrograms per aerosol puff, epoxyanethole in an amount of at least about 0.2 micrograms per aerosol puff, and benzyl isoeugenol ether in an amount of at least about 0.1 micrograms per aerosol puff, the aerosol puff preferably having a volume of 55 milliliters generated by a smoking machine. According to the present invention, the amount of (E)-anethole per puff is no more than about 5 times the amount of epoxyanethole per puff, and the amount of (E)-anethole per gram of homogenized plant material is no more than about 10 times the amount of benzyl isoeugenol ether per puff.

[0014] The present disclosure also relates to an aerosol-generating substrate formed of homogenized plant material including star anise particles, referred to herein as "homogenized star anise material." The homogenized star anise material may further comprise an aerosol former. The homogenized star anise material may further comprise a binder. The aerosol-generating substrate may comprise at least about 70 micrograms of (E)-anethole per gram of substrate, on a dry weight basis; at least about 50 micrograms of epoxyanethole per gram of substrate, on a dry weight basis; and at least about 130 micrograms of benzyl isoeugenol ether per gram of substrate, on a dry weight basis.

[0015] According to the present invention, there is also provided an aerosol-generating substrate formed from a homogenized star anise material, the homogenized star anise material comprising star anise particles, an aerosol former, and a binder. The aerosol-generating substrate comprises at least about 70 micrograms of (E)-anethole per gram substrate, on a dry weight basis, at least about 50 micrograms of epoxyanethole per gram substrate, on a dry weight basis, and at least about 130 micrograms of benzyl isoeugenol ether per gram substrate, on a dry weight basis.

[0016] The invention further provides an aerosol produced upon heating of an aerosol-generating substrate, the aerosol comprising (E)-anethole in an amount of at least about 0.4 micrograms per aerosol puff, epoxyanethole in an amount of at least about 0.2 micrograms per aerosol puff, and benzyl isoeugenol ether in an amount of at least about 0.1 micrograms per aerosol puff, the aerosol puff having a volume of 55 milliliters generated in a smoking machine of Test Method A. According to the invention, the amount of (E)-anethole per puff is no more than about 5 times the amount of epoxyanethole per puff, and the amount of (E)-anethole in the homogenized plant material is no more than about 10 times the amount of benzyl isoeugenol ether per puff.

[0017] The present invention further provides a method of making an aerosol-generating substrate comprising forming a slurry comprising star anise particles, water, an aerosol former, a binder, and optionally tobacco particles, casting or extruding the slurry in the form of a sheet or strand, and drying the sheet or strand, preferably at a temperature of from 80° C. to 160° C. If a sheet of the aerosol-generating substrate is formed, the sheet may optionally be cut into strands or the sheet may be assembled to form a rod. The sheet may optionally be crimped prior to the assembly step.

[0018] The following references to aerosol-generating substrates and aerosols of the invention are considered to be applicable to all aspects of the invention, unless otherwise indicated.

[0019] As used herein, the term "aerosol-generating article" refers to an article for generating an aerosol, where the article comprises an aerosol-generating substrate suitable and intended to be heated or burned to release volatile compounds capable of forming an aerosol. A conventional cigarette is ignited when a user applies a flame to one end of the cigarette and draws air through the other end. The localized heat provided by the flame and the oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion generates inhalable smoke. In contrast, in a "heated aerosol-generating article", the aerosol is generated by heating the aerosol-generating substrate, rather than by burning the aerosol-generating substrate. Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which the aerosol is generated by transferring heat from a combustible fuel element or heat source to a physically separated aerosol-generating substrate.

[0020] Also known are aerosol-generating articles adapted for use in aerosol-generating systems that supply aerosol formers to the aerosol-generating article, where the aerosol-generating substrate in the aerosol-generating article contains substantially less aerosol former relative to the aerosol-generating substrate that carries and provides substantially all of the aerosol formers used to form the aerosol during operation.

[0021] The term "aerosol-generating substrate" as used herein refers to a substrate capable of generating, upon heating, volatile compounds capable of forming an aerosol. The aerosol generated from an aerosol-generating substrate may or may not be visible to the human eye and may include vapor (e.g., gaseous fine particles of a substance that is normally a liquid or solid at room temperature), as well as gas and liquid droplets of condensed vapor.

[0022] The term "homogenized plant material" as used herein includes any plant material formed by agglomeration of plant particles. For example, a sheet or web of homogenized plant material for the aerosol-generating substrate of the present invention may be formed by agglomerating particles of star anise plant material and, optionally, plant material obtained by grinding, crushing, or comminuting tobacco material, such as tobacco blades or tobacco stems. The homogenized plant material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0023] As used herein, the term "homogenized star anise material" refers to homogenized plant material containing star anise particles, optionally in combination with tobacco particles. The term "homogenized tobacco material" refers to homogenized plant material containing tobacco particles but not containing star anise particles, and is therefore not in accordance with the present invention.

[0024] The term "star anise particles" as used herein encompasses particles derived from the dried fruit of plants of the Illicium genus, preferably from Illicium vulgare (Illicaceae).

[0025] In contrast, star anise essential oil is a distillate and (E)-anethole is a compound derived from star anise. They are not considered star anise particles and are not included in the percentage of particulate plant material.

[0026] The present invention provides an aerosol-generating article incorporating an aerosol-generating substrate formed of homogenized plant material containing star anise particles, referred to herein as "homogenized star anise material". The present invention also provides an aerosol derived from such an aerosol-generating substrate. The inventors of the present invention have found that by incorporating star anise particles into an aerosol-generating substrate, an aerosol can be produced that advantageously provides a novel sensory experience. Such an aerosol can provide a unique flavour and an enhanced level of body.

[0027] Furthermore, the inventors have found that it is possible to produce an aerosol with an advantageously improved star anise aroma and flavor, as compared to aerosols produced by the addition of star anise additives such as star anise oil. Star anise oil is distilled from the leaves, fruits and seeds of the star anise tree and has a different flavorant composition than star anise particles, possibly due to the distillation process which may selectively remove or retain certain flavorants. Furthermore, in certain aerosol-generating substrates provided herein, star anise particles are incorporated at a level sufficient to provide a desirable star anise flavor, while retaining sufficient tobacco material to provide a desirable level of nicotine to the consumer.

[0028] Moreover, it has surprisingly been found that the inclusion of star anise particles in an aerosol-generating substrate provides a significant reduction in certain undesirable aerosol compounds compared to aerosols produced from an aerosol-generating substrate comprising 100 percent tobacco particles, without the star anise particles.

[0029] The flavor released by star anise is due to the presence of one or more volatile flavorants that are vaporized upon heating and transmitted to the aerosol. (E)-anethole ((E)-1-methoxy-4-(1-propenyl)benzene, chemical formula: C 10 H 12 Star anise essential oil (Chemical Abstracts Service Registry Number 25679-28-1) typically constitutes about 80% to about 90% by mass of star anise essential oil (Chemical Abstracts Service Registry Number 8007-70-3).

[0030] The presence of star anise in homogenized plant material (such as cast leaves) can be reliably identified by DNA barcoding. Methods for performing DNA barcoding based on the nuclear genes ITS2, rbcL and matK lineages, and the plastid intergenic spacer trnH-psbA are known in the art and can be used (Chen S, Yao H, Han J, Liu C, Song J, et al. (2010) Validation of the ITS2 Region as a Novel DNA Barcode for Identifying Medicinal Plant Species. PLoSONE 5(1): e8613; Hollingsworth PM, Graham SW, Little DP (2011) Choosing and Using a Plant DNA Barcode. PLoS ONE 6(5): e19254).

[0031] The inventors have carried out a complex analysis and characterization of the aerosols generated from the aerosol-generating substrate of the present invention incorporating star anise particles and mixtures of star anise particles and tobacco particles, and a comparison of such aerosols with aerosols generated from existing aerosol-generating substrates formed from tobacco material without star anise particles. Based on this, the inventors have been able to identify a group of "signature compounds" present in the aerosols, which are compounds originating from star anise particles. Thus, detection of the characteristic compounds within a specific range of weight percentages in the aerosol can be used to identify aerosols originating from aerosol-generating substrates containing star anise particles. These characteristic compounds are notably absent in aerosols generated from tobacco material. Moreover, the proportions of the characteristic compounds in the aerosols and the ratios of the characteristic compounds to each other clearly indicate the use of star anise plant material, rather than star anise oil. Similarly, the presence of these characteristic compounds in a specific percentage in the aerosol-generating substrate indicates the inclusion of star anise particles in the substrate.

[0032] In particular, the defined levels of the characteristic compounds in the substrate and aerosol are specific for the star anise particles present in the homogenized star anise material. The level of each of the characteristic compounds depends on the way in which the star anise particles have been treated during the manufacture of the homogenized star anise material. The levels also depend on the composition of the homogenized star anise material and may in particular be influenced by the levels of other components in the homogenized star anise material. The level of the characteristic compounds in the homogenized star anise material may differ from the level of the same compounds in the starting star anise material. It may also differ from the level of the characteristic compounds in a material containing star anise particles but not according to the invention as defined herein.

[0033] To perform aerosol characterization, the inventors used a complementary non-targeted differential screening (NTDS) using liquid chromatography coupled to a high-resolution accurate mass spectrometer (LC-HRAM-MS) in parallel with two-dimensional gas chromatography coupled to a time-of-flight mass spectrometer (GCxGC-TOFMS).

[0034] Non-targeted screening (NTS) is an important method to characterize the chemical composition of complex matrices, either by matching the features of unknown detected compounds to spectral databases (suspect screening [SSA]) or by elucidating unknown structures in the absence of prior knowledge matches, for example, using primary fragmentation (MS / MS) derived information matching in silico predicted fragments from compound databases (non-targeted analysis [NTA]). NTS allows for simultaneous measurements and the ability to semi-quantitate a large number of small molecules from a sample using an unbiased approach.

[0035] As mentioned above, non-targeted differential screening (NTDS) can be performed when focusing on the comparison of two or more aerosol samples to assess in an uncontrolled way significant differences in the chemical composition between the samples or when prior knowledge related groups are available between the sample groups. A complementary differential screening using liquid chromatography coupled to a high resolution accurate mass spectrometer (LC-HRAM-MS) in parallel with two-dimensional gas chromatography coupled to a time-of-flight mass spectrometer (GCxGC-TOFMS) is applied to ensure comprehensive analytical coverage to identify the most relevant differences in aerosols between an article containing 100% by weight star anise as particulate plant material and an article containing 100% by weight tobacco as particulate plant material.

[0036] The aerosol was generated and collected using the apparatus and methods described in detail below.

[0037] LC-HRAM-MS analysis was performed using a Thermo QExactive™ high-resolution mass spectrometer in both full scan and data-dependent modes. Thus, three different methods were applied to cover a wide range of materials with different ionization properties and compound classes. Samples were analyzed using heated electrospray ionization (HESI) in positive and negative modes, and RP chromatography with atmospheric pressure chemical ionization (APCI) in positive mode. The methods are: Arndt, D. et al, “In depth characterization of chemical differences between heat-not-burn tobacco products and cigarettes using LC-HRAM-MS-based non-targeted differential screening” (DOI:10.13140 / RG.2.2.11752.16643), Wachsmuth, C. et al, “Comprehensive chemical characterization of complex matrices through integration of multiple analytical modes and databases for LC-HRAM-MS-based non-targeted screening” (DOI:10.13140 / RG.2.2.12701.61927) and “Buchholz, C. et al, “Increasing confidence for compound identification by fragmentation database and in silico fragmentation comparison with LC-HRAM-MS-based non-targeted screening of complex matrices” (DOI:10.13140 / RG.2.2.17944.49927) (all from the 66th ASMS Conference on Mass Spectrometry and Allied Topics, San Diego, USA (2018)).The method is further described in: Arndt, D. et al, “A complex matrix characterization approach, applied to sicachine moke, that integration multiple analysis methods and compound identification strategies for non-targeted liquid chromatography with high-resolution mass spectrometry” (DOI: 10.1002 / rcm.8571).

[0038] GCxGC-TOFMS analyses were performed in three different ways for non-polar, polar, or highly volatile compounds in the aerosol using an Agilent GC Model 6890A or 7890A instrument equipped with an automatic liquid injector (Model 7683B) and a thermal modulator coupled to a LECO Pegasus 4D™ mass spectrometer. The methods are described in: Almstetter et al., “Non-targeted screening using GC×GC-TOFMS for in-depth chemical characterization of aerosol from a heat-not-burn tobacco product” (DOI:10.13140 / RG.2.2.36010.31688 / 1), and Almstetter et al., “Non-targeted differential screening of complex matrices using GC×GC-TOFMS for comprehensive characterization of the chemical composition and determination of significant differences” (DOI:10.13140 / RG.2.2.32692.55680) (66th and 64th ASMS Conferences on Mass Spectrometry and Allied Topics, San Diego, USA, respectively).

[0039] Results from the analytical method provided information on the main compounds responsible for the differences in the aerosols generated by these articles. The untargeted differential screening using both analytical platforms LC-HRAM-MS and GCxGC-TOFMS was focused on compounds that were present in higher amounts in the aerosols of samples of aerosol-generating substrates according to the invention containing 100 percent star anise particles versus a comparison sample of aerosol-generating substrates containing 100 percent tobacco particles. The NTDS method is described in the literature listed above.

[0040] Based on this information, the inventors were able to identify certain compounds in the aerosol that may be considered "signature compounds" derived from star anise particles in the substrate. Signature compounds specific to star anise include, but are not limited to, (E)-anethole, epoxyanethole, and benzyl isoeugenol ether. For purposes of the present invention, targeted screening may be performed on samples of the aerosol-generating substrate to identify the presence and amount of each of the signature compounds in the substrate. Such targeted screening methods are described below. As described, signature compounds may be detected and measured in both the aerosol-generating substrate and in the aerosol derived from the aerosol-generating substrate.

[0041] As defined above, the aerosol-generating article of the present invention comprises an aerosol-generating substrate formed of homogenized star anise material containing star anise particles. As a result of the inclusion of star anise particles, the aerosol-generating substrate contains a specific proportion of star anise "characteristic compounds" as described above. In particular, the aerosol-generating substrate contains, on a dry weight basis, at least about 70 micrograms of (E)-anethole per gram substrate, at least about 50 micrograms of epoxyanethole per gram substrate, and at least about 130 micrograms of benzyl isoeugenol ether per gram substrate.

[0042] By defining the aerosol-generating substrate for a desired level of the characteristic compound, it is possible to ensure consistency between products despite potential differences in the levels of the characteristic compound in the raw materials, which advantageously allows for more effective control of product quality.

[0043] The aerosol-generating substrate preferably contains at least about 0.75 mg (E)-anethole per gram of substrate, more preferably at least about 1.5 mg (E)-anethole per gram of substrate, on a dry weight basis. Alternatively or additionally, the aerosol-generating substrate preferably contains no more than about 3 mg (E)-anethole per gram of substrate, more preferably no more than about 2.5 mg (E)-anethole per gram of substrate, and more preferably no more than about 2.2 mg (E)-anethole per gram of substrate. For example, the aerosol-generating substrate may contain from about 70 micrograms to about 3 mg (E)-anethole per gram of substrate, or from about 0.75 mg to about 2.5 mg (E)-anethole per gram of substrate, or from about 1.5 mg to about 2.2 mg (E)-anethole per gram of substrate, on a dry weight basis.

[0044] The aerosol-generating substrate preferably contains at least about 0.75 mg of epoxy anethole per gram of substrate, more preferably at least about 1.5 mg of epoxy anethole per gram of substrate, on a dry weight basis. Alternatively or additionally, the aerosol-generating substrate preferably contains no more than about 3 mg of epoxy anethole per gram of substrate, more preferably no more than about 2.5 mg of epoxy anethole per gram of substrate, and more preferably no more than about 2 mg of epoxy anethole per gram of substrate. For example, the aerosol-generating substrate may contain, on a dry weight basis, about 50 micrograms to about 3 mg of epoxy anethole per gram of substrate, or about 0.75 mg to about 2.5 mg of epoxy anethole per gram of substrate, or about 1.5 mg to about 2 mg of epoxy anethole per gram of substrate.

[0045] The aerosol-generating substrate preferably contains at least about 1 mg of benzyl isoeugenol ether per gram of substrate, more preferably at least about 2 mg of benzyl isoeugenol ether per gram of substrate, on a dry weight basis. Alternatively or additionally, the aerosol-generating substrate preferably contains no more than about 5 mg of benzyl isoeugenol ether per gram of substrate, more preferably no more than about 4.5 mg of benzyl isoeugenol ether per gram of substrate, and more preferably no more than about 4 mg of benzyl isoeugenol ether per gram of substrate. For example, the aerosol-generating substrate may contain, on a dry weight basis, about 130 micrograms to about 5 mg of benzyl isoeugenol ether per gram of substrate, or about 1 mg to about 4.5 mg of benzyl isoeugenol ether per gram of substrate, or about 2 mg to about 4 mg of benzyl isoeugenol ether per gram of substrate.

[0046] The ratio of characteristic compounds in the aerosol-generating substrate is preferably such that the amount of (E)-anethole per gram of substrate is not more than 5 times the amount of epoxyanethole per gram of substrate, and more preferably is not more than 3 times the amount of epoxyanethole per gram of substrate, on a dry weight basis. This ratio of (E)-anethole to epoxyanethole is significantly lower than the corresponding ratio in star anise oil, and is characteristic of the inclusion of star anise particles in the aerosol-generating substrate. In contrast, star anise oil typically contains no more than trace amounts of epoxyanethole and a relatively high proportion of (E)-anethole.

[0047] Alternatively or additionally, the amount of benzyl isoeugenol ether per gram of substrate is preferably at least 1.5 times the amount of (E)-anethole per gram of substrate, and preferably at least 1.75 times the amount of (E)-anethole per gram of substrate, on a dry weight basis. The presence of benzyl isoeugenol ether at a level higher than (E)-anethole is characteristic of the inclusion of star anise particles. In contrast, star anise oil typically contains no more than trace amounts of benzyl isoeugenol ether and a relatively high proportion of (E)-anethole.

