Hot-pressed tobacco substrate

Abstract

The present invention relates to a method for forming a stable aerosol-releasing substrate for use in a heat-not-burn device, the aerosol-releasing substrate comprising: 20-70% aerosol-forming agent and an inhalable agent comprising at least one of tobacco particles and / or a stimulant and / or a flavor. The aerosol-releasing substrate further comprises a gelling agent for gelling the aerosol-releasing substrate, and a disintegrant and / or a thickening stabilizer. The method comprises: a) producing the aerosol-releasing substrate; and b) compressing the aerosol-releasing substrate into a desired shape using a mold under pressure and heat. The present invention further relates to an aerosol-releasing substrate for use in a heat-not-burn device, which is a breathable compressed mass comprising tobacco particles and / or an inhalable agent, a gelling agent, a disintegrant and / or a thickening stabilizer, and 20-70% aerosol-forming agent.

Description

[Technical field]

[0001] The present invention relates to a method of forming a stable shape of an aerosol-releasing substrate for use in a heat-not-burn device, the aerosol-releasing substrate containing at least 20-70% aerosol-forming agent and tobacco particles and / or an inhalable agent. The method comprises: a) producing the aerosol-releasing substrate; and b) compressing the aerosol-releasing substrate into a desired shape using pressure and heat. The present invention further relates to an aerosol-releasing substrate that is a compressed, breathable mass. [Background technology]

[0002] Tobacco products are popular and widespread. Generally, tobacco is used in various forms, such as smoked and smokeless tobacco products. Primarily, tobacco is smoked as combusted cigarettes, which, being a combustion product, carries risk factors that affect, among other things, the lungs. For this reason, other tobacco products, such as smokeless tobacco, have become popular so that tobacco can be enjoyed with reduced risk. These smokeless tobacco products can be designed in a number of ways, for example, with additional flavors that enhance the experience during smoking.

[0003] A number of oral tobacco products have been developed to be suitable for oral and non-combustible smoking. US Patent Publication No. 20180220696 and US Patent No. 9307787 both present orally smokable tobacco products that include tobacco as a main component and several other ingredients.

[0004] However, electronic cigarettes (e-cigarettes) have created the need and potential for new tobacco products that are vaporized and inhaled by the smoker, and avoid combustion products. These e-cigarettes or similar devices, such as e-pipes, usually generate aerosols by heating a liquid containing flavors, e.g., water and optionally an aerosol-forming agent, such as nicotine. However, this can result in an uneven smoking profile, where the flavor of the puffs experienced can vary significantly, e.g., due to insufficient extraction of key compounds in the liquid. This has led consumers to seek alternatives to heated, but not burned, tobacco products.

[0005] Meanwhile, heated devices, which can be used to heat tobacco instead of burning it, have become increasingly popular. These heated devices can be filled with several tobacco products that produce tobacco-based vapor and are heated to approximately 350°C by activating an electric heater. Tobacco products suitable for use in heated devices require a large surface area and at least a certain amount of aerosol-forming agent. Such tobacco products are, for example, tobacco sticks or simply reconstituted tobacco. Tobacco sticks include crushed tobacco leaves compressed into a stick, containing a small amount of humectant, and surrounded by a plastic capsule. Common tobacco products, such as tobacco sticks for use in heated devices, are quite large because they have a small amount of humectant that is vaporized, and the low level of humectant generates a small amount of vape. The large size of these products makes them unwieldy, and the heated devices must be quite large to accommodate the tobacco products. Furthermore, the shape of conventional tobacco products for use in heated devices is unstable during smoking, causing the collapse of the structure of such products. Summary of the Invention [Problem to be solved by the invention]

[0006] It is therefore an object of the present invention to provide a method for producing a steam generating substrate that is smaller than conventional products and at the same time has a solid, stable form and is capable of delivering a similar or increased steam volume to conventional products. The steam generating substrate thus produced should be smaller than conventional products and, if the volume of steam to be delivered is not reduced, the steam generating substrate should be more effective. [Means for solving the problem]

[0007] The above-mentioned problems are solved by a method of forming a stable aerosol-releasing substrate for use in a heated device, the aerosol-releasing substrate containing: 20-70% aerosol-forming agent and an inhalable agent containing at least one of tobacco particles and / or stimulants and / or flavors. The aerosol-releasing substrate further contains a gelling agent for gelling the aerosol-releasing substrate and a disintegrant and / or a thickening stabilizer. The gelling agent is responsible for the soft texture of the substrate when compressed into a sheet. Without the gelling agent, the substrate would be too hard and brittle when compressed. The stabilizer acts as a binder to hold the substrate in a crumb form. The method comprises: a) producing the aerosol-releasing substrate; and b) compressing the aerosol-releasing substrate into a desired shape by using a mold with pressure and heat.

[0008] Because conventional substrates are low in aerosol-forming agent (less than 20% by weight) or are crumbly and brittle, it is beneficial to be able to force an aerosol-releasing substrate with a higher amount (less than 20% by weight) of aerosol-forming agent into a desired shape. Using pressure, heat and a mold, it is possible to force the aerosol-releasing substrate into a desired shape.

[0009] Preferably, the weight of the aerosol-forming agent is more than 25% by weight, preferably more than 30% by weight and preferably more than 35% by weight of the aerosol-emitting substrate, and / or the weight of the tobacco and / or inhalable agent is less than 70% by weight, preferably less than 60% by weight, preferably less than 50% by weight of the aerosol-emitting substrate. Most preferably, the aerosol-forming agent is about 40% by weight of the aerosol-emitting substrate.