[0048] As defined above, the present invention also provides an aerosol-generating article comprising an aerosol-generating substrate formed from homogenised plant material comprising star anise particles, wherein upon heating of the aerosol-generating substrate an aerosol is generated comprising the "characteristic compounds" of star anise.

[0049] For purposes of the present invention, the aerosol-generating substrate is heated in accordance with "Test Method A." In Test Method A, an aerosol-generating article incorporating the aerosol-generating substrate is heated in a Tobacco Heating System 2.2 Holder (THS2.2 Holder) under Health Canada's mechanical smoking regime. For purposes of carrying out Test Method A, the aerosol-generating substrate is provided in an aerosol-generating article that is compatible with a THS2.2 holder.

[0050] The Tobacco Heating System 2.2 Holder (THS2.2 Holder) corresponds to the commercially available iQOS device (Philip Morris Products SA, Switzerland) described in Smith et al., 2016, Regul. Toxicol. Pharmacol. 81(S2)S82-S92. Aerosol-generating articles for use with the IQOS device are also commercially available.

[0051] The Health Canada smoking regimen is a clearly defined and accepted smoking protocol in Health Canada's Tobacco Product Information Regulations 2000, SOR / 2000-273, Schedule 2 (published by the Canadian Ministry of Justice). The test method is described in ISO / TR 19478-1:2014. In the Health Canada smoking test, aerosol is collected from a sample aerosol-generating substrate over 12 puffs with a puff volume of 55 millimeters, a puff duration of 2 seconds, and a 30 second interval between puffs, with all ventilation shut off, if any.

[0052] Thus, in the context of the present invention, the expression "involving heating of an aerosol-generating substrate in accordance with Test Method A" means heating of the aerosol-generating substrate in a THS2.2 holder under the Health Canada Tobacco Product Information Regulations 2000, SOR / 2000-273, Schedule 2 (published by the Canadian Department of Justice), Health Canada's mechanical smoking regimen, which test method is described in ISO / TR 19478-1:2014.

[0053] For analytical purposes, the aerosol generated from heating the aerosol-generating substrate is confined using an appropriate device, depending on the analytical method being used.

[0054] In a suitable method to generate samples for analysis by LC-HRAM-MS, the particulate phase is trapped using a conditioned 44 mm Cambridge glass fiber filter pad (compliant with ISO 3308) and filter holder (compliant with ISO 4387 and ISO 3308). The remaining gas phase is collected downstream from the filter pad using two successive microimpingers (20 mL) each containing methanol and an internal standard (ISTD) solution (10 mL), maintained at -60 degrees Celsius using a mixture of dry ice and isopropanol. The trapped particulate and gas phases are then recombined and extracted from the microimpingers with methanol by shaking the sample, stirring for 5 min and centrifuging (4500 g, 5 min, 10 degrees Celsius). The resulting extract is diluted with methanol and mixed in an Eppendorf ThermoMixer (5 degrees Celsius, 2000 rpm). Test samples from the extracts are analyzed by LC-HRAM-MS in a combination of full scan and data-dependent fragmentation modes to identify characteristic compounds. For the purposes of the present invention, LC-HRAM-MS analysis is suitable for the identification and quantification of (E)-anethole, epoxyanethole, and benzyl isoeugenol ether.

[0055] Samples for analysis by GCxGC-TOFMS can be generated in a similar manner, however, for GCxGC-TOFMS analysis, different solvents are appropriate for extraction and analysis of polar, non-polar, and volatile compounds separated from the bulk aerosol.

[0056] For non-polar and polar compounds, the whole aerosol is collected using a calibrated 44 mm Cambridge glass fiber filter pad (compliant with ISO 3308) and filter holder (compliant with ISO 4387 and ISO 3308) followed by two micro-impingers connected in series and sealed. Each micro-impinger (20 mL) contains 10 mL of dichloromethane / methanol (80:20 v / v) containing internal standard (ISTD) and retention index marker (RIM) compounds. The micro-impingers are maintained at -80 degrees Celsius using a mixture of dry ice and isopropanol. For the analysis of non-polar compounds, the particulate phase of the whole aerosol is extracted from the glass fiber filter pad using the contents of the micro-impinger. Water is added to an aliquot (10 mL) of the resulting extract and the sample is shaken and centrifuged as described above. The dichloromethane layer is separated, dried over sodium sulfate and analyzed by GCxGC-TOFMS in full scan mode. For the analysis of polar compounds, use the remaining aqueous layer from the non-polar sample preparation described above. ISTD and RIM compounds are added to the aqueous layer, which is then directly analyzed by GCxGC-TOFMS in full scan mode.

[0057] For volatile compounds, the entire aerosol is collected using two serially connected and sealed microimpingers (20 mL), filled with 10 mL of N,N-dimethylformamide containing ISTD and RIM compounds, respectively. The microimpingers are maintained at -50 to -60 degrees Celsius using a mixture of dry ice and isopropanol. After collection, the contents of the two microimpingers are combined and analyzed by GCxGC-TOFMS in full scan mode.

[0058] For the purposes of the present invention, GCxGC-TOFMS analysis is suitable for the identification and quantification of (E)-anethole.

[0059] The aerosol generated upon heating of an aerosol-generating substrate according to the present invention by Test Method A is characterized by the amounts and ratios of the characteristic compounds, (E)-anethole, epoxyanethole, and benzyl isoeugenol ether, as defined above.

[0060] Preferably, in an aerosol-generating article comprising the above-mentioned aerosol-generating substrate, upon heating of the aerosol-generating substrate by Test Method A, an aerosol is generated comprising, on a dry weight basis, at least 20 micrograms of (E)-anethole per gram of aerosol-generating substrate, at least 10 micrograms of epoxyanethole per gram of aerosol-generating substrate, and at least 3.5 micrograms of benzyl isoeugenol ether per gram of aerosol-generating substrate.

[0061] The ranges define the amount of each of the characteristic compounds in the generated aerosol per gram of aerosol-generating substrate (also referred to herein as "substrate"), which is equal to the total amount of the characteristic compound measured in the aerosol collected during Test Method A divided by the dry weight of the aerosol-generating substrate before heating.

[0062] Upon heating of an aerosol-generating substrate according to the present invention by Test Method A, an aerosol is generated that preferably comprises at least about 100 micrograms of (E)-anethole per gram of substrate, more preferably at least about 300 micrograms of (E)-anethole per gram of substrate. Alternatively, or additionally, the aerosol generated from the aerosol-generating substrate comprises at most about 750 micrograms of (E)-anethole per gram of substrate, preferably at most about 650 micrograms of (E)-anethole per gram of substrate, more preferably at most about 600 micrograms of (E)-anethole per gram of substrate. For example, the aerosol generated from the aerosol-generating substrate may contain from about 20 micrograms to about 750 micrograms of (E)-anethole per gram of substrate, or from about 100 micrograms to about 650 micrograms of (E)-anethole per gram of substrate, or from about 300 micrograms to about 600 micrograms of (E)-anethole per gram of substrate.

[0063] Upon heating the aerosol-generating substrate according to the present invention by Test Method A, an aerosol is generated that preferably contains at least about 100 micrograms of epoxy anethole per gram of substrate, more preferably at least about 200 micrograms of epoxy anethole per gram of substrate. Alternatively or additionally, the aerosol generated from the aerosol-generating substrate contains at most about 400 micrograms of epoxy anethole per gram of substrate, preferably at most about 350 micrograms of epoxy anethole per gram of substrate, more preferably at most about 300 micrograms of epoxy anethole per gram of substrate. For example, the aerosol generated from the aerosol-generating substrate may contain from about 10 micrograms to about 400 micrograms of epoxy anethole per gram of substrate, or from about 100 micrograms to about 350 micrograms of epoxy anethole per gram of substrate, or from about 200 micrograms to about 300 micrograms of epoxy anethole per gram of substrate.

[0064] Upon heating of an aerosol-generating substrate according to the present invention in accordance with Test Method A, an aerosol is generated which preferably comprises at least about 50 micrograms of benzyl isoeugenol ether per gram of substrate, more preferably at least about 100 micrograms of benzyl isoeugenol ether per gram of substrate. Alternatively or additionally, the aerosol generated from the aerosol-generating substrate comprises at most about 250 micrograms of benzyl isoeugenol ether per gram of substrate, preferably at most about 200 micrograms of benzyl isoeugenol ether per gram of substrate, more preferably at most about 150 micrograms of benzyl isoeugenol ether per gram of substrate. For example, the aerosol generated from the aerosol-generating substrate may contain from about 3.5 micrograms to about 250 micrograms of benzyl isoeugenol ether per gram of substrate, or from about 50 micrograms to about 200 micrograms of benzyl isoeugenol ether per gram of substrate, or from about 100 micrograms to about 150 micrograms of benzyl isoeugenol ether per gram of substrate.

[0065] In accordance with the present invention, the aerosol generated from the aerosol-generating substrate during Test Method A has an amount of (E)-anethole per gram of substrate that is no more than five times the amount of epoxyanethole per gram of substrate. Thus, the ratio of (E)-anethole to epoxyanethole is no more than 5:1.

[0066] Preferably, the amount of (E)-anethole per gram of substrate is no more than 3 times the amount of epoxyanethole per gram of substrate, such that the ratio of (E)-anethole to epoxyanethole is no more than 3:1. More preferably, the amount of (E)-anethole per gram of substrate is no more than 2.5 times the amount of epoxyanethole per gram of substrate, such that the ratio of (E)-anethole to epoxyanethole is no more than 2.5:1.

[0067] The aerosol generated from the aerosol-generating substrate during Test Method A preferably has an amount of (E)-anethole per gram of substrate that is 10 times or less than the amount of benzyl isoeugenol ether per gram of substrate. Thus, the ratio of (E)-anethole to benzyl isoeugenol ether is 10:1 or less.

[0068] Preferably, the amount of (E)-anethole per gram of substrate is 8 times or less than the amount of benzyl isoeugenol ether per gram of substrate, such that the ratio of (E)-anethole to benzyl isoeugenol ether is 8:1 or less. More preferably, the amount of (E)-anethole per gram of substrate is 6 times or less than the amount of benzyl isoeugenol ether per gram of substrate, such that the ratio of (E)-anethole to benzyl isoeugenol ether is 6:1 or less.

[0069] The ratio of epoxyanethole to benzyl isoeugenol ether in the aerosol is preferably about 4:1 to 1:1.

[0070] Defined ratios of (E)-anethole to epoxyanethole and benzyl isoeugenol ether characterize aerosols derived from star anise particles. In contrast, in aerosols generated from star anise oil, the ratios of (E)-anethole to epoxyanethole and of (E)-anethole to benzyl isoeugenol ether can differ significantly. This is due to the relatively high proportion of (E)-anethole in star anise oil compared to star anise plant material. The levels of the other characteristic compounds in star anise oil, epoxyanethole and benzyl isoeugenol ether, are zero or near zero.

[0071] The aerosol generated from the aerosol-generating substrate of the present invention during Test Method A preferably contains at least about 0.1 micrograms of nicotine per gram of substrate, more preferably at least about 1 microgram of nicotine per gram of substrate, and more preferably at least about 2 micrograms of nicotine per gram of substrate. The aerosol preferably contains at most about 10 micrograms of nicotine per gram of substrate, more preferably at most about 7.5 micrograms of nicotine per gram of substrate, and more preferably at most about 4 micrograms of nicotine per gram of substrate. For example, the aerosol may contain from about 0.1 micrograms to about 10 micrograms of nicotine per gram of substrate, or from about 1 microgram to about 7.5 micrograms of nicotine per gram of substrate, or from about 2 micrograms to about 4 micrograms of nicotine per gram of substrate. In some embodiments of the present invention, the aerosol may contain zero micrograms of nicotine.

[0072] Various methods known in the art can be applied to measure the amount of nicotine in the aerosol.

[0073] Alternatively or additionally, the aerosol generated from the aerosol-generating substrate according to the present invention during Test Method A may optionally further comprise at least about 20 milligrams of cannabinoid compound per gram of substrate, more preferably at least about 50 milligrams of cannabinoid compound per gram of substrate, more preferably at least about 100 milligrams of cannabinoid compound per gram of substrate. Preferably, the aerosol comprises at most about 250 milligrams of cannabinoid compound per gram of substrate, more preferably at most about 200 milligrams of cannabinoid compound per gram of substrate, and more preferably at most about 150 milligrams of cannabinoid compound per gram of substrate. For example, the aerosol may comprise from about 20 milligrams to about 250 milligrams of cannabinoid compound per gram of substrate, or from about 50 milligrams to about 200 milligrams of cannabinoid compound per gram of substrate, or from about 100 milligrams to about 150 milligrams of cannabinoid compound per gram of substrate. In some embodiments of the invention, the aerosol may contain zero micrograms of cannabinoid compound.

[0074] Preferably the cannabinoid compound is selected from CBD and THC, more preferably the cannabinoid compound is CBD.

[0075] Various methods known in the art can be applied to measure the amount of cannabinoid compounds in the aerosol.

[0076] Carbon monoxide may also be present in the aerosol generated from an aerosol-generating substrate according to the invention during Test Method A, and can be measured and used to further characterize the aerosol. Oxides of nitrogen, such as nitric oxide and nitrogen dioxide, may also be present in the aerosol, and can be measured and used to further characterize the aerosol.

[0077] The aerosol generated from the aerosol-generating substrate of the present invention during Test Method A may further comprise at least about 5 milligrams of aerosol former per gram of aerosol-generating substrate, or at least about 10 milligrams of aerosol per gram of substrate, or at least about 15 milligrams of aerosol former per gram of substrate. Alternatively, or additionally, the aerosol may comprise up to about 30 milligrams of aerosol former per gram of substrate, or up to about 25 milligrams of aerosol former per gram of substrate, or up to about 20 milligrams of aerosol former per gram of substrate. For example, the aerosol may comprise from about 5 milligrams to about 30 milligrams of aerosol former per gram of substrate, or from about 10 milligrams to about 25 milligrams of aerosol former per gram of substrate, or from about 15 milligrams to about 20 milligrams of aerosol former per gram of substrate. In alternative embodiments, the aerosol may comprise less than 5 milligrams of aerosol former per gram of substrate. This may be appropriate, for example, where the aerosol former is provided separately within the aerosol-generating article or device.

[0078] Suitable aerosol formers for use in the present invention are described below.

[0079] Various methods known in the art can be applied to measure the amount of aerosol formers in an aerosol.

[0080] As mentioned above, the presence and defined amounts and ratios of characteristic compounds in the aerosol indicate the inclusion of star anise particles within the homogenized star anise material forming the aerosol-generating substrate.

[0081] The star anise particles preferably contain at least about 3 weight percent volatile oil, more preferably at least about 4 weight percent volatile oil, and most preferably at least about 5 weight percent volatile oil, on a dry weight basis. The essential oil content of the star anise particles may be determined using steam distillation as described in ISO 6571:2008. This provides an indication of the essential oil content of the star anise particles.

[0082] Preferably, an aerosol-generating substrate according to the present invention comprises a homogenized star anise material comprising at least about 2.5 weight percent star anise particles on a dry weight basis. Preferably, the particulate plant material comprises at least about 3 percent by weight star anise particles, more preferably at least about 4 percent by weight star anise particles, more preferably at least about 5 percent by weight star anise particles, more preferably at least about 6 percent by weight star anise particles, more preferably at least about 7 percent by weight star anise particles, more preferably at least about 8 percent by weight star anise particles, more preferably at least about 9 percent by weight star anise particles, more preferably at least about 10 percent by weight star anise particles, more preferably at least about 11 percent by weight star anise particles, more preferably at least about 12 percent by weight star anise particles, more preferably at least about 13 percent by weight star anise particles, more preferably at least about 14 percent by weight star anise particles, more preferably at least about 15 percent by weight star anise particles, more preferably at least about 20 percent by weight star anise particles, and more preferably at least about 30 percent by weight star anise particles.

[0083] In certain embodiments of the invention, the plant particles forming the homogenized star anise material may comprise at least 98 percent by weight star anise particles, or at least 95 percent by weight star anise particles, or at least 90 percent by weight star anise particles, based on the dry weight of the plant particles. Thus, in such embodiments, the aerosol-generating substrate comprises star anise particles and is substantially free of other plant particles. For example, the plant particles forming the homogenized star anise material may comprise about 100 percent by weight star anise particles.

[0084] In an alternative embodiment of the present invention, the homogenized star anise material may include star anise particles in combination with at least one of tobacco particles or cannabis particles, as described below.

[0085] In the following description of the invention, the term "particulate plant material" is used collectively to refer to the particles of plant material used to form the homogenized plant material. The particulate plant material may consist essentially of star anise particles, or may be a mixture of star anise particles with tobacco particles, cannabis particles, or both tobacco particles and cannabis particles.

[0086] The homogenized star anise material may comprise up to about 95 percent by weight star anise particles on a dry weight basis, preferably up to about 90 percent by weight star anise particles, more preferably up to about 80 percent by weight star anise particles, more preferably up to about 70 percent by weight star anise particles, more preferably up to about 60 percent by weight star anise particles, and more preferably up to about 50 percent by weight star anise particles on a dry weight basis.

[0087] For example, the homogenized star anise material may contain, on a dry weight basis, from about 2.5 weight percent to about 95 weight percent star anise particles, or from about 5 weight percent to about 90 weight percent star anise particles, or from about 10 weight percent to about 80 weight percent star anise particles, or from about 15 weight percent to about 70 weight percent star anise particles, or from about 20 weight percent to about 60 weight percent star anise particles, or from about 30 weight percent to about 50 weight percent star anise particles.

[0088] As mentioned above, the inventors have identified a number of "signature compounds", which are compounds that are characteristic of the star anise plant and thus indicative of the inclusion of star anise plant particles within the aerosol-generating substrate.