[0010] Preferably, the weight of tobacco and / or inhalable agent is more than 5% by weight, preferably more than 10% by weight and preferably more than 20% by weight of the aerosol-releasing substrate, and / or the weight of tobacco and / or inhalable agent is less than 70% by weight, preferably less than 60% by weight, preferably less than 50% by weight of the aerosol-releasing substrate. Most preferred is an amount of tobacco between 30% and 50% by weight of the substrate. This ensures that there is a sufficient amount of tobacco flavor and irritant in the substrate. If the amount of tobacco is increased, for example to more than 50% by weight of the substrate, the amount of other components, for example aerosol formers or stabilizers, must be reduced, so that the substrate may become too brittle and unstable to retain the desired shape after compression.

[0011] Preferably, the tobacco and / or inhalable agent may be any compound, mixture, particulate matter and / or solution that may be inhaled, for example, as a gas and / or aerosol, and that contains and / or carries at least one of the following stimulants, for example caffeine, guarana, and combinations thereof. The tobacco may further essentially contain at least one type of tobacco, preferably a blend of at least two or more different types of tobacco. The use of a blend of different types of tobacco allows the flavor to be adjusted and tailored to the consumer's preferred flavor.

[0012] Preferably, the inhalable agent and / or flavoring is selected from the group consisting of, but not limited to, menthol, natural and / or artificial botanical flavors, sugars, animal flavors, and other flavorings known for use in conventional e-liquids, such as, but not limited to, cinnamon, sage, herbs, chamomile, kudzu (Pueraria lobata), sweet tea (Hydrangeae dulcis folium), cloves, lavender, cardamom, cloves, nutmeg, bergamot, geranium, honey essence, rose oil, lemon, orange, cinnamon, caraway, jasmine, ginger, coriander, vanilla extract, spearmint, peppermint, cassia, coffee, celery, cascarilla, sandalwood, cocoa, ylang ylang, fennel, anise, licorice, carob (St John's The flavoring agent may be selected from the following: bread, prune extract and peach extract; monosaccharides such as glucose, fructose, isomerized sugar and caramel; cocoa, such as powder and extract; esters such as isoamyl acetate, linalyl acetate, isoamyl propionate and linalyl butyrate; ketones such as menthone, ionones, damascenone and ethyl maltol; alcohols such as geraniol, linalool, anethole and eugenol; aldehydes such as vanillin, benzaldehyde and anisaldehyde; lactones such as gamma-undecalactone and gamma-nonalactone; animal flavors such as musk, ambergris, civet and beaver; and hydrocarbons such as limonene and pinene and combinations thereof. Such flavors or others may be used alone or in combination. The inhalable agent and / or flavour and / or combination of flavours may also be combined with at least one or more tobaccos such that the flavour of the substrate can be tailored to the consumer's optimum preferred flavour.

[0013] Preferably, the aerosol former comprises glycerol, propylene glycol, ethanol and / or water. In addition, the aerosol former may comprise, but is not limited to, other alcohol and / or glycol derivatives, sebacate esters and / or mixtures thereof. A glycol derivative that may be used in certain embodiments is propylene glycol, and a suitable sebacate ester may be di-2-ethylhexyl sebacate. In addition, any possible combination of compounds belonging to the above-mentioned classes may be used. For example, a combination of glycerol and propylene glycol may be used as an aerosol former. The majority of these aerosol formers are flavorless and therefore do not mask the inherent flavor of the tobacco, tobacco extract and / or inhalable agent, such as flavors. However, flavorless aerosol formers can still produce aerosols and vapes that carry the flavor of the tobacco, tobacco extract and / or inhalable agent, such as flavors. Moreover, the aerosol former contributes to the consistency and moldability of the substrate.

[0014] Preferably, the stabilizer comprises carboxymethylcellulose and / or hydroxyalkylated carbohydrate. Preferably, purified carboxymethylcellulose is used, such as, for example, Ceroga 4550 C or CEKOL® 2000 (CERoeper GmbH). The stabilizer, such as, for example, carboxymethylcellulose, acts as a binder to make the substrate friable, further preventing its disintegration and thickening it.

[0015] Preferably, the gelling agent is a non-protein containing polysaccharide and / or comprises gellan gum, lecithin, agar and / or mixtures thereof. The gelling agent, especially gellan gum and preferably Gellan gum Roeper 700f, causes the substrate to jelly so that it is moldable. The gelling agent keeps the substrate soft and fluffy. Without the gelling agent, the substrate would be too hard and too brittle.

[0016] Furthermore, it is conceivable to use temperatures above 60°C, preferably above 80°C, preferably above 90°C and / or temperatures below 200°C, preferably below 160°C, preferably below 130°C. Ideally, the temperature range is 100°C to 110°C. By using such temperatures, the conformity of the aerosol-releasing substrate is particularly soft to mold it into the desired shape. Furthermore, the aerosol-releasing substrate has a high risk of losing the aerosol-forming agent because evaporation occurs at temperatures above 200°C. At temperatures below 60°C, the aerosol-releasing substrate may become too fragile to be molded.

[0017] Preferably, the substrate is prepared in step a by mixing the aerosol-forming agent with tobacco particles and / or inhalable agents, gelling agents and anti-disintegration agents and / or thickening stabilizers, followed by a step of maturing the mixture for at least 4 hours, preferably at least 12 hours. Preferably, the maturing step is followed by a step of sieving the substrate, which makes it possible to obtain a substrate in granular form. The sieving step is preferably carried out at a particle size of less than 2 mm, preferably less than 1.7 mm.

[0018] According to a preferred embodiment, the aerosol-releasing substrate is compressed into a mold by compression molding the substrate to less than the desired thickness under a pressure of more than 1 bar, preferably more than 3 bar, preferably more than 5 bar and / or less than 50 bar, preferably less than 30 bar, preferably less than 20 bar. A pressure of 1-50 bar is the best condition for molding the aerosol-releasing substrate and for preserving the pores in the aerosol-releasing substrate necessary to ensure sufficient release of the aerosol. Using a pressure of more than 50 bar will result in an extremely hard and brittle substrate that no longer has pores.

[0019] In a preferred embodiment, the aerosol-releasing substrate is wrapped with a paper sheet layer. Preferably, the aerosol-releasing substrate is wrapped with a paper sheet layer after the aerosol is compressed into a desired shape. Ideally, the paper sheet is permeable to vapor during smoking and / or can absorb the aerosol in the oven area of ​​the vaping device after smoking. It is also possible that the paper sheet can avoid a shrunk and / or burnt shape.

[0020] Preferably, the thickness of the paper is not more than 100 μm (microns), preferably 80 μm, preferably not more than 60 μm, preferably more than 20 μm, preferably more than 30 μm, preferably more than 40 μm. Ideally, the thickness is between 40 μm and 45 μm. The wrapper is beneficial in terms of retaining the shape of the substrate during vaping. Without the wrapper, the substrate tends to deform as its bulk heats up. The wrapper can also keep the color of the substrate consistent.

[0021] Ideally, the paper sheet layer has a thickness of 5 g / m 2 More than 8 g / m 2 More than 10 g / m 2 and / or 25 g / m 2 Less than 20 g / m 2 Less than 15 g / m 2 Furthermore, the paper sheet layer may have a basis weight of less than 1,100 L / m 2 More than 1,200 L / m 2 More than 1,300 L / m 2 These properties ensure the transport of a sufficient amount of aerosol from the substrate through the paper sheet layer.

[0022] In a preferred embodiment, the aerosol-releasing substrate is compressed into a shape-stable sheet that can be placed in the oven area of ​​a heated device without requiring significant space compared to conventional substrate products.

[0023] In a further preferred embodiment, the sheet of aerosol-releasing substrate is compressed to a thickness of less than 5 mm, preferably less than 3 mm, preferably less than 1.5 mm. Ideally, the thickness of the sheet substrate is between 1 and 2 mm. A thickness of 1 to 5 mm is important to ensure heat transfer through the substrate without requiring too much energy, especially since in a given device the sheet will only be heated from one side of the sheet.

[0024] In another preferred embodiment, the additional further compressing step comprises forming grooves or recesses on at least one side of the sheet. Ideally, in the case of a sheet-like substrate, the grooves and / or recesses extend from a first edge to a second edge, where the first edge faces the second edge. Preferably, the grooves and / or recesses extend in the length or width direction of the sheet-like substrate. Furthermore, it is also possible that the grooves and / or recesses have a closed contour circumscribed on the surface of the sheet-like substrate, e.g. representing a brand, logo or image. The advantage is that the surface area of ​​the substrate in contact with the oven is reduced to provide faster heating and more aerosol release. To facilitate air inflow and convection heating, slots can also provide airflow between the oven and the substrate.

[0025] In another preferred embodiment, the mold is preferably made of metal or metal-like material, preferably aluminum. The mold can also be made of plastic and / or composite materials. Ideally, the mold is made of a material that is resistant to heat and pressure and can retain its shape under extremely high temperature and pressure conditions.

[0026] In another preferred embodiment, the mold consists of two parts, preferably more than two parts, and especially three parts, such as a frame that defines the final thickness of the substrate, the bottom plate (e.g., female part) and the top plate (e.g., male part). Ideally, the parts are variable in shape and can be changed, for example, so that the first male part can be used together with the fifth female part. With at least three variable parts of the mold, it is possible to use the mold for different purposes, for example to press different brands on the substrate.

[0027] In another preferred embodiment, the aerosol-releasing substrate is a granular or foam material before compression. Preferably, the aerosol-releasing substrate is a granular material with a particle size of more than 0.1 mm, preferably more than 0.5 mm and preferably more than 1.0 mm and / or a particle size of less than 10 mm, preferably less than 5 mm and preferably less than 3 mm. The particle size of the aerosol-releasing substrate is most preferably in the range of 0.2 mm to 4 mm and particularly preferably 0.7 mm to 2 mm. The granules agglomerate after compression leaving small gaps in the substrate, which is essential to ensure effective vaping during smoking. Less aerosol-forming agents escape from a granular substrate than from a foam substrate, which is also an advantage. It is also possible for the aerosol-releasing substrate to be a foam material. The foam structure includes bubbles trapped as pores in an open or closed structure, where the bubbles may contain air and / or other gases such as nitrogen or oxygen. The open pore structure provides a large surface area that allows heat and aerosol to circulate through the foam, thus enhancing the extraction of flavors and stimulants during smoking, and providing a particularly soft molded consistency.

[0028] If the aerosol-releasing substrate is granular, the tobacco particles have a size of more than 0.1 mm, preferably more than 0.2 mm and preferably more than 0.4 mm and / or less than 1.5 mm, preferably less than 1 mm and preferably 0.8 mm. The particle size of the aerosol-releasing substrate is most preferably in the range of 0.5 mm to 0.7 mm. Such tobacco particle sizes are particularly useful for the release of aerosols. Small particles have a larger outer surface than larger particles and can therefore release much more aerosol than larger particles.

[0029] The above-mentioned problems are solved by an aerosol-releasing substrate for use in a heated device, which is breathable and comprises tobacco particles and / or an inhalable agent containing at least one of a stimulant and / or a flavor. The substrate further comprises a gelling agent for gelling the aerosol-releasing substrate and a disintegrant and / or a thickening stabilizer, and 20-70% of an aerosol-forming agent. Furthermore, the aerosol-releasing substrate is a compressed mass. The compressed mass is convenient and easy for a user to handle. In the compressed mass, the particles are bound together, and the user only needs to pick up one compressed tobacco article to place it in the heated device.