[0089] The amount of characteristic compounds present in pure star anise particles is expected to be different from the amount present in the aerosol-generating substrate. The substrate fabrication process, including hydration in a slurry or suspension and drying at high temperatures, as well as the presence of other components such as aerosol formers, will differentially modify the amount of each of the characteristic compounds. The integrity of the star anise particles and the stability of the compounds under temperature and manipulation during manufacture can affect the final amount of the compounds present in the substrate. Thus, it is intended that the ratio of the characteristic compounds to each other will be different after the star anise particles are incorporated into substrates in various physical forms, such as sheets, strands, and granules.

[0090] The presence of star anise in the aerosol-generating substrate and the proportion of star anise provided in the aerosol-generating substrate can be determined by measuring the amount of the characteristic compound in the substrate and comparing this to the corresponding amount of the characteristic compound in the pure star anise material. The presence and amount of the characteristic compound can be carried out using any suitable technique that would be known to a person skilled in the art.

[0091] In a suitable technique, a sample of 250 milligrams of aerosol-generating substrate is mixed with 5 milliliters of methanol and extracted by shaking, stirring for 5 minutes and centrifugation (4500 g, 5 minutes, 10 degrees Celsius). An aliquot of the extract (300 microliters) is transferred to a silanized chromatography vial and diluted with methanol (600 microliters) and an internal standard (ISTD) solution (100 microliters). The vial is closed and mixed for 5 minutes using an Eppendorf ThermoMixer (5 degrees Celsius, 2000 rpm). Samples from the resulting extract are analyzed by LC-HRAM-MS in a combination of full scan and data-dependent fragmentation modes for identification of characteristic compounds.

[0092] In some embodiments, the homogenized star anise material further comprises up to about 92 weight percent tobacco particles on a dry weight basis.

[0093] For example, the homogenized star anise material preferably contains, on a dry weight basis, from about 10 weight percent to about 92 weight percent tobacco particles, more preferably from about 20 weight percent to about 90 weight percent tobacco particles, more preferably from about 30 weight percent to about 85 weight percent tobacco particles, more preferably from about 40 weight percent to about 80 weight percent tobacco particles, and even more preferably from about 50 weight percent to about 70 weight percent tobacco particles.

[0094] In some preferred embodiments, the homogenized star anise material comprises, on a dry weight basis, from about 5 weight percent to about 20 weight percent star anise particles, and from about 55 weight percent to about 70 weight percent tobacco particles.

[0095] The weight ratio of star anise particles to tobacco particles in the particulate plant material forming the homogenized star anise material can vary depending on the desired flavor characteristics and composition of the aerosol. Preferably, the homogenized star anise material comprises a weight ratio of star anise particles to tobacco particles of about 1:4 or less, meaning that the star anise particles make up 20 percent or less of the total particulate plant material. More preferably, the homogenized star anise material comprises a weight ratio of star anise particles to tobacco particles of 1:5 or less, and more preferably, 1:6 or less.

[0096] For example, in a first preferred embodiment, the weight ratio of star anise particles to tobacco particles is 1:4. A ratio of 1:4 corresponds to a particulate plant material consisting of about 20 weight percent star anise particles and about 80 weight percent tobacco particles. For a homogenized star anise material formed with about 75 weight percent particulate plant material, this corresponds to about 15 weight percent star anise particles and about 60 weight percent tobacco particles in the homogenized star anise material on a dry weight basis.

[0097] In another embodiment, the homogenized star anise material comprises a weight ratio of star anise particles to tobacco particles of 1:9. In yet another embodiment, the homogenized star anise material comprises a weight ratio of star anise particles to tobacco particles of 1:30.

[0098] In the context of the present invention, the term "tobacco particles" describes particles of any plant member of the Nicotiana species. The term "tobacco particles" includes ground or powdered tobacco lamina, ground or powdered tobacco stems, tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. In a preferred embodiment, the tobacco particles are substantially entirely derived from tobacco lamina. In contrast, isolated nicotine and nicotine salts, although compounds derived from tobacco, are not considered tobacco particles for purposes of the present invention and are not included in the percentage of particulate plant material.

[0099] The tobacco particles may be prepared from one or more tobacco plant varieties. Any type of tobacco may be used in the blend. Examples of types of tobacco materials that may be used include, but are not limited to, sun-cured, flue-cured, Burley, Maryland, Orient, Virginia, and other specialty tobaccos.

[0100] Flame-curing is a tobacco curing method used specifically with Virginia tobacco. During the flue-curing process, heated air is circulated through tightly packed tobacco. During the first stage, the tobacco leaves turn yellow and wither. During the second stage, the leaf lamina dries completely. During the third stage, the leaf stem dries completely.

[0101] Burley tobacco plays an important role in many tobacco blends. It has a unique flavor and aroma and the ability to absorb large amounts of casing.

[0102] Orient is a type of tobacco that has small leaves and high aromatic qualities. However, Orient tobacco has a milder flavor than, for example, Burley. Thus, Orient tobacco is generally used in relatively small proportions in tobacco blends.

[0103] Kasturi, Madura, and Jatim are subtypes of sun-cured tobacco that may be used. Preferably, Kasturi and flue-cured tobaccos are used in a blend to produce tobacco particles. Thus, the tobacco particles in the particulate plant material may comprise a blend of Kasturi and flue-cured tobaccos.

[0104] The tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, the tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent. When the aerosol-generating substrate contains tobacco particles in combination with star anise particles, the tobacco with high nicotine content preferably maintains a similar level of nicotine to a typical aerosol-generating substrate without star anise particles, since the total amount of nicotine would otherwise be reduced due to the replacement of tobacco particles with star anise particles.

[0105] As a result of the inclusion of tobacco particles, the aerosol-generating substrates and aerosols generated therefrom of such embodiments contain a particular proportion of "signature compounds" of tobacco. Characteristic compounds generated from tobacco include, but are not limited to, anatabine, cotinine, and damascenone.

[0106] Nicotine may optionally be incorporated into the aerosol-generating substrate, which for purposes of the present invention is considered a non-tobacco material. The nicotine may comprise one or more nicotine salts selected from the list consisting of nicotine lactate, nicotine citrate, nicotine pyruvate, nicotine bitartrate, nicotine benzoate, nicotine pectinate, nicotine alginate, and nicotine salicylate. The nicotine may be incorporated in addition to low-nicotine content tobacco, or the nicotine may be incorporated into an aerosol-generating substrate having reduced or zero tobacco content.

[0107] In a particular embodiment of the invention, the aerosol-generating substrate comprises a homogenised star anise material formed from particulate plant material consisting solely of star anise particles, having nicotine, such as a nicotine salt, incorporated into the aerosol-generating substrate.

[0108] Preferably, the aerosol-generating substrate comprises at least about 0.1 mg of nicotine per gram of substrate on a dry weight basis. More preferably, the aerosol-generating substrate comprises at least about 0.5 mg of nicotine per gram of substrate on a dry weight basis, more preferably at least about 1 mg of nicotine per gram of substrate, more preferably at least about 1.5 mg of nicotine per gram of substrate, more preferably at least about 2 mg of nicotine per gram of substrate, more preferably at least about 3 mg of nicotine per gram of substrate, more preferably at least about 4 mg of nicotine per gram of substrate, more preferably at least about 5 mg of nicotine per gram of substrate.

[0109] Preferably, the aerosol-generating substrate comprises, on a dry weight basis, a maximum of about 50 mg of nicotine per gram of substrate. More preferably, the aerosol-generating substrate comprises, on a dry weight basis, a maximum of about 45 mg of nicotine per gram of substrate, more preferably a maximum of about 40 mg of nicotine per gram of substrate, more preferably a maximum of about 35 mg of nicotine per gram of substrate, more preferably a maximum of about 30 mg of nicotine per gram of substrate, more preferably a maximum of about 25 mg of nicotine per gram of substrate, more preferably a maximum of about 20 mg of nicotine per gram of substrate.

[0110] For example, the aerosol-generating substrate may contain, on a dry weight basis, from about 0.1 mg to about 50 mg of nicotine per gram of substrate, or from about 0.5 mg to about 45 mg of nicotine per gram of substrate, or from about 1 mg to about 40 mg of nicotine per gram of substrate, or from about 2 mg to about 35 mg of nicotine per gram of substrate, or from about 5 mg to about 30 mg of nicotine per gram of substrate, or from about 10 mg to about 25 mg of nicotine per gram of substrate, or from about 15 mg to about 20 mg of nicotine per gram of substrate. In certain preferred embodiments of the invention, the aerosol-generating substrate contains, on a dry weight basis, from about 1 mg to about 20 mg of nicotine per gram of substrate.

[0111] The defined range of nicotine content for the aerosol-generating substrate includes all forms of nicotine that may be present in the aerosol-generating substrate, including nicotine inherently present in the tobacco material, as well as nicotine optionally added separately to the aerosol-generating substrate, for example in the form of a nicotine salt.

[0112] As an alternative or in addition to the inclusion of tobacco particles in the homogenized star anise material of the aerosol-generating substrate according to the invention, the homogenized star anise material may comprise up to 92 weight percent cannabis particles on a dry weight basis. The term "cannabis particles" refers to particles of the cannabis plant, such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis.

[0113] For example, the particulate plant material may contain, on a dry weight basis, from about 10 weight percent to about 92 weight percent cannabis particles, more preferably from about 20 weight percent to about 90 weight percent tobacco particles, more preferably from about 30 weight percent to about 85 weight percent tobacco particles, more preferably from about 40 weight percent to about 80 weight percent tobacco particles, and more preferably from about 50 weight percent to about 70 weight percent tobacco particles.

[0114] One or more cannabinoid compounds may optionally be incorporated into the aerosol-generating substrate, which is considered a non-cannabis material for purposes of the present invention. As used herein with respect to the present invention, the term "cannabinoid compounds" describes any one of a class of naturally occurring compounds found in parts of the cannabis plant, namely Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are particularly concentrated in the female flower heads, which are commonly sold as cannabis oil. Naturally occurring cannabinoid compounds in the cannabis plant include tetrahydrocannabinol (THC) and cannabidiol (CBD). In the context of the present invention, the term "cannabinoid compounds" is used to describe both naturally occurring and synthetically produced cannabinoid compounds.

[0115] For example, the aerosol-generating substrate may comprise a cannabinoid compound selected from the group consisting of tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol (CBD), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclol (CBL), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT), and combinations thereof.

[0116] The homogenized star anise material may further comprise a proportion of other plant flavour particles in addition to star anise particles or a combination of star anise particles and at least one of tobacco particles and cannabis particles ("particulate plant material").

[0117] For purposes of the present invention, the term "other botanical flavour particles" refers to particles of non-star anise, non-tobacco and non-cannabis plant material capable of generating one or more flavourings upon heating. This term is intended to exclude particles of inert plant material, such as cellulose, that do not contribute to the sensory output of the aerosol-generating substrate. The particles may be derived from ground or powdered leaf laminae, fruits, petioles, stems, roots, seeds, buds or skins from other plants. Suitable botanical flavour particles for inclusion in aerosol-generating substrates according to the present invention are known to those skilled in the art and include, but are not limited to, clove particles and tea particles.

[0118] The composition of the homogenized star anise material can advantageously be adjusted by blending desired amounts and types of different plant particles. This allows an aerosol-generating substrate to be formed from a single homogenized star anise material, if desired, without the need for combining or mixing different blends, as is the case, for example, in the manufacture of conventional cut fillers. Thus, manufacture of the aerosol-generating substrate can potentially be simplified.

[0119] The particulate plant material used in the aerosol-generating substrate of the present invention can be adapted to provide a desired particle size distribution. The particle size distribution herein is described as a D value, whereby the D value refers to the percentage of the number of particles having a diameter equal to or less than a given D value. For example, in a D95 particle size distribution, 95 percent of the number of particles have a diameter equal to or less than a given D95 value, and 5 percent of the number of particles have a diameter greater than the given D95 value. Similarly, in a D5 particle size distribution, 5 percent of the number of particles have a diameter equal to or less than the D5 value, and 95 percent of the number of particles have a diameter greater than the given D5 value. Thus, in combination, the D5 and D95 ​​values ​​provide an indication of the particle size distribution of the particulate plant material.

[0120] The particulate plant material may have a D95 value of 50 microns or more to a D95 value of 400 microns or less. This means that the particulate plant material may be of a distribution represented by any D95 value within a given range, i.e., the D95 may be 50 microns, or the D95 may be 55 microns, etc., up to a D95 of 400 microns. By providing a D95 value within this range, the inclusion of relatively large plant particles within the homogenized star anise material is avoided. This is desirable because aerosol generation from such large plant particles is likely to be relatively inefficient. Furthermore, the inclusion of large plant particles in the homogenized star anise material may have a detrimental effect on the consistency of the material.

[0121] The particulate plant material may have a D95 value of about 100 microns or more and about 350 microns or less, preferably about 200 microns or more and about 300 microns or less. Both the particulate star anise material and the particulate tobacco material may have a D95 value of about 50 microns or more and about 400 microns or less, preferably about 100 microns or more and about 350 microns or less, more preferably about 200 microns or more and about 300 microns or less.

[0122] Preferably, the particulate plant material may have a D5 value of about 10 microns or more to about 50 microns or less, more preferably about 20 microns or more to about 40 microns or less. By providing a D5 value within this range, the inclusion of very small dust particles in the homogenized star anise material is avoided, which may be desirable from a manufacturing standpoint.

[0123] In some embodiments, the particulate plant material may be purposely ground to form particles having a desired particle size distribution. The use of purposely ground plant material advantageously improves the homogeneity of the particulate plant material and the consistency of the homogenized star anise material.

[0124] The diameter of 100 percent of the particulate plant material may be about 500 microns or less, more preferably about 450 microns or less. The diameter of 100 percent of the particulate star anise material and 100 percent of the particulate tobacco material may be about 500 microns or less, more preferably about 450 microns or less. The particle size range of the star anise particles allows them to be combined with tobacco particles in existing cast leaf processes.

[0125] The homogenized star anise material preferably comprises at least about 55 weight percent of particulate plant material, including star anise particles, on a dry weight basis, more preferably at least about 60 weight percent of particulate plant material, and even more preferably at least about 65 weight percent of particulate plant material, as described above. The homogenized star anise material preferably comprises no more than about 95 weight percent particulate plant material, more preferably no more than about 90 weight percent particulate plant material, and even more preferably no more than about 85 weight percent particulate plant material, on a dry weight basis. For example, the homogenized star anise material may comprise from about 55 weight percent to about 95 weight percent particulate plant material, or from about 60 weight percent to about 90 weight percent particulate plant material, or from about 65 weight percent to about 85 weight percent particulate plant material, on a dry weight basis. In one particularly preferred embodiment, the homogenized star anise material comprises about 75 weight percent particulate plant material, on a dry weight basis.

[0126] Thus, the particulate plant material is typically combined with one or more other ingredients to form a homogenized star anise material.

[0127] As defined above, the homogenized star anise material further comprises a binder for modifying the mechanical properties of the particulate plant material, the binder being included in the homogenized star anise material during manufacture as described herein. Suitable exogenous binders known to those skilled in the art are known in the art and include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic and locust bean gum, cellulosic binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose, polysaccharides such as starch, organic acids such as alginic acid, sodium alginate, conjugate base salts of organic acids such as agar and pectin, and combinations thereof. Preferably, the binder comprises guar gum.

[0128] The binder is preferably present in an amount of about 1 weight percent to about 10 weight percent by dry weight of the homogenized star anise material, and preferably in an amount of about 2 weight percent to about 5 weight percent by dry weight of the homogenized star anise material.

[0129] Alternatively or additionally, the homogenized star anise material may further comprise one or more lipids to enhance the diffusion rate of the volatile components (e.g., aerosol formers, (E)-anethole, and nicotine), which lipids are included in the homogenized star anise material during preparation as described herein. Suitable lipids for inclusion in the homogenized star anise material include, but are not limited to, medium chain triglycerides, cocoa butter, palm oil, kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and Revel A, and combinations thereof.

[0130] Alternatively, or additionally, the homogenized star anise material may further comprise a pH adjuster.

[0131] Alternatively or additionally, the homogenized star anise material may further comprise fibers to alter the mechanical properties of the homogenized star anise material, the fibers being included in the homogenized star anise material during the manufacture described herein. Suitable exogenous fibers for inclusion in the homogenized star anise material are known in the art and include fibers formed from non-tobacco and non-star anise materials, including, but not limited to, cellulose fibers, soft wood fibers, hard wood fibers, jute fibers, and combinations thereof. Exogenous fibers derived from tobacco and / or star anise may also be added. Any fibers added to the homogenized star anise material are not considered to form part of the "particulate plant material" as defined above. Prior to inclusion in the homogenized star anise material, the fibers may be treated by any suitable process known in the art, including, but not limited to, mechanical pulping, refining, chemical pulping, bleaching, sulfate pulping, and combinations thereof. Typically, the fibers have a length greater than their width.

[0132] Suitable fibers are typically greater than 400 micrometers and have a length of 4 mm or less, with lengths preferably within the range of 0.7 mm to 4 mm. The fibers are preferably present in an amount of at least about 2 weight percent, based on the dry weight of the substrate. The amount of fiber in the homogenized star anise material may depend on the type of material, particularly the method used to produce the homogenized star anise material. In some embodiments, the fibers may be present in an amount of about 2 weight percent to about 15 weight percent, most preferably about 4 weight percent, based on the dry weight of the substrate. For example, this level of fiber may be present where the homogenized star anise material is in the form of cast leaves. In other embodiments, the fibers may be present in an amount of at least about 30 weight percent, or at least about 40 weight percent. For example, this higher level of fiber is likely to be provided where the homogenized star anise material is star anise paper formed in a papermaking process.