[0030] Ideally, the tobacco particles have a size greater than 0.1 mm, preferably greater than 0.2 mm and preferably greater than 0.4 mm and / or less than 1.5 mm, preferably less than 1 mm and preferably 0.8 mm. The particle size of the aerosol-emitting substrate is most preferably in the range of 0.5 mm to 0.7 mm. Such tobacco particle sizes are particularly useful for aerosol emission. Small particles have a larger outer surface than larger particles and can therefore emit much more aerosol than larger particles.

[0031] Since the aerosol-forming agent generates an aerosol when heated, the aerosol-releasing substrate can release a large amount of aerosol when it contains an aerosol-forming agent that is spread in an amount of 10% of the composition of the substrate. Thus, the substrate can generate a much larger amount of aerosol / vape than a conventional tobacco product. The advantage of a large amount of aerosol-forming agent is that it is a compressed mass, which means that the aerosol-releasing substrate can be placed in a space-saving manner in a heated device or other container, such as a container for transporting and dispensing the substrate.

[0032] Preferably, the weight of tobacco and / or inhalable agent is more than 5% by weight, preferably more than 10% by weight and preferably more than 20% by weight of the aerosol-releasing substrate, and / or the weight of tobacco and / or inhalable agent is less than 70% by weight, preferably less than 60% by weight, preferably less than 51% by weight, more preferably less than 40% by weight of the aerosol-releasing substrate. Most preferred is an amount of tobacco between 30% and 50% by weight of the substrate. This ensures that there is a sufficient amount of tobacco flavor and irritant in the substrate. If the amount of tobacco is increased to, for example, 50% by weight of the substrate, the amount of other components, such as, for example, aerosol formers or stabilizers, must be reduced, so that the substrate may become too brittle and unstable to retain the desired shape after compression.

[0033] Preferably, the tobacco and / or inhalable agent may be any compound, mixture, particulate matter and / or solution that may be inhaled, for example as a gas and / or aerosol, and that contains and / or carries at least one of the following stimulants, for example caffeine, guarana, and combinations thereof. The tobacco may further essentially contain at least one type of tobacco, preferably a blend of at least two or more different types of tobacco. The use of a blend of different types of tobacco allows the flavor to be adjusted, and the flavor to be tailored to suit the consumer's preference.

[0034] Preferably, the inhalable agent and / or flavoring is selected from the group consisting of, but not limited to, menthol, natural and / or artificial botanical flavors, sugars, animal flavors, and other flavorings known for use in conventional e-liquids, such as, but not limited to, cinnamon, sage, herbs, chamomile, kudzu (Pueraria lobata), sweet tea (Hydrangeae dulcis folium), cloves, lavender, cardamom, cloves, nutmeg, bergamot, geranium, honey essence, rose oil, lemon, orange, cinnamon, caraway, jasmine, ginger, coriander, vanilla extract, spearmint, peppermint, cassia, coffee, celery, cascarilla, sandalwood, cocoa, ylang ylang, fennel, anise, licorice, carob (St John's The flavoring agent may be selected from the following: bread, prune extract and peach extract; monosaccharides such as glucose, fructose, isomerized sugar and caramel; cocoa, such as powder and extract; esters such as isoamyl acetate, linalyl acetate, isoamyl propionate and linalyl butyrate; ketones such as menthone, ionones, damascenone and ethyl maltol; alcohols such as geraniol, linalool, anethole and eugenol; aldehydes such as vanillin, benzaldehyde and anisaldehyde; lactones such as gamma-undecalactone and gamma-nonalactone; animal flavors such as musk, ambergris, civet and beaver; and hydrocarbons such as limonene and pinene and combinations thereof. Such flavors or others may be used alone or in combination. The inhalable agent and / or flavour and / or combination of flavours may also be combined with at least one or more tobaccos such that the flavour of the substrate can be tailored to the consumer's optimum preferred flavour.

[0035] Preferably, the aerosol former comprises glycerol, propylene glycol, ethanol and / or water. In addition, the aerosol former may comprise, but is not limited to, other alcohol and / or glycol derivatives, sebacate esters and / or mixtures thereof. A glycol derivative that may be used in certain embodiments is propylene glycol, and a suitable sebacate ester may be di-2-ethylhexyl sebacate. In addition, any possible combination of compounds belonging to the above-mentioned classes may be used. For example, a combination of glycerol and propylene glycol may be used as an aerosol former. The majority of these aerosol formers are flavorless and therefore do not mask the inherent flavor of tobacco, tobacco extracts and / or inhalable agents, such as flavors. However, flavorless aerosol formers can still produce aerosols and vapes that carry the flavor of tobacco, tobacco extracts and / or inhalable agents, such as flavors. Moreover, the aerosol former contributes to the consistency and moldability of the substrate.

[0036] Preferably, the stabilizer comprises carboxymethylcellulose and / or hydroxyalkylated carbohydrate. Preferably, purified carboxymethylcellulose is used, such as, for example, Ceroga 4550 C or CEKOL® 2000 (CERoeper GmbH). The stabilizer, such as, for example, carboxymethylcellulose, serves to prevent the matrix from collapsing and thickens it.

[0037] In a preferred embodiment, the gelling agent is a non-protein containing polysaccharide and / or comprises gellan gum, lecithin, agar and / or mixtures thereof. The gelling agent, especially gellan gum and preferably Gellan gum Roeper 700f, causes the substrate to gel so that it is moldable.

[0038] In a preferred embodiment, the aerosol former comprises glycerol, propylene glycol, ethanol and / or water. In addition, the aerosol former may comprise, but is not limited to, other alcohol and / or glycol derivatives, sebacate esters and / or mixtures thereof. A glycol derivative that may be used in certain embodiments is propylene glycol, and a suitable sebacate ester may be di-2-ethylhexyl sebacate. In addition, any possible combination of compounds belonging to the above-mentioned classes may be used. For example, a combination of glycerol and propylene glycol may be used as an aerosol former. The majority of these aerosol formers are flavorless and therefore do not mask the inherent flavor of the tobacco, tobacco extracts and / or inhalable agents, such as flavors. However, flavorless aerosol formers can still produce aerosols and vapes that carry the flavor of the tobacco, tobacco extracts and / or inhalable agents, such as flavors. Moreover, the aerosol former contributes to the consistency and moldability of the substrate.

[0039] In a preferred embodiment, the ratio of propylene glycol to glycerol is 80:20 to 20:80, preferably 30:70 to 70:30, preferably 40:60 to 60:40. Glycerol and propylene glycol can be used in the same weight percentage, but also with different weight percentages, preferably more than 10% by weight, preferably more than 30% by weight, preferably more than 40% by weight of glycerol, as well as less than 90% by weight, preferably less than 80% by weight, preferably less than 70% by weight of glycerol in combination with more than 10% by weight, preferably more than 30% by weight, preferably more than 40% by weight, and less than 90% by weight, preferably less than 80% by weight, preferably less than 70% by weight of propylene glycol.

[0040] Highly preferred is an excess of glycerol relative to propylene glycol. The amount of propylene glycol can be 10% to 20% by weight of the base material, while the amount of glycerol is 20% to 30% by weight of the base material. Thus, these two components can be suitably set in terms of their ratio. The ratio of propylene glycol to glycerol affects the base viscosity, with more glycerol resulting in a higher viscosity and therefore better texture and moldability of the base material.

[0041] In a preferred embodiment, the aerosol-releasing substrate has a sheet shape. Since a thin sheet can be heated very quickly, heat can be transferred through the sheet in a short time. Thus, the aerosol-releasing substrate has the ability to heat up quickly and release the aerosol uniformly across the sheet.

[0042] In a preferred embodiment, the aerosol-releasing substrate comprises grooves and / or recesses on at least one side of the sheet. Preferably, the aerosol-releasing substrate has grooves and / or recesses on at least one side, preferably both sides, which in particular means that one or both sides of the aerosol-releasing substrate are provided with slots. The grooves and / or recesses can extend from a first edge to an opposing second edge. Preferably, the grooves and / or recesses extend in the length or width direction of the aerosol-releasing substrate. It may also be preferred that the grooves and / or recesses have a closed contour circumscribing on the surface of the sheet-like aerosol-releasing substrate, e.g. representing a brand, logo or image. An advantage of an aerosol-releasing substrate with grooves or recesses is that it reduces the surface area in contact with the oven to provide more rapid heating and faster release of the aerosol. The grooves or recesses can also provide airflow between the oven and the aerosol-releasing substrate to facilitate air inflow and convective heating.

[0043] In a preferred embodiment, the aerosol-releasing substrate has a thickness of more than 0.1 mm, preferably more than 0.3 mm, preferably more than 0.5 mm, and / or a thickness of less than 5 mm, preferably less than 3 mm, preferably less than 1.5 mm. Ideally, the thickness of the aerosol-releasing substrate is less than the width and / or length of the aerosol-releasing substrate. A thickness of 0.1 mm to 5 mm ensures the ability to deliver a sufficient amount of aerosol during smoking.

[0044] In a preferred embodiment, the aerosol-emitting substrate has a width of more than 5 mm, preferably more than 8 mm, preferably more than 10 mm and / or a width of less than 30 mm, preferably less than 20 mm, preferably less than 15 mm and a length of more than 5 mm, preferably more than 8 mm, preferably more than 10 mm and / or a length of less than 30 mm, preferably less than 20 mm, preferably less than 15 mm. Rectangular substrates with a width and / or length of 5 to 20 mm fit best within heated devices. However, it is also possible for the aerosol-emitting substrate to be elliptical or circular with a radius of more than 5 mm, preferably more than 8 mm, preferably more than 10 mm and / or less than 30 mm, preferably less than 20 mm, preferably less than 15 mm. Substrates with a width and / or length fit best within heated devices. Substrates larger or smaller are generally difficult to use in heated devices.

[0045] In a preferred embodiment, the aerosol-releasing substrate is used to release an aerosol when heated by an oven at the volatilization temperature of the aerosol-forming agent in the heated device. When the aerosol-releasing substrate is used to deliver the aerosol to the heated device, the consumer will have a good smoking experience accompanied by a strong flavor.

[0046] Further advantages, objects and features of the present invention will be explained, by way of example only, in the following description with reference to the accompanying drawings in which similar components in different embodiments may bear the same reference symbols, in which: [Brief description of the drawings]

[0047] [Figure 1] FIG. 1 illustrates a method for forming a stable shape of an aerosol-releasing substrate, as illustrated in a chart. [Diagram 2] FIG. 1 shows a schematic diagram of a compressed aerosol emitting substrate. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] In FIG. 1, a method M is illustrated for forming an aerosol-releasing substrate into a stable shape 4. In a first step 1, an aerosol-releasing substrate is produced. Preferably, the aerosol-releasing substrate contains 30% to 60% by weight, ideally 40% to 50% by weight of an aerosol-forming agent by weight of the aerosol-releasing substrate. The aerosol-forming agent ideally comprises 2% to 6% by weight of water and 10% to 20% by weight of propylene glycol and 20% to 30% by weight of glycerol by weight of the substrate. The aerosol-forming agent further comprises water in an amount of more than 1% by weight, preferably more than 2% by weight, preferably more than 3% by weight and / or less than 20% by weight, preferably less than 10% by weight, preferably less than 6% by weight, and ideally 2% to 5% by weight by weight of the aerosol-releasing substrate.