[0133] As defined above, the homogenized star anise material further comprises an aerosol former. Upon volatilization, the aerosol former can carry other vaporized compounds that are released from the aerosol-generating substrate upon heating, such as nicotine and flavorants in the aerosol. The aerosolization of a particular compound from an aerosol-generating substrate is not determined solely by its boiling point. The amount of a compound that is aerosolized can be influenced by the physical form of the substrate, as well as by other components that are also present in the substrate. The stability of the compound under the temperature and time frame of aerosolization also impacts the amount of the compound present in the aerosol.

[0134] Suitable aerosol formers for inclusion in the homogenized star anise material are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (such as glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and tetradecanedioate).

[0135] The homogenized star anise material preferably has an aerosol former content of from about 5 weight percent to about 30 weight percent on a dry weight basis, such as from about 10 weight percent to about 25 weight percent on a dry weight basis, or from about 15 weight percent to about 20 weight percent on a dry weight basis.

[0136] For example, where the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, the aerosol former content may preferably be from about 5 weight percent to about 30 weight percent on a dry weight basis.When the substrate is intended for use in an aerosol-generating article for an electrically-operated aerosol-generating system having a heating element, the aerosol former is preferably glycerol.

[0137] In another embodiment, the homogenized star anise material may have an aerosol former content of about 1 percent to about 5 percent by weight on a dry weight basis. For example, if the substrate is intended for use in an aerosol-generating article in which the aerosol former is held in a reservoir separate from the substrate, the substrate may have an aerosol former content of greater than 1 percent and less than about 5 percent. In such an embodiment, the aerosol former volatilizes upon heating and the stream of aerosol former contacts the aerosol-generating substrate so as to entrain flavors from the aerosol-generating substrate in the aerosol.

[0138] The aerosol former may act as a wetting agent in the aerosol-generating substrate.

[0139] In a preferred embodiment of the present invention, the homogenized star anise material comprises star anise particles, about 5 weight percent to about 30 weight percent aerosol former, and about 1 weight percent to about 10 weight percent binder, on a dry weight basis. In such an embodiment, the homogenized star anise material preferably further comprises about 2 weight percent to about 15 weight percent fiber. Particularly preferred, the binder is guar gum.

[0140] Alternatively, or additionally, the homogenized star anise material may further comprise an acid. The acid may comprise a carboxylic acid. The carboxylic acid may comprise a ketone group. Preferably, the carboxylic acid may comprise a ketone group having less than about 10 carbon atoms, such as levulinic acid or lactic acid, or less than about 6 carbon atoms or less than about 4 carbon atoms. The inclusion of an acid may be particularly advantageous when the aerosol-generating substrate is in the form of a gel, as described below.

[0141] The homogenized plant material of the aerosol-generating substrate according to the invention may comprise a single type of homogenized plant material, or two or more types of homogenized plant material having mutually different compositions or morphologies. For example, in one embodiment, the aerosol-generating substrate comprises star anise particles and tobacco or cannabis particles contained within the same sheet of homogenized plant material. However, in other embodiments, the aerosol-generating substrate may comprise tobacco or cannabis particles and star anise particles within mutually different sheets.

[0142] The homogenized plant material is preferably in the form of a solid or gel. However, in some embodiments, the homogenized material may be in the form of a solid that is not a gel. The homogenized material is preferably not in the form of a membrane.

[0143] The homogenized star anise material may be provided in any suitable form. For example, the homogenized star anise material may be in the form of one or more sheets. The term "sheet" as used herein with respect to the present invention describes a laminar element having a width and length that is significantly greater than its thickness.

[0144] Alternatively, or additionally, the homogenized star anise material may be in the form of a plurality of pellets or granules.

[0145] Alternatively, or additionally, the homogenized star anise material may be in a form that can be filled into a cartridge or shisha consumable or used in a shisha device. The present invention includes a cartridge or shisha device containing the homogenized star anise material.

[0146] Alternatively or additionally, the homogenized star anise material may be in the form of multiple strands, strips, or pieces. As used herein, the term "strand" describes an elongated element of material having a length substantially greater than its width and thickness. The term "strand" is deemed to encompass strips, pieces, and any other homogenized star anise material having a similar morphology. Strands of homogenized star anise material may be formed from a sheet of homogenized star anise material, for example, by cutting or chopping, or by other methods, such as extrusion methods.

[0147] In some embodiments, the strands may be formed in situ within the aerosol-generating substrate as a result of splitting or cracking of the sheet of homogenized star anise material during formation of the aerosol-generating substrate, for example as a result of crimping. The strands of homogenized star anise material within the aerosol-generating substrate may be separated from one another. Alternatively, each strand of homogenized star anise material within the aerosol-generating substrate may be at least partially connected to adjacent strands along the length of the strand. For example, adjacent strands may be connected by one or more fibers. This may occur, for example, when strands are formed due to splitting of a sheet of homogenized star anise material during manufacture of the aerosol-generating substrate as described above.

[0148] The aerosol-generating substrate is preferably in the form of one or more sheets of homogenized star anise material. In various embodiments of the invention, the one or more sheets of homogenized star anise material may be produced by a casting process. In various embodiments of the invention, the one or more sheets of homogenized star anise material may be produced by a papermaking process. The one or more sheets described herein may each individually have a thickness of from 100 micrometers to 600 micrometers, preferably from 150 micrometers to 300 micrometers, and most preferably from 200 micrometers to 250 micrometers. Individual thickness refers to the thickness of an individual sheet, and combined thickness refers to the total thickness of all sheets that make up the aerosol-generating substrate. For example, if the aerosol-generating substrate is formed from two individual sheets, the combined thickness is the thickness of the two individual sheets, or the sum of the measured thicknesses of the two sheets, and the two sheets are stacked within the aerosol-generating substrate.

[0149] One or more of the sheets described herein may each individually have a weight of about 100 g / m 2 ~about 300g / m 2 The sheet may have a basis weight of 100 g.

[0150] One or more of the sheets described herein may each individually have a density of about 0.3 g / cm 3 ~Approx. 1.3g / cm 3 and may have a density of about 0.7 g / cm 3 ~Approx. 1.0g / cm 3 It is preferred that the density of the granular material is 0.01 to 0.15.

[0151] The term "tensile strength" is used throughout this specification to indicate a measurement of the force required to stretch a sheet of homogenized star anise material to breakage. More specifically, tensile strength is the highest pulling force per unit width that the sheet material will withstand before breaking, measured in the machine direction or cross direction of the sheet material. It is expressed in units of Newtons per meter of material (N / m). Tests for measuring the tensile strength of sheet materials are well known. A suitable test is described in the 2014 edition of International Standard ISO 1924-2, entitled "Paper and paperboard - Test methods for tensile properties - Part 2: Constant rate of extension method".

[0152] The materials and equipment required to perform the tests in accordance with ISO 1924-2 are a general purpose tensile / compression testing machine (Instron 5566, or equivalent), a 100 Newton tensile load cell (Instron, or equivalent), two pneumatically operated grips, a steel gauge block 180 ± 0.25 mm long (width: approximately 10 mm, thickness: approximately 3 mm), a double blade strip cutter (size 15 ± 0.05 x approximately 250 mm, Adamel Lhomargy, or equivalent), a scalpel, computer operated acquisition software (Merlin, or equivalent), and compressed air.

[0153] Samples are prepared by first conditioning a sheet of homogenized star anise material at 22±2 degrees Celsius and 60±5% relative humidity for at least 24 hours prior to testing. Samples are then cut into approximately 250 x 15±0.1 millimeters in either the machine or cross direction with a double blade strip cutter. The ends of the test pieces should be neatly cut so that no more than three test specimens are cut at the same time.

[0154] The tension / compression testing apparatus is set up by installing a 100 Newton tension load cell, powering on the universal tension / compression testing machine and computer, selecting a predefined measurement method in the software, and setting the test speed to 8 millimeters / minute. The tension load cell is then calibrated and pneumatically actuated grips are attached. The test distance between the pneumatically actuated grips is adjusted to 180 ± 0.5 millimeters by a steel gauge block, and the distance and force are set to zero.

[0155] The test specimen is then placed straight and centered between the grips, avoiding finger contact with the area to be tested. The upper grip is closed and the paper strip is suspended in the open lower grip. The force is set to zero. The paper strip is gently pulled down and then the lower grip is closed, the initial force should be 0.05-0.20 Newtons. While the upper grip is moving upwards, a gradually increasing force is applied until the test specimen breaks. The same procedure is repeated with the remaining test specimens. The result is valid when the test specimen breaks when the grips are moved apart a distance of more than 10 millimeters. If not, the result is rejected and additional measurements are performed.

[0156] If the available test specimen of homogenized star anise material is smaller than the sample described in the test according to ISO 1924-2, as described above, the test can be easily scaled down to accommodate the available size of the test specimen.

[0157] One or more sheets of homogenized star anise material described herein may each individually have a tensile strength at cross-direction peak of 50 N / m to 400 N / m, or preferably 150 N / m to 350 N / m. Given that sheet thickness affects tensile strength, and that batches of sheets may exhibit thickness variations, it may be desirable to normalize values ​​to a particular sheet thickness.

[0158] One or more sheets described herein may each individually have a tensile strength of 100N / m to 800N / m, or preferably 280N / m to 620N / m, at the peak in the machine direction, normalized to a sheet thickness of 215 μm. The machine direction refers to the direction in which the sheet material is wound onto or unwound from the bobbin and fed into the machine, and the tolerance direction is perpendicular to the machine direction. Such values ​​of tensile strength make the sheets and methods described herein particularly suitable for subsequent operations involving mechanical stress. Providing a sheet with the above-defined levels of thickness, basis weight, and tensile strength advantageously optimizes the machinability of the sheet to form an aerosol-generating substrate, and ensures that damage, such as tearing of the sheet, is avoided during high speed processing of the sheet.

[0159] In embodiments of the invention in which the aerosol-generating substrate comprises one or more sheets of homogenized star anise material, the sheets are preferably in the form of an assembly of one or more sheets. As used herein, the term "assembly" means that the sheet of homogenized star anise material has been spiralled, folded or otherwise compressed or contracted in a direction substantially transverse to the cylindrical axis of the plug or rod. The step of "assembling" the sheets may be carried out by any suitable means that provides the required transverse compression of the sheets.

[0160] The term "longitudinal" as used herein refers to a direction corresponding to the major longitudinal axis of the aerosol-generating article extending between the upstream and downstream ends of the aerosol-generating article. In use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "transverse" refers to a direction perpendicular to the longitudinal axis. As used herein, the term "length" refers to the dimension of a component in the longitudinal direction and the term "width" refers to the dimension of a component in the transverse direction. For example, for a plug or rod having a circular cross section, the maximum width corresponds to the diameter of the circle.

[0161] The term "plug" as used herein means a generally cylindrical element having a substantially polygonal, circular, oval or elliptical cross section. The term "rod" as used herein refers to a generally cylindrical element of a substantially polygonal cross section, and preferably a circular, oval or elliptical cross section. A rod may have a length equal to or greater than the length of a plug. Typically, a rod has a length greater than the length of a plug. A rod may include one or more plugs, which are preferably aligned longitudinally.

[0162] As used herein, the terms "upstream" and "downstream" describe the relative location of an element (or portion of an element) of an aerosol-generating article with respect to the direction in which aerosol is transported through the aerosol-generating article during use. The downstream end of the airflow path is the end at which the aerosol is delivered to a user of the article.

[0163] One or more sheets of homogenized star anise material may be collected transversely to their longitudinal axis and surrounded by a wrapper to form a continuous rod or plug. The continuous rod may be cut into a plurality of individual rods or plugs. The wrapper may be a paper wrapper or a non-paper wrapper, as described in more detail below.

[0164] Alternatively, one or more sheets of homogenized star anise material may be cut into strands, as mentioned above. In such an embodiment, the aerosol-generating substrate comprises a plurality of strands of homogenized star anise material. The strands may be used to form plugs.

[0165] Typically, the width of such strands is at least about 0.2 mm, or at least about 0.5 mm. Typically, the width of such strands is preferably about 5 mm, or about 4 mm, or about 3 mm, or about 1.5 mm or less. For example, the width of the strands can be about 0.25 mm to about 5 mm, or about 0.25 mm to about 3 mm, or about 0.5 mm to about 1.5 mm.

[0166] The length of the strands is preferably greater than about 5 mm, for example, about 5 mm to about 15 mm, or about 8 mm to about 12 mm, or about 12 mm. The strands preferably have substantially the same length as each other. The length of the strands may be determined by the manufacturing process whereby the rod is cut into shorter plugs, the length of the strands corresponding to the length of the plugs. The strands are fragile and may break, especially during transportation. In such cases, the length of some of the strands may be shorter than the length of the plugs.

[0167] The plurality of strands are preferably aligned with a longitudinal axis and extend substantially along the length of the aerosol-generating substrate. The plurality of strands are therefore preferably aligned substantially parallel to one another. The plurality of longitudinal strands of aerosol-generating material are preferably substantially non-coiled.

[0168] The strands of homogenized star anise material preferably each have a mass to surface area ratio of at least about 0.02 milligrams per square millimeter, more preferably at least about 0.05 milligrams per square millimeter. Preferably, the strands of homogenized star anise material each have a mass to surface area ratio of about 0.2 milligrams per square millimeter or less, more preferably about 0.15 milligrams per square millimeter or less. The mass to surface area ratio is calculated by dividing the mass of the strands of homogenized star anise material in milligrams by the geometric surface area of ​​the strands of homogenized star anise material in square millimeters.

[0169] The one or more sheets of homogenized star anise material may be textured by crimping, embossing, or perforation. The one or more sheets may be textured before being assembled or before being cut into strands. The one or more sheets of homogenized star anise material are preferably crimped prior to assembly so that the homogenized star anise material may be in the form of a crimped sheet, more preferably in the form of a collection of crimped sheets. As used herein, the term "crimped sheet" refers to a sheet having a plurality of substantially parallel ridges or corrugations that are generally aligned along the longitudinal axis of the article.

[0170] In one embodiment, the aerosol-generating substrate may be in the form of a single plug of aerosol-generating substrate. The plug of aerosol-generating substrate may preferably comprise a plurality of strands of homogenized star anise material. Most preferably, the plug of aerosol-generating substrate may comprise one or more sheets of homogenized star anise material. The one or more sheets of homogenized star anise material may preferably be crimped to have a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the plug. This process advantageously facilitates assembling the crimped sheet of homogenized star anise material to form a plug. Preferably, the one or more sheets of homogenized star anise material may be assembled. Of course, the crimped sheet of homogenized star anise material may alternatively or additionally have a plurality of substantially parallel ridges or corrugations that form an acute or obtuse angle with respect to the cylindrical axis of the plug. The sheet may be crimped to such an extent that the integrity of the sheet is interrupted at the plurality of parallel ridges or corrugations, causing separation of the material and resulting in the formation of pieces, strands or strips of homogenized plant material.

[0171] In another embodiment, the aerosol-generating substrate includes a first plug including a first homogenized plant material and a second plug including a second homogenized plant material, the first homogenized plant material and the second homogenized plant material including different levels of star anise particles and tobacco particles. At least one of the first homogenized plant material and the second homogenized plant material is a homogenized star anise material. For example, the first homogenized plant material may include about 50 weight percent to about 95 weight percent star anise particles on a dry weight basis, and the second homogenized plant material may include about 50 weight percent to about 95 weight percent tobacco particles on a dry weight basis. Generally, the homogenized star anise material in the aerosol-generating substrate includes at least 2.5 weight percent star anise particles and up to 95 weight percent tobacco particles on a dry weight basis.

[0172] Optionally, the first homogenized star anise material may comprise at least 60 percent by weight star anise particles and the second homogenized star anise material may comprise at least 60 percent by weight tobacco particles. Optionally, the first homogenized star anise material may comprise at least about 90 percent by weight star anise particles and the second homogenized star anise material may comprise at least about 90 percent by weight tobacco particles.

[0173] In such an arrangement, the first homogenized plant material preferably comprises a first particulate plant material having a higher percentage of star anise particles than the second homogenized plant material, which may be a homogenized tobacco material substantially free of star anise particles.

[0174] The first homogenized plant material may be in the form of one or more sheets and the second homogenized plant material may be in the form of one or more sheets.

[0175] Optionally, the aerosol-generating substrate may comprise one or more plugs. Preferably, the substrate may comprise a first plug and a second plug, and the first homogenized plant material may be located within the first plug and the second homogenized plant material may be located within the second plug.

[0176] Two or more plugs may extend end-to-end in abutting relationship to form a rod. Two plugs may be longitudinally positioned with a gap between them, thereby creating a cavity within the rod. The plugs may be in any suitable arrangement within the rod.

[0177] For example, in a preferred arrangement, a downstream plug containing a major proportion of star anise particles may abut an upstream plug containing a major proportion of tobacco particles to form a rod. Alternative configurations are also envisaged in which the upstream and downstream positions of each plug are altered relative to one another to form a third plug, also of differing proportions of star anise particles and tobacco particles. If more than one plug is provided, the homogenized plant material may be provided in the same form in each plug, or in different forms in each plug, i.e., aggregated or chopped. One or more plugs may optionally be individually or together wrapped in a thermally conductive sheet material, as described below.

[0178] The first plug may comprise one or more sheets of the first homogenized plant material, and the second plug may comprise one or more sheets of the second homogenized plant material. The total length of the plugs may be about 10 mm to about 40 mm, preferably about 10 to about 15 mm, more preferably about 12 mm. The first plug and the second plug may have the same length or different lengths. When the first plug and the second plug have the same length, the length of each plug may preferably be about 6 mm to about 20 mm. The second plug may preferably be longer than the first plug to provide a desired ratio of tobacco particles to star anise particles in the substrate. In general, the substrate preferably comprises, on a dry weight basis, 0 to 72.5 weight percent tobacco particles and 75 to 2.5 weight percent star anise particles. The second plug is preferably at least 40 to 50 percent longer than the first plug.