[0049] Preferably, the aerosol-releasing substrate contains a gelling agent, especially in the form of gellan gum, in an amount of more than 2% by weight, preferably more than 4% by weight and / or less than 12% by weight, preferably less than 10% by weight, preferably less than 8% by weight, and ideally from 5% to 8% by weight, by weight of the aerosol-releasing substrate. For significantly higher tobacco contents, for example more than 45% by weight, for example about 50% by weight, gellan gum may be present in an amount of about 3 to 6% by weight, preferably 3.5 to 5.5% by weight.

[0050] The aerosol-releasing substrate further comprises an anti-disintegrant and / or thickening stabilizer, especially based on cellulose and especially cellulose derivatives, in an amount of more than 8% by weight, preferably more than 10% by weight, preferably 12% or more and / or less than 30% by weight, preferably less than 25% by weight, preferably less than 20% by weight, and ideally between 14% and 18% by weight of the aerosol-releasing substrate. For significantly higher tobacco contents, for example more than 40% by weight, for example about 50% by weight, the stabilizer may be present in an amount of about 8-15% by weight, preferably 10-13% by weight.

[0051] Ideally, the content of tobacco and / or inhalable agent in the aerosol-releasing substrate is greater than 5% by weight, preferably greater than 10% and preferably greater than 20% and / or less than 70% by weight, preferably less than 60% by weight, preferably less than 40% by weight, and ideally between 30% and 40% by weight of the aerosol-releasing substrate. The size of the tobacco particles is preferably less than 800 μm, preferably less than 700 μm, and ideally less than 600 μm.

[0052] After the ingredients of the aerosol-releasing substrate have been mixed and processed to provide the aerosol-releasing substrate, the aerosol-releasing substrate is preferably in granular form 1a with a preferred particle size of 1 mm to 3 mm. It is also possible for the aerosol-releasing substrate to have a foam structure 3b prior to the compression step.

[0053] In a second step 2, the aerosol-releasing substrate is compressed into a solid and stable form. A die with male and female parts is used to compress the aerosol-releasing substrate into the desired shape. The die provides slots with which the aerosol-generating substrate is compressed into a sheet-like form with grooves and / or recesses. Preferably, the slots are aligned in the airflow direction. Ideally, the aerosol-releasing substrate is compressed together with a paper layer W, where each paper layer preferably has a weight of 10 g / m 2 ~15g / m 2 Weight, thickness 40μm~45μm, 1.100L / m 2Preferably, the substrate is compressed with at least a first paper layer on a first side and especially with a second paper layer on an opposing second side of the compressed substrate.

[0054] The aerosol-releasing substrate is compressed under conditions comprising a temperature T lying in the range of 90° C. to 120° C. and / or a pressure P lying between 5 and 15 bar.

[0055] The aerosol-releasing substrate is compressed to a desired thickness of 1 mm to 2 mm and then cut in a third step 3 into the desired final shape 4 shown in Figure 2. Ideally, the compressed aerosol-releasing substrate 4 in its final shape has a weight of more than 50 mg, preferably more than 100 mg, preferably more than 150 mg and / or less than 400 mg, preferably less than 350 mg, preferably less than 300 mg.

[0056] After the cutting step 3, the compressed aerosol-releasing substrate 4 is a rectangle with a width 4b and / or length 4c of 10 mm to 20 mm (see FIG. 2). Preferably, the compressed aerosol-releasing substrate 4 has grooves 4a and / or recesses extending in the direction of the length 4c or width 4d of the sheet-like substrate 4. The grooves and / or recesses are arranged on a first side and / or a second side opposite to the first side. Ideally, the thickness of the compressed aerosol-releasing substrate is less than the width 4b and / or length 4c of the aerosol-releasing substrate. Preferably, the width 4b is equal to, greater than, or less than the length 4d of the aerosol-releasing substrate.

[0057] Generally, the weight of the substrate is related to the TPM (total particulate matter) and the warm-up time before the first puff. The heavier the weight, the more TPM is released and the longer the warm-up time. The shape does not significantly affect the TPM, but the slotted substrate requires a shorter warm-up time. However, for the same amount of substrate and the same heating conditions, the TPM of the substrate of the present invention is higher than that of the standard tobacco reconstituted substrate. EXAMPLES

[0058] The following two examples illustrate preferred embodiments of the aerosol-releasing substrate. The following numbers are given in weight percent calculated relative to the total weight of the complete mixture.

[0059] Example 1 Preferred embodiments of the aerosol-releasing substrate include: 33.0% by weight of tobacco particles; 6.8% by weight of gellan gum, 16.4% by weight of binder, 3.8% by weight of water, 24.0% by weight of glycerin, Contains 16.0% by weight of propylene glycol.

[0060] The tobacco particles contain nicotine as a stimulant. The size of the tobacco particles in this embodiment is preferably 600 μm. Water is used to activate the binder that together forms a thickening stabilizer. Preferably, the binder is carboxymethylcellulose (CMC), more preferably Ceroga 4550C.

[0061] Example 2 Another preferred embodiment of the aerosol-releasing substrate is: 49.0% by weight of tobacco particles; 4.7% by weight of gellan gum, 11.7% by weight of binder, 2.8% by weight of water, 19.3% by weight of glycerin, Contains 12.5% ​​by weight propylene glycol.

[0062] The tobacco particles contain nicotine as a stimulant. Due to the high amount of tobacco particles, the release of nicotine is higher compared to Example 1, and also the sensory impact is stronger than that of Example 1. The size of the tobacco particles in this example is preferably 600 μm. Water is used to activate the binder that together forms a thickening stabilizer. Preferably, the binder is carboxymethylcellulose (CMC), more preferably Ceroga 4550C. The aerosol releasing substrates of Examples 1 and 2 contain the same visual and tactile properties.

[0063] The following provides an example of a preferred embodiment of the method for producing an aerosol-emitting substrate. The preferred embodiment of the method is preferably combined with Examples 1 and 2 provided above.