[0179] When the first homogenized plant material and the second homogenized plant material are in the form of one or more sheets, the one or more sheets of the first homogenized plant material and the second homogenized plant material can preferably be a conglomerate of sheets. The one or more sheets of the first homogenized plant material and the second homogenized plant material can preferably be a crimped sheet. Of course, all other physical properties described with respect to the embodiment in which a single homogenized plant material is present are equally applicable to the embodiment in which a first homogenized plant material and a second homogenized plant material are present. Furthermore, of course, the description of additives (e.g., binders, lipids, fibers, aerosol formers, humectants, plasticizers, flavors, fillers, aqueous and non-aqueous solvents, and combinations thereof) with respect to a single homogenized plant material are equally applicable to the embodiment in which a first homogenized plant material and a second homogenized plant material are present.

[0180] In yet another embodiment of the aerosol-generating substrate, the first homogenized plant material is in the form of a first sheet and the second homogenized plant material is in the form of a second sheet, the second sheet at least partially overlying the first sheet.

[0181] The first sheet may be a textured sheet and the second sheet may be a non-textured sheet.

[0182] Both the first and second sheets may be textured sheets.

[0183] The first sheet may be a textured sheet that is textured in a different manner than the second sheet, for example the first sheet may be crimped and the second sheet perforated, or alternatively the first sheet may be perforated and the second sheet crimped.

[0184] Both the first and second sheets may be morphologically different crimped sheets from one another, for example, the second sheet may be crimped with a different number of crimps per sheet unit width compared to the first sheet.

[0185] The sheets may be assembled to form a plug. The sheets that are assembled to form a plug may have different physical dimensions. The width and thickness of the sheets may vary.

[0186] It may be desirable to assemble two sheets, each having a different thickness, or each having a different width, which may vary the physical properties of the plug, which may facilitate the formation of a blended plug of aerosol-generating substrate from sheets of different chemical composition.

[0187] The first sheet may have a first thickness and the second sheet may have a second thickness that is a multiple of the first thickness, for example, the second sheet may have a thickness that is two or three times the first thickness.

[0188] The first sheet may have a first width and the second sheet may have a second width different from the first width.

[0189] The first sheet and the second sheet may be disposed in an overlapping relationship before or when assembled together. The sheets may have the same width and thickness. The sheets may have different thicknesses. The sheets may have different widths. The sheets may be textured differently.

[0190] If it is desired that both the first and second sheets are textured, the sheets may be textured simultaneously before being assembled. For example, the sheets may be placed in overlapping relationship and passed through a texturing means such as a pair of crimping rollers. Suitable apparatus and processes for simultaneous crimping are described with reference to Figure 2 of WO-A-2013 / 178766. In a preferred embodiment, a second sheet of the second homogenized plant material is placed on top of the first sheet of the first homogenized plant material, and the combined sheets are assembled to form a plug of aerosol-generating substrate. Optionally, the sheets may be crimped together prior to assembly to facilitate assembly.

[0191] Alternatively, each sheet may be textured separately and then assembled together into a plug. For example, if the two sheets have different thicknesses, it may be desirable to crinkle the first sheet differently relative to the second sheet.

[0192] It will be understood that all other physical properties described with respect to the embodiment in which a single homogenized star anise material is present are equally applicable to the embodiment in which a first homogenized plant material and a second homogenized plant material are present. Additionally, it will be understood that the descriptions of additives (such as binders, lipids, fibers, aerosol formers, humectants, plasticizers, flavors, fillers, aqueous and non-aqueous solvents, and combinations thereof) with respect to a single homogenized star anise material are equally applicable to the embodiment in which a first homogenized plant material and a second homogenized plant material are present.

[0193] The homogenized star anise material used in the aerosol-generating substrate according to the present invention may be produced by a variety of methods including papermaking, casting, dough reconstitution, extrusion or any other suitable process.

[0194] The homogenized star anise material is preferably in "cast leaf" form. The term "cast leaf" is used to refer to a sheet product made by a casting process based on casting a slurry containing plant particles (e.g., star anise particles, or a mixture of tobacco particles and star anise particles) and a binder (e.g., guar gum, etc.) onto a support surface (e.g., a belt conveyor), drying the slurry, and removing the dried sheet from the support surface. An example of a casting or cast leaf process is described, for example, in US-A-5,724,998 for making cast leaf tobacco. In the cast leaf process, particulate plant material is mixed with a liquid component, typically water, to form a slurry. Other added ingredients in the slurry may include fibers, binders, and aerosol formers. The particulate plant material may be agglomerated in the presence of a binder. The slurry is cast onto a support surface and dried to form a sheet of homogenized star anise material.

[0195] In certain preferred embodiments, the homogenized star anise material used in the articles according to the invention is produced by casting. Homogenized star anise material made by a casting process typically comprises agglomerated particulate plant material.

[0196] The cast leaf process advantageously preserves most of the flavor because virtually all of the soluble fraction is retained within the plant material, and also avoids the energy-intensive papermaking process.

[0197] In one preferred embodiment of the present invention, a mixture is formed that includes particulate plant material, water, a binder, and an aerosol former to form a homogenized star anise material. A sheet is formed from the mixture, and the sheet is then dried. The mixture is preferably an aqueous mixture. As used herein, "dry weight" refers to the weight of the particulate non-water component relative to the sum of the weights of all non-water components in the mixture, expressed as a percentage. The composition of an aqueous mixture may be referred to by "dry weight percent", which refers to the weight of the non-water component relative to the weight of the entire aqueous mixture, expressed as a percentage.

[0198] The mixture may be a slurry. As used herein, a "slurry" is a homogenized aqueous mixture having a relatively low dry weight. The slurry used in the methods herein may preferably have a dry weight of 5 percent to 60 percent.

[0199] Alternatively, the mixture may be a dough. As used herein, a "dough" is an aqueous mixture having a relatively high dry weight. Preferably, the dough used in the method herein may have a dry weight of at least 60 percent, more preferably at least 70 percent.

[0200] Slurries containing greater than 30 percent dry weight and crumb are preferred in certain embodiments of the process of the present invention.

[0201] The step of mixing the particulate plant material, water, and other optional ingredients can be carried out by any suitable means. For low viscosity mixtures, i.e. some slurries, mixing is preferably carried out using a high energy mixer or high shear mixer. Such mixing breaks down and distributes the various phases of the mixture evenly. For high viscosity mixtures, i.e. some lumps, a kneading process can be used to distribute the various phases of the mixture evenly.

[0202] The method according to the invention may further comprise a step of vibrating the mixture to distribute the various components. Vibrating the mixture, i.e., vibrating, for example, the tank or silo in which the homogenized mixture is present, may help homogenize the mixture, especially if it is a low-viscosity mixture, i.e., some slurry. If vibration is performed in conjunction with mixing, shorter mixing times may be required to homogenize the mixture to the optimal target value for casting.

[0203] When the mixture is a slurry, the web of homogenized star anise material is preferably formed by a casting process that includes casting the slurry onto a support surface, such as a belt conveyor. The method of making homogenized star anise material includes drying the cast web to form a sheet. The cast web may be dried at room temperature or at an ambient temperature of at least about 60 degrees Celsius, more preferably at least about 80 degrees Celsius, for a suitable length of time. The cast web is preferably dried at an ambient temperature not exceeding 200 degrees Celsius, more preferably not exceeding about 160 degrees Celsius. For example, the cast web may be dried at a temperature of about 60 degrees Celsius to about 200 degrees Celsius, or about 80 degrees Celsius to about 160 degrees Celsius. The moisture content of the sheet after drying is preferably about 5 percent to about 15 percent based on the total weight of the sheet. The sheet may then be removed from the support surface after drying. The cast sheet has a tensile strength such that it can be mechanically manipulated and wound onto or unwound from a bobbin without breaking or deforming.

[0204] If the mixture is a dough mass, the dough mass may be extruded in the form of sheets, strands, or strips prior to the step of drying the extruded mixture. The dough mass may be extruded in the form of a sheet. The extruded mixture may be dried at room temperature or at a temperature of at least about 60 degrees Celsius, more preferably at least about 80 degrees Celsius, for a suitable length of time. The cast web is preferably dried at an ambient temperature not exceeding about 200 degrees Celsius, more preferably not exceeding about 160 degrees Celsius. For example, the cast web may be dried at a temperature of about 60 degrees Celsius to about 200 degrees Celsius, or about 80 degrees Celsius to about 160 degrees Celsius. The moisture content of the extruded mixture after drying is preferably about 5 percent to about 15 percent based on the total weight of the sheet. As a result of the significantly lower moisture content relative to a web formed from a slurry, the sheet formed from the dough mass requires less drying time and / or lower drying temperature.

[0205] After drying the sheet, the method may optionally include the step of coating a nicotine salt onto the sheet, preferably together with an aerosol former, as described in the disclosure of WO-A-2015 / 082652.

[0206] After drying the sheet, the method according to the invention may optionally include cutting the sheet into strands, pieces or strips for formation of the aerosol-generating substrate described above. The strands, pieces or strips may be brought together using suitable means to form a rod of the aerosol-generating substrate. In the formed rod of the aerosol-generating substrate, the strands, pieces or strips may be substantially aligned, for example, along the longitudinal axis of the rod. Alternatively, the strands, pieces or strips may be randomly oriented within the rod.

[0207] The method according to the invention may optionally further comprise the step of winding the sheet onto a bobbin after the drying step.

[0208] The present invention further provides an alternative paper-making process for producing sheets of homogenized star anise material in the form of "vegetable paper".

[0209] Plant paper refers to a reconstituted plant sheet formed by a process of extracting plant material with a solvent to produce an extract of soluble plant compounds and an insoluble residue of fibrous plant material, and recombining the extract with the insoluble residue. The extract may optionally be concentrated or further processed before being recombined with the insoluble residue. The insoluble residue may optionally be purified and combined with additional plant fiber before being recombined with the extract. In a method according to the invention, the plant material includes particles of star anise, optionally combined with particles of tobacco.

[0210] More specifically, the method of producing plant paper includes a first step of mixing plant material with water to form a dilute suspension that primarily contains discrete cellulose fibers. The suspension has a lower viscosity and higher water content than the slurries produced in the casting process. This first step can optionally involve steeping in the presence of an alkali such as sodium hydroxide, and optionally the application of heat.

[0211] The method further includes a second step of separating the suspension into an insoluble portion comprising the insoluble residue of the fibrous plant material and a liquid or aqueous portion comprising the soluble plant compounds. Water remaining within the insoluble residue of the fibrous plant material may be drained through a screen acting as a sieve, and a web of randomly woven fibers may be laid down. Water may be further removed from this web by pressing with rollers, optionally with the assistance of suction or vacuum.

[0212] After the aqueous portion and water are removed, the insoluble residue is formed into a sheet. Preferably, a generally flat, uniform sheet of plant fibers is formed.

[0213] Preferably, the method further comprises concentrating the extract of soluble plant compounds removed from the sheet and adding the concentrated extract to the sheet of insoluble fibrous plant material to form a sheet of homogenized star anise material. Alternatively, or additionally, soluble plant matter or concentrated plant matter from a separate process may be added to the sheet. The extract or concentrated extract may be from a different variety of the same species of plant, or from a different species of plant.

[0214] This process has been used with tobacco to make reconstituted tobacco products, also known as tobacco paper, as described in US-A-3,860,012. The same process can be used with one or more plants to produce paper-like sheet materials, such as sheets of star anise paper.

[0215] In certain preferred embodiments, the homogenized star anise material used in the articles according to the invention is produced by the paper-making process defined above, in such embodiments, the homogenized star anise material is in the form of star anise paper.

[0216] The homogenized tobacco material or homogenized star anise material produced by such a process is called tobacco paper or star anise paper. The homogenized plant material produced by the papermaking process is identifiable by the presence of multiple fibers throughout the material, visible by eye or under a light-forehead microscope, especially when the paper is moistened with water. In contrast, the homogenized plant material produced by the casting process contains fewer fibers than paper and tends to separate into a slurry when moistened. Mixed star anise paper refers to the homogenized plant material produced by such a process using a mixture of tobacco material and star anise material.

[0217] In embodiments where the aerosol-generating substrate comprises a combination of star anise particles and tobacco particles, the aerosol-generating substrate may comprise one or more sheets of star anise paper and one or more sheets of tobacco paper. The sheets of star anise paper and tobacco paper may be interleaved or stacked with one another before being assembled to form a rod. Optionally, the sheets may be crimped. Alternatively, the sheets of star anise paper and tobacco paper may be cut into strands, strips or pieces and then combined to form a rod. The relative amounts of tobacco and star anise in the aerosol-generating substrate may be adjusted by varying the number of tobacco and star anise sheets, respectively, or the amount of star anise and tobacco strands, strips or pieces, respectively, within the rod.

[0218] For example, the number or amount of tobacco and star anise sheets or strands may be adjusted to provide a star anise to tobacco ratio of about 1:4, or about 1:9, or about 1:30.

[0219] Other known processes which may be applied to the production of homogenized plant material are, for example, the dough reconstitution process of the type described in US-A-3,894,544, and the extrusion process of the type described in GB-A-983,928. Generally, the density of homogenized plant material produced by the extrusion and dough reconstitution processes is greater than the density of homogenized plant material produced by the casting process.

[0220] In an alternative embodiment of the present invention, the homogenized star anise material is in the form of a gel composition formed of star anise particles, an aerosol former, and a binder.

[0221] When the homogenized star anise material is in the form of a gel composition containing star anise particles, the binder preferably comprises a cellulose ether, such as carboxymethyl cellulose. The binder may be present in an amount of about 1 weight percent to about 5 weight percent, based on the total weight of the gel. For example, the gel composition may comprise 1.5 weight percent to 3.5 weight percent sodium carboxymethyl cellulose.

[0222] The gel composition preferably comprises at least about 60 weight percent of an aerosol former, such as glycerin, based on the total weight of the gel. For example, the gel composition may comprise 65 to 85 weight percent glycerin.

[0223] Optionally, the gel composition may further comprise an acid, such as lactic acid. The acid may be present in an amount of up to about 6 weight percent, based on the total weight of the gel composition. Optionally, the gel composition may comprise up to about 5 weight percent nicotine, based on the total weight of the gel composition. Optionally, the gel composition comprises about 10 weight percent to about 30 weight percent water, based on the total weight of the gel composition.

[0224] In embodiments where the homogenized star anise material is in the form of a gel composition, the aerosol-generating substrate preferably comprises a porous medium loaded with the gel composition. The term "porous" is used herein to refer to a material that provides a plurality of pores or openings that allow the passage of air through the material.

[0225] The porous medium may be any suitable porous material capable of holding or retaining the gel composition. Ideally, the porous medium may allow the gel composition to move within it. In certain embodiments, the porous medium comprises natural materials, synthetic, or semi-synthetic, or a combination thereof. In certain embodiments, the porous medium comprises a sheet material, a foam, or a fiber, such as loose fiber, or a combination thereof. In certain embodiments, the porous medium comprises a woven, non-woven, or extruded material, or a combination thereof. It is preferred that the porous medium comprises cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. It is preferred that the porous medium comprises a sheet material, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium comprises a sheet made from cotton fibers.

[0226] The porous media used in the present invention may be crimped or chopped. In a preferred embodiment, the porous media is crimped. In an alternative embodiment, the porous media comprises chopped porous media. The crimping or chopping process can be before or after loading with the gel composition.

[0227] Where the homogenised star anise material is in the form of a gel composition loaded onto a porous medium, the aerosol-generating substrate preferably comprises an elongated susceptor element extending longitudinally through or adjacent to the porous medium.

[0228] Preferably, the aerosol-generating substrate of an aerosol-generating article according to the present invention comprises at least about 200 mg of homogenized plant material, more preferably at least about 250 mg of homogenized plant material, more preferably at least about 300 mg of homogenized plant material.

[0229] An aerosol-generating article according to the present invention comprises a rod comprising an aerosol-generating substrate in one or more plugs. The rod of aerosol-generating substrate may have a length of from about 5 mm to about 120 mm. For example, the rod may preferably have a length of from about 10 to about 45 mm, more preferably from about 10 mm to 15 mm, and most preferably about 12 mm.

[0230] In alternative embodiments, the rod preferably has a length of from about 30 mm to about 45 mm, or from about 33 mm to about 41 mm. When the rod is formed from a single plug of aerosol-generating substrate, the plug has the same length as the rod.

[0231] The rods of aerosol-generating substrates may have an outer diameter of about 5 mm to about 10 mm depending on their intended use. For example, in some embodiments, the rods may have an outer diameter of about 5.5 mm to about 8 mm, or about 6.5 mm to about 8 mm. The "outer diameter" of the rod of the aerosol-generating substrate corresponds to the diameter of the rod including any wrapper.

[0232] The rod of aerosol-generating substrate in an aerosol-generating article according to the invention is preferably surrounded along at least a portion of its length by one or more wrappers. The one or more wrappers may comprise a paper wrapper or a non-paper wrapper, or both. Suitable paper wrappers for use in certain embodiments of the invention are known in the art and include, but are not limited to, cigarette paper and filter plug wrap. Suitable non-paper wrappers for use in certain embodiments of the invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material. Homogenized tobacco wrappers are particularly suitable for use in embodiments in which the aerosol-generating substrate comprises one or more sheets of homogenized star anise material formed with particulate plant material, the particulate plant material containing star anise particles in combination with a low weight percentage of tobacco particles, such as between 20 weight percent and 0 weight percent tobacco particles, on a dry weight basis.

[0233] In certain embodiments of the present invention, the aerosol-generating substrate is surrounded along at least a portion of its length by a thermally conductive sheet material, such as a metal foil, for example, aluminum foil or metalized paper. The metal foil or metalized paper serves the purpose of rapidly conducting heat throughout the aerosol-generating substrate. In addition, the metal foil or metalized paper may serve to prevent the aerosol-generating substrate from igniting if a consumer attempts to ignite it. Furthermore, during use, the metal foil or metalized paper may prevent odors generated with heating of the outer wrapper from entering the aerosol generated from the aerosol-generating substrate. For example, this may be problematic for aerosol-generating articles having an aerosol-generating substrate that is heated externally during use to generate an aerosol. Alternatively, or additionally, the metalized wrapper may be used to facilitate detection or recognition of the aerosol-generating article when inserted into an aerosol-generating device during use. The metal foil or metalized paper may include metal particles, such as iron particles.