[0064] First, propylene glycol, glycerin and water are mixed in the bowl of a Kenwood mixer and mixed at level 5 for 3 minutes. Gellan gum is then added to the mixture at the lowest mixing speed and then mixed with other ingredients for 3 minutes using level 5 mixing speed. Tobacco particles are then added to the mixture at the lowest mixing speed and then mixed with other ingredients for 3 minutes using level 5 mixing speed. Subsequently, binder is added to the mixture, preferably at the lowest mixing speed, and then mixed with other ingredients for 1 minute using level 5 mixing speed. The mixing bowl is then removed from the mixer and the mixture is further mixed manually or alternatively in the mixer at the lowest mixing speed until a homogenous color of the mixture is achieved. The mixture is then stored in a closed container for 24 hours. The mixture is then sieved through a 1.7 mm sieve at 280 rpm for 5 minutes. This sieving process is repeated until the entire mixture is sieved. The aerosol-releasing substrate is now complete. The aerosol-releasing substrate now preferably contains a moisture content of 15.94%. The aerosol-releasing substrate is then compressed into the desired shape using a mold with pressure and heat.

[0065] The applicant reserves the right to claim all features disclosed in the present application as essential features of the invention, insofar as they are novel in the light of the prior art, either individually or in combination. It should further be noted that the figures describe features that may be advantageous individually. Those skilled in the art will immediately recognize that certain features disclosed in the figures may be advantageous without incorporating additional features of the figures. Moreover, those skilled in the art will recognize that advantages may develop from combinations of various features disclosed in one or various figures. The present invention includes the following embodiments. [1] A method M for forming a stable aerosol-emitting substrate for use in a heated device, the aerosol-emitting substrate comprising: - 20-70% aerosol formers; - an inhalable agent containing at least one of tobacco particles and / or pungents and / or flavors; - a gelling agent for gelling the aerosol-releasing substrate; - containing a disintegrant and / or a thickening stabilizer, Below: a. Step 1 of producing the aerosol-releasing substrate; b. compressing the aerosol-releasing substrate into a desired shape using a mold with pressure and heat. [2] The method M according to [1], characterized in that a temperature T above 60° C., preferably above 80° C., preferably above 90° C. and / or a temperature T below 200° C., preferably below 160° C., preferably below 130° C. is used. [3] The method according to [1] or [2], characterized in that the aerosol-releasing substrate is compressed into the mold by compression molding the substrate to a desired thickness under a pressure P of more than 1 bar, preferably more than 3 bar, preferably more than 5 bar and / or a pressure P of less than 50 bar, preferably less than 30 bar, preferably less than 20 bar. [4] The method according to any one of [1] to [3], wherein the aerosol-releasing substrate is surrounded by a paper sheet layer. [5] The method according to any one of [1] to [4], wherein the aerosol-releasing substrate is compressed 2 into a shape-stable sheet 4. [6] The method according to [5], characterized in that the sheet 4 of aerosol-releasing substrate is compressed 2 to a thickness of less than 5 mm, preferably less than 3 mm, preferably less than 1.5 mm. [7] The method according to [5] or [6], wherein the compressing step 2 further comprises forming grooves 4a or recesses on at least one side of the sheet 4. [8] The method M according to any one of [1] to [7], wherein the aerosol-releasing substrate is a granular 1a or foam 1b material before compression. [9] Method M according to any one of [1] to [8], characterized in that the substrate is produced by adding a gelling agent to the substrate in an amount of more than 2% by weight, preferably 4% or more and / or less than 12% by weight, preferably less than 10% by weight, preferably less than 8% by weight, and ideally between 5% and 8% by weight, based on the weight of the aerosol-releasing substrate.

[10] Method M according to any one of [1] to [9], characterized in that the substrate is produced by adding the anti-disintegrant and / or thickening stabilizer in an amount of more than 8% by weight, preferably more than 10% by weight, preferably more than 12% by weight, preferably more than 14% by weight and / or less than 30% by weight, preferably less than 25% by weight, preferably less than 20% by weight, and ideally between 14% and 18% by weight, based on the weight of the aerosol-releasing substrate.

[11] The method according to any one of [1] to

[10] , characterized in that the substrate is produced in step a by mixing the aerosol-forming agent with tobacco particles and / or an inhalable agent, the gelling agent and the disintegration inhibitor and / or thickening stabilizer, followed by maturing the mixture for at least 4 hours.

[12] It is breathable, - an inhalable agent containing at least one of tobacco particles and / or stimulants and / or flavors; - a gelling agent for gelling the aerosol-releasing substrate; - anti-disintegrants and / or thickening stabilizers, - 20-70% aerosol forming agent, 1. An aerosol-emitting substrate 4 for use in a heated device, characterized in that the aerosol-emitting substrate 4 is a compressed mass.

[13] The substrate 4 described in

[12] , characterized in that the gelling agent is a non-protein-containing polysaccharide and / or comprises gellan gum, lecithin, agar and / or a mixture thereof.

[14] The substrate 4 according to

[12] or

[13] , characterized in that the aerosol forming agent contains glycerol, propylene glycol, ethanol and / or water.

[15] The base material 4 according to

[12] , characterized in that the ratio of propylene glycol to glycerol is 80:20 to 20:80, preferably 30:70 to 70:30, and preferably 40:60 to 60:40.

[16] The aerosol-releasing substrate 4 according to any one of

[12] to

[15] , wherein the aerosol-releasing substrate 4 is in the form of a sheet.

[17] The substrate 4 according to

[16] , characterized in that at least one side of the sheet includes a groove 4a or a recess.

[18] The substrate 4 according to any one of

[12] to

[17] , characterized in that the aerosol-releasing substrate 4 has a thickness of more than 0.1 mm, preferably more than 0.3 mm, preferably more than 0.5 mm, and / or a thickness of less than 5 mm, preferably less than 3 mm, preferably less than 1.5 mm.