[0234] The one or more wrappers surrounding the aerosol-generating substrate preferably have an overall thickness of from about 0.1 mm to about 0.9 mm.

[0235] The inner diameter of the rod of the aerosol-generating substrate is preferably from about 3 mm to about 9.5 mm, more preferably from about 4 mm to about 7.5 mm, more preferably from about 5 mm to about 7.5 mm. "Inner diameter" corresponds to the diameter of the rod of the aerosol-generating substrate, not including the thickness of the wrapper, but measured with the wrapper still in place.

[0236] Aerosol-generating articles according to the present invention also include, but are not limited to, cartridges or shisha consumables.

[0237] The aerosol-generating article according to the invention may optionally include a support element comprising at least one hollow tube immediately downstream of the aerosol-generating substrate. One function of the tube is to position the aerosol-generating substrate towards the distal end of the aerosol-generating article so that it can come into contact with the heating element. The tube acts to prevent the aerosol-generating substrate from being forced along the aerosol-generating article towards other downstream elements when the heating element is inserted into the aerosol-generating substrate. The tube also acts as a spacer element to separate the downstream elements from the aerosol-generating substrate. The tube may be made of any material such as cellulose acetate, polymer, cardboard, or paper.

[0238] As an alternative or in addition to the support element, the aerosol-generating article according to the invention optionally includes an aerosol cooling element downstream of the aerosol-generating substrate and immediately downstream of the hollow tube forming the support element. In use, the aerosol formed by the volatile compounds released from the aerosol-generating substrate passes through and is cooled by the aerosol cooling element before being inhaled by the user. The low temperature allows the vapor to condense into an aerosol. The aerosol cooling element may be a hollow tube, such as a hollow cellulose acetate tube or cardboard tube, which may be similar to the support element immediately downstream of the aerosol-generating substrate. The aerosol cooling element may be a hollow tube of equal outer diameter to the cellulose acetate tube of the hollow tube of the support element, but smaller or larger inner diameter.

[0239] In one embodiment, the paper-wrapped aerosol cooling element comprises one or more longitudinal channels made of any suitable material, such as metal foil, foil-laminated paper, polymeric sheets preferably made of synthetic polymers, and substantially non-porous paper or cardboard. In some embodiments, the paper-wrapped aerosol cooling element may include one or more sheets made of a material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), paper laminated with a polymeric sheet, and aluminum foil. Alternatively, the aerosol cooling element may be made of woven fibers or non-woven filaments of a material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), and cellulose acetate (CA). In a preferred embodiment, the aerosol cooling element is a crimped and assembled polylactic acid sheet wound into a filter paper. In another preferred embodiment, the aerosol cooling element contains longitudinal channels and is made of woven filaments of a synthetic polymer, such as polylactic acid filaments, wrapped in paper.

[0240] One or more additional hollow tubes may be provided downstream of the aerosol cooling element.

[0241] The aerosol-generating article according to the invention may further comprise a filter or mouthpiece downstream of the aerosol-generating substrate and, if present, the support element and the aerosol cooling element. The filter may comprise one or more filtration materials for removing particulate components, gaseous components, or combinations thereof. Suitable filtration materials are known in the art and include, but are not limited to, fibrous filtration materials such as cellulose acetate tow, and papers, adsorbents such as activated alumina, zeolites, molecular sieves, and silica gel, biodegradable polymers including polylactic acid (PLA), Matabi®, hydrophobic viscose fibers, and bioplastics, and combinations thereof. The filter may be located at the downstream end of the aerosol-generating article. The filter may be a cellulose acetate filter plug. In one embodiment, the filter is about 7 mm long, but may have a length of about 5 mm to about 10 mm. The aerosol-generating article according to the invention may comprise a mouth end cavity at the downstream end of the article. The mouth end cavity may be defined by one or more wrappers extending downstream from the filter or mouthpiece. Alternatively, the mouth end cavity may be defined by a separate tubular element provided at the downstream end of the aerosol-generating article.

[0242] The aerosol-generating article according to the present invention preferably further comprises a ventilation zone provided at a location along the aerosol-generating article, for example the aerosol-generating article may be provided at a location along a hollow tube provided downstream of the aerosol-generating substrate.

[0243] Aerosol-generating articles according to the present invention may optionally further comprise an upstream element at the upstream end of the aerosol-generating substrate. The upstream element may be a porous plug element, such as a plug of fibrous filtration material, such as cellulose acetate.

[0244] In a preferred embodiment of the invention, the aerosol-generating article comprises an aerosol-generating substrate, at least one hollow tube downstream of the aerosol-generating substrate, and a filter downstream of the at least one hollow tube. Optionally, the aerosol-generating article further comprises an oral end cavity at the downstream end of the filter. Optionally, the aerosol-generating article further comprises an upstream element at the upstream end of the aerosol-generating substrate. A ventilation zone is preferably provided at a location along the at least one hollow tube.

[0245] In a particularly preferred embodiment having this arrangement, the aerosol-generating article comprises an aerosol-generating substrate, an upstream element at the upstream end of the aerosol-generating substrate, a support element downstream of the aerosol-generating substrate, an aerosol cooling element downstream of the support element, and a filter downstream of the aerosol cooling element. Both the support element and the aerosol cooling element are preferably in the form of a hollow tube. The aerosol-generating substrate preferably comprises an elongated susceptor element extending longitudinally through the substrate.

[0246] In one particularly preferred embodiment, the aerosol-generating substrate has a length of about 33 mm and an outer diameter of about 5.5 mm to 6.7 mm, the aerosol-generating substrate comprises about 340 mg of homogenized star anise material in the form of a plurality of strands, the homogenized star anise material comprising about 14 weight percent glycerol on a dry weight basis. In this embodiment, the aerosol-generating article has an overall length of about 74 mm and includes a cellulose acetate tow filter having a length of about 10 mm, and an oral end cavity defined by a hollow tube having a length of about 6 to 7 mm. The aerosol-generating article includes a hollow tube downstream of the aerosol-generating substrate, the hollow tube having a length of about 25 mm, and a ventilation zone is provided.

[0247] Aerosol-generating articles according to the invention may have an overall length of at least about 30mm, or at least about 40mm. The overall length of the aerosol-generating article may be less than 90mm, or less than about 80mm.

[0248] In one embodiment, the aerosol-generating article has an overall length of about 40 mm to about 50 mm, preferably about 45 mm. In another embodiment, the aerosol-generating article has an overall length of about 70 mm to about 90 mm, preferably about 80 mm to about 85 mm. In another embodiment, the aerosol-generating article has an overall length of about 72 mm to about 76 mm, preferably about 74 mm.

[0249] The aerosol-generating article may have an outer diameter of from about 5 mm to about 8 mm, preferably from about 6 mm to about 8 mm, In one embodiment, the aerosol-generating article has an outer diameter of about 7.3 mm.

[0250] The aerosol-generating article according to the present invention may further comprise one or more aerosol modification elements. The aerosol modification elements may provide an aerosol modifier. As used herein, the term aerosol modifier is used to describe any substance that, in use, modifies one or more characteristics or properties of the aerosol that passes through the filter. Suitable aerosol modifiers include, but are not limited to, agents that impart a taste or aroma to the aerosol that passes through the filter in use, or agents that remove flavors from the aerosol that passes through the filter in use.

[0251] The aerosol modifier may be one or more of water or liquid flavourings. The water or moisture may modify the sensory experience of the user, for example, by moistening the generated aerosol, which may provide a cooling effect to the aerosol and reduce the perception of harshness experienced by the user. The aerosol modifier may be in the form of a flavour delivery element for delivering one or more liquid flavourings. Alternatively, the liquid flavourings may be added directly to the homogenized star anise material, for example by adding flavour to the slurry or ingredients during the manufacture of the homogenized star anise material, or by spraying the liquid flavourings onto the surface of the homogenized star anise material.

[0252] The one or more liquid flavoring agents may include any flavoring compound or plant extract suitable for releasably disposing in liquid form within the flavor delivery element to enhance the flavor of the aerosol generated during use of the aerosol generating article. Liquid or solid flavoring agents may also be disposed directly on the material forming the filter, such as cellulose acetate tow. Suitable flavors or flavoring agents include, but are not limited to, menthol, mint (such as peppermint and menthol), chocolate, licorice, citrus and other fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavors, spice flavors (such as cinnamon), methyl salicylate, linalool, eugenol, bergamot oil, geranium oil, lemon oil, cannabis oil, and tobacco flavors. Other suitable flavors may include flavoring compounds selected from the group consisting of acids, alcohols, esters, aldehydes, ketones, pyrazines, combinations thereof, or blends thereof, and the like.

[0253] In certain embodiments of the present invention, the aerosol modifier may be an essential oil derived from one or more plants, for example, the homogenized star anise material may include star anise oil, such as star anise essential oil, to further enhance the star anise flavor delivered to the consumer upon heating.

[0254] In certain embodiments of the invention, the aerosol-generating substrate may comprise homogenised plant material comprising a combination of particulate plant material, such as tea particles, and star anise oil.

[0255] The aerosol modifier may be an adsorbent material, such as activated carbon, that removes certain components of the aerosol passing through the filter, thereby altering the taste and aroma of the aerosol.

[0256] The one or more aerosol modifying elements may be located downstream of or within the aerosol-generating substrate. The aerosol-generating substrate may include the homogenized star anise material and the aerosol modifying elements. In various embodiments, the aerosol modifying elements may be located adjacent to the homogenized star anise material or embedded in the homogenized star anise material. Typically, the aerosol modifying elements may be located downstream of the aerosol-generating substrate, most typically within an aerosol cooling element, within a filter of the aerosol-generating article, e.g., within a filter plug, or within a cavity, preferably within a cavity between filter plugs. The one or more aerosol modifying elements may be in the form of one or more of threads, capsules, microcapsules, beads, or polymeric matrix materials, or combinations thereof.

[0257] Where the aerosol modifying element is in the form of a thread, the thread may be formed from paper, such as a filter plug wrap, and the thread may be loaded with at least one aerosol modifier and located within the body of the filter, as described in WO-A-2011 / 060961. Other materials that can be used to form the thread include cellulose acetate and cotton.

[0258] Where the aerosol modifying element is in the form of a capsule, the capsule may be a frangible capsule located within a filter, the inner core of the capsule containing the aerosol modifier that may be released upon rupture of the outer shell of the capsule when the filter is subjected to an external force, as described in WO-A-2007 / 010407, WO-A-2013 / 068100 and WO-A-2014 / 154887. The capsule may be located within a filter plug or cavity, or within a cavity between filter plugs.

[0259] When the aerosol modifying element is in the form of a polymeric matrix material, the polymeric matrix material releases the flavouring when the aerosol-generating article is heated, such as when the polymeric matrix is ​​heated above the melting point of the polymeric matrix material, as described in WO-A-2013 / 034488. Typically, such a polymeric matrix material may be located within beads within the aerosol-generating substrate. Alternatively, or additionally, the flavouring may be trapped within a domain of the polymeric matrix material and releasable from the polymeric matrix material upon compression of the polymeric matrix material. Preferably, the flavouring is released upon compression of the polymeric matrix material at a force of about 15 Newtons. Such a flavour modifying element may provide a sustained release of the liquid flavouring over a force range of at least 5 Newtons, such as 5N to 20N, as described in WO-A-2013 / 068304. Typically, such a polymeric matrix material may be located within beads within the filter.

[0260] The aerosol-generating article may comprise a combustible heat source and an aerosol-generating substrate downstream of the combustible heat source, the aerosol-generating substrate being as described above in relation to the first aspect of the invention.

[0261] For example, the substrates described herein may be used in heated aerosol-generating articles of the type disclosed in WO-A-2009 / 022232, which comprise a combustible carbon-based heat source, an aerosol-generating substrate downstream of the combustible heat source, and a thermally conductive element surrounding and in contact with a rear portion of the combustible carbon-based heat source and an adjacent front portion of the aerosol-generating substrate, although it will be appreciated that the substrates described herein may also be used in heated aerosol-generating articles with combustible heat sources having other configurations.

[0262] The present invention provides an aerosol generating system comprising an aerosol generating device including a heating element and an aerosol generating article for use in the aerosol generating device, the aerosol generating article comprising an aerosol generating substrate as described above.

[0263] In a preferred embodiment, the aerosol-generating substrates described herein may be used in a heated aerosol-generating article for use in an electrically operated aerosol-generating system in which the aerosol-generating substrate of the heated aerosol-generating article is heated by an electrical heat source.

[0264] For example, the aerosol-generating substrates described herein may be used in heated aerosol-generating articles of the type disclosed in EP-A-0 822 760.

[0265] The heating element of such an aerosol-generating device may be in any suitable form that conducts heat. Heating of the aerosol-generating substrate may be accomplished internally, externally, or both. The heating element may preferably be a heater blade or pin adapted to be inserted into the substrate such that the substrate is heated internally. Alternatively, the heating element may partially or completely surround the substrate and heat it circumferentially from the outside.

[0266] The aerosol-generating system may be an electrically operated aerosol-generating system equipped with an induction heating device. The induction heating device typically includes an induction source configured to be coupled to the susceptor, which may be provided external to the aerosol-generating substrate or internal to the aerosol-generating substrate. The induction source generates an alternating electromagnetic field, which induces magnetization or eddy currents in the susceptor. The susceptor may heat up as a result of hysteresis losses or induced eddy currents, which heat the susceptor through ohmic or resistive heating.

[0267] The electrically operated aerosol generating system comprising an induction heating device also comprises an aerosol-generating article having an aerosol-generating substrate and a susceptor in thermal proximity to the aerosol-generating substrate. Typically, the susceptor is in direct contact with the aerosol-generating substrate and heat is transferred from the susceptor to the aerosol-generating substrate primarily by conduction. Examples of electrically operated aerosol generating systems comprising an induction heating device and an aerosol-generating article having a susceptor are described in WO-A1-95 / 27411 and WO-A1-2015 / 177255.

[0268] The susceptor may be a plurality of susceptor particles that may be deposited on or embedded within the aerosol-generating substrate. If the aerosol-generating substrate is in the form of one or more sheets, the susceptor particles may be deposited on or embedded within the one or more sheets. The susceptor particles may, for example, be fixed by the substrate in sheet form and remain in their initial position. The susceptor particles may preferably be uniformly distributed within the homogenized star anise material of the aerosol-generating substrate. Due to the particulate nature of the susceptor, heat is generated according to the distribution of the particles within the homogenized star anise material sheet of the substrate. Alternatively, susceptors in the form of one or more sheets, strips, pieces, or rods may also be used that are placed next to the homogenized star anise material or embedded in the homogenized star anise material. In one embodiment, the aerosol-forming substrate comprises one or more susceptor strips. For example, a rod of the aerosol-generating substrate may comprise an elongated susceptor element that extends longitudinally through its substrate. In another embodiment, the susceptor is present in an aerosol generating device.

[0269] The susceptor may have a heat loss of more than 0.05 Joules / kilogram, preferably more than 0.1 Joules / kilogram. Heat loss is the capacity of the susceptor to transfer heat to the surrounding material. Since the susceptor particles are preferably uniformly distributed within the aerosol-generating substrate, uniform heat loss from the susceptor particles may be achieved, thus resulting in a uniform heat distribution within the aerosol-generating substrate, leading to a uniform temperature distribution within the aerosol-generating article. It has been found that a specific minimum heat loss of 0.05 Joules / kilogram in the susceptor particles allows the aerosol-generating substrate to be heated to a substantially uniform temperature to provide aerosol generation. In such an embodiment, the average temperature reached within the aerosol-generating substrate is preferably about 200 degrees Celsius to about 240 degrees Celsius.

[0270] The reduction of the risk of overheating of the aerosol-generating substrate may be supported by the use of a susceptor material with a Curie temperature, which allows the heating process due to hysteresis losses to reach only up to a certain maximum temperature. The susceptor may have a Curie temperature of about 200 degrees Celsius to about 450 degrees Celsius, preferably about 240 degrees Celsius to about 400 degrees Celsius, for example about 280 degrees Celsius. When the susceptor material reaches its Curie temperature, it changes magnetic properties. At the Curie temperature, the susceptor material changes from a ferromagnetic phase to a paramagnetic phase. At this point, heating based on energy losses due to the orientation of the ferromagnetic regions stops. Thereafter, further heating is mainly based on the formation of eddy currents, such that the heating process is automatically reduced when the Curie temperature of the susceptor material is reached. The susceptor material and its Curie temperature are preferably adapted to the composition of the aerosol-generating substrate in order to achieve optimal temperature and temperature distribution within the aerosol-generating substrate for optimal aerosol generation.

[0271] In some preferred embodiments of the aerosol-generating article according to the invention, the susceptor is made of ferrite. Ferrite is a ferromagnetic material with high magnetic permeability and is particularly suitable as a susceptor material. The main component of ferrite is iron. Other metallic components (e.g. zinc, nickel, manganese) or non-metallic components (e.g. silicon) may be present in various amounts. Ferrite is a relatively inexpensive commercially available material. Ferrite is available in particulate form within the size range of the particles used in the particulate plant material forming the homogenized star anise material according to the invention. The particles are preferably fully sintered ferrite powders, such as, for example, FP160, FP215, FP350 by PPT (Indiana, USA).

[0272] In certain embodiments of the present invention, the aerosol generating system comprises an aerosol-generating article comprising an aerosol-generating substrate as defined above, a source of aerosol former, and a means for vaporizing the aerosol former, preferably a heating element as described above. The source of aerosol former may be a refillable or replaceable reservoir present on the aerosol generating device. The reservoir is physically separate from the aerosol-generating article, and the generated vapor is directed through the aerosol-generating article. The vapor contacts the aerosol-generating substrate which releases volatile compounds, such as nicotine and flavorants in the particulate plant material, to form an aerosol. Optionally, to assist in the vaporization of the compounds in the aerosol-generating substrate, the aerosol generating system may further comprise a heating element, preferably coordinated with the aerosol former, for heating the aerosol-generating substrate. However, in certain embodiments, the heating element used to heat the aerosol-generating article is separate from the heater that heats the aerosol former.

[0273] The present invention further provides an aerosol produced upon heating of an aerosol-generating substrate as defined above, the aerosol comprising specific amounts and ratios of characteristic compounds derived from star anise particles as defined above.

[0274] According to the present invention, the aerosol comprises (E)-anethole in an amount of at least 0.4 micrograms per aerosol puff, epoxyanethole in an amount of at least 0.2 micrograms per aerosol puff, and benzyl isoeugenol ether in an amount of at least 0.1 micrograms per aerosol puff. For purposes of the present invention, a "puff" is defined as the volume of aerosol released from an aerosol-generating substrate upon heating and collected for analysis, and an aerosol puff has a puff volume of 55 milliliters generated by a smoking machine. Thus, any reference herein to an aerosol "puff" is understood to refer to a 55 milliliter puff unless otherwise stated.

[0275] The ranges shown define the total amount of each component measured in a 55 milliliter puff of aerosol. The aerosol may be generated from an aerosol-generating substrate using any suitable means, and may be trapped and analyzed as described above to identify and measure the amounts of characteristic compounds within the aerosol. For example, a "puff" may correspond to a 55 milliliter puff measured in a smoking machine, such as that used in the Health Canada test method described herein.

[0276] Preferably, the aerosol according to the invention comprises at least about 1 microgram of (E)-anethole per aerosol puff, more preferably at least about 2 micrograms of (E)-anethole per aerosol puff, and even more preferably at least about 5 micrograms of (E)-anethole per aerosol puff. Alternatively or additionally, the aerosol generated from the aerosol-generating substrate comprises at most about 15 micrograms of (E)-anethole per aerosol puff, preferably at most about 12 micrograms of (E)-anethole per aerosol puff, and even more preferably at most about 10 micrograms of (E)-anethole per aerosol puff. For example, the aerosol generated from the aerosol-generating substrate may contain from about 0.4 micrograms to about 15 micrograms of (E)-anethole per aerosol puff, or from about 1 micrograms to about 12 micrograms of (E)-anethole per aerosol puff, or from about 2 micrograms to about 10 micrograms of (E)-anethole per aerosol puff.

[0277] Preferably, the aerosol according to the invention comprises at least about 0.5 micrograms of epoxy anethole per aerosol puff, more preferably at least about 1 microgram of epoxy anethole per aerosol puff, and even more preferably at least about 2 micrograms of epoxy anethole per aerosol puff. Alternatively or additionally, the aerosol generated from the aerosol-generating substrate comprises at most about 10 micrograms of epoxy anethole per aerosol puff, preferably at most about 8 micrograms of epoxy anethole per aerosol puff, and even more preferably at most about 6 micrograms of epoxy anethole per aerosol puff. For example, the aerosol generated from the aerosol-generating substrate may contain from about 0.2 micrograms to about 10 micrograms of epoxy anethole per aerosol puff, or from about 0.5 micrograms to about 8 micrograms of epoxy anethole per aerosol puff, or from about 1 microgram to about 6 micrograms of epoxy anethole per aerosol puff, or from about 2 micrograms to about 6 micrograms of epoxy anethole per aerosol puff.

[0278] Aerosols according to the invention preferably contain at least about 0.1 micrograms of benzyl isoeugenol ether per aerosol puff, more preferably at least about 0.25 micrograms of benzyl isoeugenol ether per aerosol puff, and more preferably at least about 0.5 micrograms of benzyl isoeugenol ether per aerosol puff. Alternatively or additionally, the aerosol generated from the aerosol-generating substrate contains at most about 5 micrograms of benzyl isoeugenol per aerosol puff, preferably at most about 3.5 micrograms of benzyl isoeugenol ether per aerosol puff, and more preferably at most about 2 micrograms of benzyl isoeugenol ether per aerosol puff. For example, the aerosol generated from the aerosol-generating substrate may contain from about 0.1 micrograms to about 5 micrograms of benzyl isoeugenol ether per aerosol puff, or from about 0.25 micrograms to about 3.5 micrograms of benzyl isoeugenol ether per aerosol puff, or from about 0.5 micrograms to about 2 micrograms of benzyl isoeugenol ether per aerosol puff, or from about 5 micrograms to about 10 micrograms of benzyl isoeugenol ether per aerosol puff.

[0279] According to the invention, the aerosol composition is such that the amount of (E)-anethole per puff is not more than 5 times the amount of epoxyanethole per puff, and thus the ratio of (E)-anethole to epoxyanethole in the aerosol is not more than 5:1.

[0280] Preferably, the amount of (E)-anethole per aerosol puff is no more than three times the amount of epoxyanethole per aerosol puff, such that the ratio of (E)-anethole to epoxyanethole in the aerosol is no more than 3:1. More preferably, the amount of (E)-anethole per aerosol puff is no more than twice the amount of epoxyanethole per aerosol puff, such that the ratio of (E)-anethole to epoxyanethole in the aerosol is no more than 2:1.

[0281] According to the invention, the aerosol composition is such that the amount of (E)-anethole per aerosol puff is not more than 10 times the amount of benzyl isoeugenol ether per aerosol puff, and thus the ratio of (E)-anethole to benzyl isoeugenol ether in the aerosol is not more than 10:1.

[0282] Preferably, the amount of (E)-anethole per aerosol puff is not more than 8 times the amount of benzyl isoeugenol ether per aerosol puff, such that the ratio of (E)-anethole to benzyl isoeugenol ether in the aerosol is not more than 8: 1. More preferably, the amount of (E)-anethole per aerosol puff is not more than 6 times the amount of (E)-anethole per aerosol puff, such that the ratio of (E)-anethole to benzyl isoeugenol ether in the aerosol is not more than 6: 1.

[0283] The ratio of epoxyanethole to benzyl isoeugenol ether in the aerosol is preferably about 4:1 to 1:1.

[0284] Defined ratios of (E)-anethole to epoxyanethole and benzyl isoeugenol ether characterize aerosols derived from star anise particles. In contrast, in aerosols generated from star anise oil, the ratios of (E)-anethole to epoxyanethole and the ratios of (E)-anethole to benzyl isoeugenol ether and (E)-anethole will be significantly greater. This is due to the relatively high proportion of (E)-anethole in star anise oil compared to star anise plant material. Furthermore, the levels of epoxyanethole and benzyl isoeugenol ether in star anise oil are zero or near zero.

[0285] The aerosol according to the invention preferably further comprises at least about 0.1 milligrams of aerosol former per aerosol puff, more preferably at least about 0.2 milligrams of aerosol per aerosol puff, and even more preferably at least about 0.3 milligrams of aerosol former per aerosol puff. The aerosol preferably comprises at most 0.6 milligrams of aerosol former per aerosol puff, more preferably at most 0.5 milligrams of aerosol former per aerosol puff, and even more preferably at most 0.4 milligrams of aerosol former per aerosol puff. For example, the aerosol may comprise from about 0.1 milligrams to about 0.6 milligrams of aerosol former per aerosol puff, or from about 0.2 milligrams to about 0.5 milligrams of aerosol former per aerosol puff, or from about 0.3 milligrams to about 0.4 milligrams of aerosol former per aerosol puff. These values ​​are based on a puff volume of 55 milliliters, as defined above.

[0286] Suitable aerosol formers for use in the present invention are described above.

[0287] The aerosol generated from the aerosol-generating substrate according to the present invention preferably further comprises at least about 2 micrograms of nicotine per aerosol puff, more preferably at least about 20 micrograms of nicotine per aerosol puff, and more preferably at least about 40 micrograms of nicotine per aerosol puff. The aerosol preferably comprises at most about 200 micrograms of nicotine per aerosol puff, more preferably at most about 150 micrograms of nicotine per aerosol puff, and more preferably at most about 75 micrograms of nicotine per aerosol puff. For example, the aerosol may comprise from about 2 micrograms to about 200 micrograms of nicotine per aerosol puff, or from about 20 micrograms to about 150 micrograms of nicotine per aerosol puff, or from about 40 micrograms to about 75 micrograms of nicotine per aerosol puff. These values ​​are based on a puff volume of 55 milliliters, as defined above. In some embodiments of the present invention, the aerosol may contain zero micrograms of nicotine.

[0288] Alternatively or additionally, the aerosol according to the present invention may optionally further comprise at least about 0.5 milligrams of cannabinoid compound per aerosol puff, more preferably at least about 1 milligram of cannabinoid compound per aerosol puff, and more preferably at least about 2 milligrams of cannabinoid compound per aerosol puff. The aerosol preferably comprises at most about 5 milligrams of cannabinoid compound per aerosol puff, more preferably at most about 4 milligrams of cannabinoid compound per aerosol puff, and more preferably at most about 3 milligrams of cannabinoid compound per aerosol puff. For example, the aerosol may comprise from about 0.5 milligrams to about 5 milligrams of cannabinoid compound per aerosol puff, or from about 1 milligrams to about 4 milligrams of cannabinoid compound per aerosol puff, or from about 2 milligrams to about 3 milligrams of cannabinoid compound per aerosol puff. In some embodiments of the present invention, the aerosol may contain zero micrograms of cannabinoid compounds. These values ​​are based on a puff volume of 55 milliliters, as defined above.

[0289] Preferably the cannabinoid compound is selected from CBD and THC, more preferably the cannabinoid compound is CBD.

[0290] Carbon monoxide may also be present in aerosols according to the invention and may be measured and used to further characterize the aerosol. Oxides of nitrogen, such as nitric oxide and nitrogen dioxide, may also be present in aerosols and may be measured and used to further characterize the aerosol.

[0291] Aerosols according to the present invention containing characteristic compounds from star anise particles may be formed from particles having a mass median aerodynamic diameter (MMAD) in the range of about 0.01 to 200 microns, or about 1 to 100 microns. When the aerosol contains nicotine as described above, the aerosol preferably contains particles having a MMAD in the range of about 0.1 to about 3 microns to optimize delivery of nicotine from the aerosol.

[0292] The median aerodynamic diameter (MMAD) of an aerosol refers to the particle dynamic diameter at which half of the particulate mass of the aerosol is occupied by particles with an aerodynamic diameter larger than the MMAD and half is occupied by particles with an aerodynamic diameter smaller than the MMAD. The aerodynamic diameter is the mass of a particle that has the same settling velocity as the particle being characterized, measured in g / cm. 3 is defined as the diameter of a spherical particle having a density of

[0293] The mass median aerodynamic diameter of the aerosol according to the present invention can be determined according to Schaller et al., “Evaluation of the Tobacco Heating System 2.2., Section 2.8, Part 2: Chemical composition, genotoxicity, cytotoxicity and physical properties of the aerosol,” Regul. Toxicol. and Pharmacol., 81 (2016) S27-S47.

[0294] Specific embodiments will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0295] [Figure 1] FIG. 1 illustrates a first embodiment of a substrate for the aerosol-generating article described herein. [Diagram 2] FIG. 2 illustrates an aerosol generating system comprising an aerosol generating device including an aerosol generating article and an electric heating element. [Diagram 3] FIG. 3 illustrates an aerosol generating system comprising an aerosol generating device that includes an aerosol-generating article and a combustible heating element. [Figure 4] 4a and 4b illustrate a second embodiment of the substrate of the aerosol-generating article described herein. [Diagram 5] FIG. 5 illustrates a third embodiment of a substrate for an aerosol-generating article described herein. [Figure 6] Figure 6 is a cross-sectional view of a filter 1050 further including an aerosol modification element. Figure 6a illustrates an aerosol modification element in the form of a spherical capsule or bead within a filter plug. Figure 6b illustrates an aerosol modification element in the form of a thread within a filter plug. Figure 6c illustrates an aerosol modification element in the form of a spherical capsule within a cavity within the filter. [Figure 7] FIG. 7 is a cross-sectional view of a plug of aerosol-generating substrate 1020 further comprising an aerosol-modifying element in the form of a bead. [Figure 8] FIG. 8 illustrates the experimental setup for collecting aerosol samples that are analyzed to measure characteristic compounds. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0296] FIG. 1 illustrates a heated aerosol-generating article 1000 that includes a substrate as described herein. The article 1000 comprises four elements: an aerosol-generating substrate 1020, a hollow cellulose acetate tube 1030, a spacer element 1040, and a mouthpiece filter 1050. These four elements are arranged in a coaxial arrangement and assembled with cigarette paper 1060 to form the aerosol-generating article 1000. The article 1000 has a mouth end 1012 that is inserted into the mouth of a user during use, and a distal end 1013 at the opposite end of the article to the mouth end 1012. The embodiment of the aerosol-generating article illustrated in FIG. 1 is particularly suitable for use in an electrically operated aerosol generating device that includes a heater for heating the aerosol-generating substrate.

[0297] When assembled, article 1000 is approximately 45 millimeters long, has an outer diameter of approximately 7.2 millimeters, and an inner diameter of approximately 6.9 millimeters.

[0298] The aerosol-generating substrate 1020 includes a plug formed from a sheet of homogenized star anise material containing star anise particles, alone or in combination with tobacco particles. Some examples of suitable homogenized star anise material for forming the aerosol-generating substrate 1020 are shown in Table 1 below (see Samples A-D). The sheet is assembled, crimped, and wrapped with filter paper (not shown) to form a plug. The sheet includes additives including glycerin as an aerosol former.

[0299] The aerosol-generating article 1000 depicted in Figure 1 is designed to be engaged with an aerosol-generating device for consumption. Such an aerosol-generating device includes a means for heating the aerosol-generating substrate 1020 to a sufficient temperature to form an aerosol. In general, the aerosol-generating device may include a heating element that surrounds the aerosol-generating article 1000 adjacent to the aerosol-generating substrate 1020 or a heating element that is inserted into the aerosol-generating substrate 1020.

[0300] Upon engaging the aerosol-generating device, a user draws on the mouth end 1012 of the smoking article 1000, causing the aerosol-generating substrate 1020 to heat to a temperature of approximately 375 degrees Celsius. At this temperature, volatile compounds are released from the aerosol-generating substrate 1020. These compounds condense to form an aerosol. The aerosol is drawn through a filter 1050 and into the user's mouth.

[0301] Figure 2 illustrates a portion of an electrically operated aerosol generating system 2000 utilizing a heating blade 2100 to heat the aerosol-generating substrate 1020 of an aerosol-generating article 1000. The heating blade is mounted within an aerosol article receiving chamber of an electrically operated aerosol generating device 2010. The aerosol generating device defines a number of air holes 2050 for allowing air to flow to the aerosol-generating article 1000. The air flow is indicated by arrows in Figure 2. The aerosol generating device includes a power source and electronic components, which are not shown in Figure 2. The aerosol-generating article 1000 of Figure 2 is as described with respect to Figure 1.

[0302] In an alternative configuration shown in Figure 3, an aerosol generating system is shown with a combustible heating element. While article 1000 of Figure 1 is intended to be consumed in conjunction with an aerosol generating device, article 1001 of Figure 3 includes a combustible heat source 1080 that can be ignited to transfer heat to an aerosol-generating substrate 1020 to form an inhalable aerosol. Combustible heat source 80 can be a charcoal element assembled adjacent to the aerosol-generating substrate at the distal end 13 of rod 11. Elements that are essentially the same as those in Figure 1 are numbered the same.

[0303] 4a and 4b illustrate a second embodiment of a heated aerosol-generating article 4000a, 4000b. The aerosol-generating substrate 4020a, 4020b comprises a first downstream plug 4021 formed from particulate plant material containing primarily star anise particles, and a second upstream plug 4022 formed from particulate plant material containing primarily tobacco particles. A homogenized plant material suitable for use in the first downstream plug is shown in Table 1 below as Sample A. A homogenized tobacco material suitable for use in the second upstream plug is shown in Table 1 below as Sample E. Sample E contains only tobacco particles and is included for comparison purposes only. In each plug, the homogenized plant material is in the form of a sheet, which is crimped and rolled into a filter paper (not shown). Both sheets contain an additive including glycerol as an aerosol former. In the embodiment shown in FIG. 4a, the plugs are assembled in an end-to-end abutting relationship to form rods, each about 6 mm long. In a more preferred embodiment (not shown), the second plug is preferably longer than the first plug, for example, preferably 2 mm longer, more preferably 3 mm longer, such that the second plug is 7 or 7.5 mm long and the first plug is 5 or 4.5 mm long to provide the desired ratio of tobacco particles to star anise particles in the substrate. In Figure 4b, the cellulose acetate tube support element 1030 has been omitted.

[0304] Articles 4000a, 4000b similar to article 1000 of Figure 1 are particularly suitable for use in the electrically powered aerosol generating system 2000 with heater shown in Figure 2. Elements essentially the same as those in Figure 1 are numbered the same. It may be envisioned by one skilled in the art that a combustible heat source (not shown) may alternatively be used in the second embodiment in place of an electric heating element in a configuration similar to that including combustible heat source 1080 of article 1001 of Figure 3.

[0305] 5 illustrates a third embodiment of a heated aerosol-generating article 5000. The aerosol-generating substrate 5020 comprises a rod formed from a first sheet of homogenized star anise material formed of particulate plant material comprising primarily star anise particles, and a second sheet of homogenized tobacco material comprising primarily cast leaf tobacco. A homogenized star anise material suitable for use as the first sheet is shown in Table 1 below as Sample A. A homogenized tobacco material suitable for use as the second sheet is shown in Table 1 below as Sample E.

[0306] A second sheet is placed on top of the first sheet, and the combined sheets are crimped, assembled, and at least partially wrapped with filter paper (not shown) to form a plug that is a part of the rod. Both sheets include an additive, including glycerol as an aerosol former. Article 5000, similar to article 1000 of FIG. 1, is particularly suitable for use in an electrically operated aerosol generating system 2000 with a heater as shown in FIG. 2. Elements that are essentially the same as those in FIG. 1 are numbered the same. It may be envisioned by one skilled in the art that a combustible heat source (not shown) may alternatively be used in the third embodiment in place of an electric heating element in a configuration similar to that including combustible heat source 1080 of article 1001 of FIG. 3.

[0307] 6 is a cross-sectional view of a filter 1050 further comprising an aerosol modification element. In FIG. 6a, filter 1050 further comprises an aerosol modification element in the form of a spherical capsule or bead 605.

[0308] In the embodiment of Figure 6a, capsules or beads 605 are embedded within filter segment 601 and are surrounded on all sides by filter material 603. In this embodiment, the capsule comprises an outer shell and an inner core, the inner core containing a liquid flavourant. The liquid flavourant is for flavouring the aerosol during use of the aerosol-generating article provided with the filter. The capsule 605 releases at least a portion of the liquid flavourant when the filter is subjected to an external force, for example by squeezing by the consumer. In the illustrated embodiment, the capsule is generally spherical and has a substantially continuous outer shell containing the liquid flavourant.

[0309] In the embodiment of Figure 6b, the filter segment 601 comprises a plug of filter material 603 and a central flavor-bearing thread 607 extending axially through the plug of filter material 603 parallel to the longitudinal axis of the filter 1050. The central flavor-bearing thread 607 is substantially the same length as the plug of filter material 603 such that the ends of the central flavor-bearing thread 607 are visible at the ends of the filter segment 601. In Figure 6b, the filter material 603 is cellulose acetate tow. The central flavor-bearing thread 607 is formed from twisted filter plug wrap and is loaded with an aerosol modifier.

[0310] In the embodiment of Figure 6c, the filter segment 601 comprises two or more plugs 603, 603' of filter material. The plugs of filter material 603, 603' are formed from cellulose acetate so as to be capable of filtering the aerosol provided by the aerosol-generating article. A wrapper 609 is wrapped around and connects the filter plugs 603, 603'. Within the cavity 611 is a capsule 605 comprising an outer shell and an inner core, the inner core containing a liquid flavourant. Alternatively, the capsule may be similar to the embodiment of Figure 6a.

[0311] 7 is a cross-sectional view of an aerosol-generating substrate 1020 further comprising an aerosol modifying element in the form of a bead 705. The aerosol-generating substrate 1020 includes a plug 703 formed from a sheet of homogenized star anise material comprising tobacco particles and star anise particles. The flavour delivery material of the bead 705 incorporates flavourants that are released upon heating the material to a temperature above 220 degrees Celsius. Thus, the flavourants are released into the aerosol as a portion of the plug is heated during use. EXAMPLES

[0312] As described above with reference to the figures, different samples of homogenised plant material for use in an aerosol-generating substrate according to the invention were prepared from aqueous slurries having the compositions set out in Table 1. Samples A to D contain star anise particles according to the invention. Sample E contains only tobacco particles and is included for comparative purposes only.

[0313] The particulate plant material in all samples accounts for 75 percent of the dry weight of the homogenized plant material, while glycerol, guar gum, and cellulose fibers account for the remaining 25 percent of the dry weight of the homogenized plant material. Samples are prepared from aqueous slurries containing 78-79 kg of water per 100 kg of slurry.

[0314] In the tables below, %DWB refers to "dry weight basis", in this case the weight percent calculated relative to the dry weight of the homogenized plant material. Star anise powder was formed from Illicium verum fruits ground by triple impact milling to a final D95=300 microns.

[0315] [Table 1]

[0316] The slurry may be cast onto a glass plate using a casting bar (0.6 mm) and dried in an oven for 7 minutes at 140 degrees Celsius, followed by a second oven for 30 seconds at 120 degrees Celsius.

[0317] For each of homogenized plant material samples A-E, plugs were generated from a single continuous sheet of homogenized plant material, each having a width of 100 mm to 125 mm. The individual sheets were approximately 220 microns thick and weighed approximately 200 g / m 2 The cut width of each sheet was adapted based on the thickness of each sheet to produce rods of comparable volume. The sheets were crimped to a height of 165 microns to 170 microns, rolled into plugs having a length of about 12 mm and a diameter of about 7 mm, and surrounded by a paper wrapper.

[0318] For each plug, an aerosol-generating article having a total length of about 45 mm was formed having a structure as shown in Figure 3, comprising, from the downstream end, an oral end cellulose acetate filter (about 7 mm long), an aerosol spacer (about 18 mm long) comprising a crimped sheet of polylactic acid polymer, a hollow acetate tube (about 8 mm long), and a plug of aerosol-generating substrate.

[0319] For Sample A of homogenized star anise material, in which the star anise particles comprised 100 percent of the particulate plant material, the characteristic compounds were extracted from a plug of homogenized star anise material using methanol as detailed above. The extract was analyzed as described above to confirm the presence of the characteristic compounds and to measure the amount of the characteristic compounds. The results of this analysis are shown below in Table 2, where the amounts shown correspond to the amount per aerosol-generating article, where the aerosol-generating substrate of the aerosol-generating article comprises 233 mg of Sample A of homogenized star anise material. For comparison purposes, the amount of the characteristic compounds present in the particulate plant material (star anise particles) used to form Sample A is also shown. For the particulate plant material, the amount shown corresponds to the amount of the characteristic compound in a sample of particulate plant material having a weight corresponding to the total weight of the particulate plant material in the aerosol-generating article containing 233 mg of Sample A. [Table 2]

[0320] For each of the samples B-D, which contain a proportion of star anise particles, the amount of the characteristic compounds can be estimated based on the values ​​in Table 2 by assuming that the amounts are present in proportion to the weight of the star anise particles.

[0321] Mainstream aerosols from aerosol-generating articles incorporating aerosol-generating substrates formed from homogenized plant material Samples A through E were generated in accordance with Test Method A defined above. For each sample, the aerosol generated was contained and analyzed.

[0322] As detailed above, the aerosol-generating article was tested using a commercially available Philip Morris Products SA iQOS® heat-not-burn device Tobacco Heating System 2.2 Holder (THS2.2 Holder) according to Test Method A. The aerosol-generating article was heated under a Health Canada machine smoking regimen for 30 puffs with a puff volume of 55 ml, a puff duration of 2 seconds, and 30 seconds between puffs (as described in ISO / TR 19478-1:2014).

[0323] Aerosols generated during smoking tests were collected on Cambridge filter pads and extracted with a liquid solvent. Figure 10 shows a suitable apparatus for generating and collecting aerosols from an aerosol-generating article.

[0324] The aerosol generating device 111 shown in Figure 10 is a commercially available tobacco heating device (IQOS). The mainstream aerosol content generated during the Health Canada smoking test detailed above is collected in an aerosol collection chamber 113 on an aerosol collection line 120. The glass fiber filter pad 140 is a 44 mm Cambridge glass fiber filter pad (CFP) that is ISO 4387 and ISO 3308 compliant.

[0325] For LC-HRAM-MS analysis : The extraction solvent 170, 170a, in this case methanol and internal standard (ISTD) solution, is present in each microimpinger 160, 160a at a volume of 10 mL. The cold baths 161, 161a each contain dry ice-isopropyl ether to maintain the microimpingers 160, 160a, respectively, at approximately -60°C. The gas-vapor phase is trapped within the extraction solvent 170, 170a as the aerosol is bubbled through the microimpingers 160, 160a. The combined solutions from the two microimpingers are separated in step 181 as impinger trapped gas-vapor phase solution 180.

[0326] The CFP and impinger trapped gas-vapor phase solution 180 are combined in a clean Pyrex® tube in step 190. In step 200, all particulate matter is extracted from the CFP using the impinger trapped gas-vapor phase solution 180 (containing methanol as a solvent) by thorough shaking (to break up the CFP), stirring for 5 minutes, and finally centrifugation (4500 g, 5 minutes, 10° C.). An aliquot (300 μL) of the total reconstituted aerosol extract 220 was transferred to a silanized chromatography vial and diluted with methanol (700 μL) since the extraction solvent 170, 170a already contains the internal standard (ISTD) solution. The vial was closed and mixed for 5 minutes using an Eppendorf ThermoMixer (5° C., 2000 rpm).

[0327] For compound identification, aliquots (1.5 μL) of the diluted extracts were injected and analyzed by LC-HRAM-MS in both full scan and data-dependent fragmentation modes.

[0328] About GCxGC-TOFMS analysis: As mentioned above, when preparing samples for GCxGC-TOFMS experiments, different solvents are appropriate for the extraction and analysis of polar, non-polar, and volatile compounds separated from whole aerosols. The experimental setup is identical to that described for LC-HRAM-MS sample collection, with the exceptions noted below.

[0329] Non-polar and polar The extraction solvent 171, 171a is present in a volume of 10 mL and is a mixture of 80:20 v / v dichloromethane and methanol, also containing a retention index marker (RIM) compound and a stable isotope labeled internal standard (ISTD). The cold baths 162, 162a each contain a dry ice-isopropanol mixture to maintain the microimpingers 160, 160a, respectively, at approximately -78°C. The gas-vapor phase is trapped within the extraction solvent 171, 171a as the aerosol is bubbled through the microimpingers 160, 160a. The combined solutions from the two microimpingers are separated in step 182 as impinger trapped gas-vapor phase solution 210.

[0330] non-polar The CFP and impinger trapped gas-vapor phase solution 210 are combined in a clean Pyrex® tube in step 190. In step 200, all particulate matter is extracted from the CFP using impinger trapped gas-vapor phase solution 210 (containing dichloromethane and methanol as solvents) by thorough shaking (to break down the CFP), stirring for 5 minutes, and finally centrifugation (4500 g, 5 minutes, 10° C.) to separate polar and non-polar components of the total aerosol extract 230.

[0331] A 10 mL aliquot 240 of the entire aerosol extract 230 was removed in step 250. A 10 mL aliquot of water was added and the entire sample was shaken and centrifuged in step 260. The non-polar fraction 270 was separated, dried over sodium sulfate, and analyzed by GCxGC-TOFMS in full scan mode.

[0332] polarity ISTD and RIM compounds were added to the polar fraction 280, which was directly analyzed by GCxGC-TOFMS in full scan mode.

[0333] Each smoking replicate (n=3) contains 270 accumulations of the entrapped reconstituted non-polar fraction and 280 accumulations of the non-polar fraction for each sample.

[0334] Volatile components The entire aerosol was trapped using two microimpingers 160, 160a in series. Extraction solvents 172, 172a, in this case N,N-dimethylformamide (DMF) retention indicator marker (RIM) compounds and stable isotope labeled internal standards (ISTDs), are present in each microimpinger 160, 160a at a volume of 10 mL. Cold baths 161, 161a each contain dry ice-isopropanol ether to maintain the microimpingers 160, 160a at approximately −60° C., respectively. The gas-vapor phase is trapped within the extraction solvent 170, 170a as the aerosol is bubbled through the microimpingers 160, 160a. The combined solution from the two microimpingers is separated as a volatile-containing phase 211 in step 183. The volatile-containing phase 211 is analyzed separately from the other phases and injected directly into the GCxGC-TOFMS using cool on-column without further preparation.

[0335] Table 3 below shows the levels of characteristic compounds from star anise particles in aerosols generated from an aerosol-generating article incorporating Sample A of homogenized star anise material containing only star anise particles. For comparative purposes, Table 3 also shows the levels of characteristic compounds in aerosols generated from an aerosol-generating article incorporating Sample E of homogenized tobacco material containing only tobacco particles (and thus not according to the invention). [Table 3]

[0336] Relatively high levels of characteristic compounds were measured in the aerosol generated from Sample A. The ratio of (E)-anethole to epoxyanethole was less than 2.5, and the ratio of (E)-anethole to benzyl isoeugenol ether was less than 6. Thus, the levels of characteristic compounds indicated the presence of star anise particles in the sample. In contrast, for tobacco-only Sample E, which was substantially free of star anise particles, the levels of characteristic compounds were found to be zero or near zero.

[0337] For each of Samples B-D containing a proportion of star anise particles, the amount of characteristic compound in the aerosol can be estimated based on the values ​​in Table 3 by assuming that the amount is present in proportion to the mass of star anise particles in the aerosol-generating substrate from which the aerosol was generated.

[0338] Table 4 below more generally illustrates the composition of the aerosol generated from an aerosol-generating article incorporating Sample A (star anise only) compared to the composition of the aerosol generated from tobacco-only Sample E (tobacco only). The reduction shown is the reduction provided by substituting star anise particles for tobacco particles in the homogenized tobacco material of Sample E.

[0339] As shown in Table 4, the aerosol generated by Sample A, which contained 100 percent star anise powder by weight, based on the dry weight of the particulate plant material, had reduced levels of propionaldehyde, crotonaldehyde, methyl ethyl ketone, butyraldehyde, acetaldehyde, phenol, o-cresol, catechol, hydroquinone, acrylonitrile, styrene, isoprene, pyridine, benzo[a]pyrene, benz[a]anthracene, pyrene, and total particulate matter, compared to the levels in the aerosol in Sample E, which was generated using 100 percent tobacco by weight, based on the dry weight of the particulate plant material. [Table 4]

Claims

1. 1. An aerosol-generating article comprising an aerosol-generating substrate comprising: star anise particles; an aerosol former; an extrinsic binder; and a homogenized star anise material comprising up to 15 weight percent fibres on a dry weight basis, the fibres having a length greater than 400 micrometres; the aerosol-generating substrate comprising: At least 70 micrograms of (E)-anethole per gram of said substrate on a dry weight basis; at least 50 micrograms of epoxyanethole per gram of said substrate on a dry weight basis; and at least 130 micrograms of benzyl isoeugenol ether per gram of said substrate on a dry weight basis.

2. 10. The aerosol-generating article of claim 1, wherein the homogenized star anise material comprises, on a dry weight basis, from 2 percent to 15 percent by weight of fiber.

3. 2. The aerosol-generating article of claim 1, wherein the amount of (E)-anethole per gram of substrate is no more than 5 times the amount of epoxyanethole per gram of substrate, and the amount of benzyl isoeugenol ether per gram of substrate is at least 1.5 times the amount of (E)-anethole per gram of substrate.

4. 4. The aerosol-generating article of claim 1, wherein the aerosol-generating substrate further comprises, on a dry weight basis, from 1 milligram to 20 milligrams of nicotine per gram of substrate.

5. 5. The aerosol-generating article of claim 1, wherein the homogenized star anise material comprises, on a dry weight basis, from 5 weight percent to 30 weight percent of an aerosol former and from 1 weight percent to 10 weight percent of a binder.

6. 6. The aerosol-generating article of claim 1, wherein the extrinsic binder comprises guar gum.

7. 7. The aerosol-generating article of any of claims 1 to 6, wherein the homogenized star anise material comprises at least 2.5 percent by weight of star anise particles on a dry weight basis.

8. 8. The aerosol-generating article of claim 1, wherein the homogenized star anise material further comprises tobacco particles, and the weight ratio of the star anise particles to the tobacco particles is 1:4 or less.

9. 9. An aerosol-generating article according to any preceding claim, wherein the homogenized star anise material in the aerosol-generating substrate is in the form of cast leaves.

10. When the aerosol-generating substrate is heated by the test method A, at least 20 micrograms of (E)-anethole per gram of said substrate on a dry weight basis; at least 10 micrograms of epoxyanethole per gram of said substrate on a dry weight basis; an aerosol is generated that contains at least 3.5 micrograms of benzyl isoeugenol ether per gram of said substrate on a dry weight basis; 10. The aerosol-generating article of claim 1, wherein the amount of (E)-anethole per gram of substrate is 5 times or less than the amount of epoxyanethole per gram of substrate, and the amount of (E)-anethole per gram of substrate is 10 times or less than the amount of benzyl isoeugenol ether per gram of substrate.

11. 11. The aerosol-generating article of claim 10, wherein the amount of (E)-anethole per gram of substrate is no more than 5 times the amount of epoxyanethole per gram of substrate, and the amount of (E)-anethole per gram of substrate is no more than 6 times the amount of benzyl isoeugenol ether per gram of substrate.

12. When the aerosol-generating substrate is heated by the test method A, the aerosol generated from the aerosol-generating substrate is (E)-anethole in an amount of at least 0.4 micrograms per aerosol puff; epoxyanethole in an amount of at least 0.2 micrograms per aerosol puff; benzyl isoeugenol ether in an amount of at least 0.1 micrograms per aerosol puff; 12. The aerosol-generating article of any one of claims 1 to 11, wherein an aerosol puff has a volume of 55 milliliters generated by a smoking machine, the amount of (E)-anethole per puff is no more than 5 times the amount of epoxyanethole per puff, and the amount of (E)-anethole per puff is no more than 10 times the amount of benzyl isoeugenol ether per puff.

13. 1. An aerosol-generating substrate comprising a homogenized star anise material comprising star anise particles, an aerosol former, an extrinsic binder and up to 15 weight percent fibres on a dry weight basis, said fibres having a length greater than 400 micrometres, said aerosol-generating substrate comprising: At least 70 micrograms of (E)-anethole per gram of said substrate on a dry weight basis; at least 50 micrograms of epoxyanethole per gram of said substrate on a dry weight basis; and at least 130 micrograms of benzyl isoeugenol ether per gram of said substrate on a dry weight basis.

14. 1. An aerosol generation system comprising: An aerosol generating device having a heating element; An aerosol generating system comprising the aerosol generating article according to any one of claims 1 to 12.

15. forming a slurry comprising star anise particles, water, an aerosol former, a binder, and optionally tobacco particles; casting or extruding the slurry in the form of a sheet or strand; and drying the sheet or strand at between 80 degrees Celsius and 160 degrees Celsius.

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