[19] The substrate 4 according to any one of

[12] to

[18] , characterized in that the aerosol-releasing substrate 4 has a width 4b of more than 5 mm, preferably more than 8 mm, preferably more than 10 mm, and / or a width 4b of less than 30 mm, preferably less than 20 mm, preferably less than 15 mm, and a length 4c of more than 5 mm, preferably more than 8 mm, preferably more than 10 mm, and / or a length 4c of less than 30 mm, preferably less than 20 mm, preferably less than 15 mm.

[20] The substrate 4 described in any one of

[12] to

[19] , characterized in that the added gelling agent in the substrate is contained in an amount of more than 2 wt%, preferably more than 4 wt%, preferably more than 6 wt% and / or less than 12 wt%, preferably less than 10 wt%, preferably less than 8 wt%, and ideally from 5 wt% to 8 wt%, based on the weight of the aerosol-releasing substrate.

[21] The substrate 4 described in any one of

[12] to

[20] , characterized in that the anti-disintegrant and / or thickening stabilizer is contained in an amount of more than 8 wt%, preferably more than 10 wt%, preferably 12 wt% or more and / or less than 30 wt%, preferably less than 25 wt%, preferably less than 20 wt%, and ideally 14 wt% to 18 wt%, based on the weight of the aerosol-releasing substrate.

[22] Use of the substrate 4 described in any one of

[12] to

[21] to deliver an aerosol when heated by an oven at the volatilization temperature of the aerosol forming agent in a heated device. [Explanation of symbols]

[0066] 1 Process 1 1a Granular aerosol releasing material 1b Aerosol-releasing substrate with foam structure 2 Process 2 3 Process 3 4. Compressed aerosol delivery substrate 4a Groove / recess 4b width 4c Length M. Method for making aerosol-releasing substrates into a stable form P Pressure T temperature W paper layer

Claims

1. 1. A method M for forming an aerosol-emitting substrate into a stable form for use in a heated device, the aerosol-emitting substrate comprising: - more than 35% by weight and up to 70% by weight of an aerosol former, - an inhalable agent containing at least one of tobacco particles and / or stimulants and / or flavors; - a gelling agent for gelling said aerosol-releasing substrate; - containing a disintegrant and / or a thickening stabilizer, Below: a. Step 1 of preparing the aerosol-releasing substrate; b. Using pressure and heat, compressing the aerosol-releasing substrate into a desired shape using a mold, where the aerosol-releasing substrate is compressed into a shape-stable sheet 4.

2. 2. The method according to claim 1, characterized in that a temperature T of the compression in step 2 is used that is greater than 60° C. and less than 200° C.

3. 3. The method according to claim 1 or 2, characterized in that the aerosol-releasing substrate is compressed into the mold by a step of compression molding the substrate to a desired thickness under a pressure P of more than 1 bar and less than 50 bar.

4. The method according to any one of claims 1 to 3, characterized in that the aerosol-releasing substrate is surrounded by a paper sheet layer.

5. Method M according to any one of claims 1 to 4, characterised in that the sheet 4 of aerosol-releasing substrate is compressed 2 to a thickness of less than 5 mm.

6. The method M according to any one of claims 1 to 5, wherein the compressing step 2 further comprises forming grooves 4a or recesses in at least one side of said sheet 4.

7. Method M according to any one of claims 1 to 6, characterized in that the aerosol-releasing substrate is a granular 1a or foam 1b material prior to compression.

8. Method M according to any one of claims 1 to 7, characterized in that the substrate is produced by adding a gelling agent to the substrate in an amount greater than 2% by weight and less than 12% by weight, based on the weight of the aerosol-emitting substrate.

9. Method M according to any one of claims 1 to 8, characterized in that the substrate is prepared by adding the disintegration inhibitor and / or thickening stabilizer in an amount of more than 8% by weight and less than 30% by weight of the aerosol-releasing substrate.

10. Method M according to any one of claims 1 to 9, characterized in that the substrate is produced in step a by mixing the aerosol-forming agent with tobacco particles and / or inhalable agent, the gelling agent and the disintegration and / or thickening stabilizer, followed by maturing the mixture for at least 4 hours.

11. It is breathable, - an inhalable agent containing at least one of tobacco particles and / or stimulants and / or flavors; a gelling agent for gelling the aerosol-releasing substrate; - disintegrants and / or thickening stabilizers, - more than 35% by weight and up to 70% by weight of an aerosol former, The aerosol-emitting substrate 4 for use in a heated device is characterized in that the aerosol-emitting substrate 4 is a compressed mass and in the form of a sheet.

12. Substrate 4 according to claim 11, characterized in that the gelling agent is a non-protein-containing polysaccharide and / or comprises gellan gum, lecithin, agar and / or mixtures thereof.

13. Substrate 4 according to claim 11 or 12, characterized in that the aerosol forming agent comprises glycerol, propylene glycol, ethanol and / or water.

14. The substrate 4 according to claim 11, characterized in that the aerosol forming agent comprises glycerol and propylene glycol, and the ratio of propylene glycol to glycerol is from 80:20 to 20:

80.

15. Substrate 4 according to any one of claims 11 to 14, characterized in that at least one side of said sheet comprises grooves 4a or recesses.

16. The aerosol-emitting substrate 4 according to any one of claims 11 to 15, characterized in that the substrate 4 has a thickness of more than 0.1 mm and less than 5 mm.

17. The aerosol-emitting substrate 4 according to any one of claims 11 to 16, characterized in that the aerosol-emitting substrate 4 has a width 4b of more than 5 mm and less than 30 mm and a length 4c of more than 5 mm and less than 30 mm.

18. The substrate 4 according to any one of claims 11 to 17, characterized in that the added gelling agent in the substrate is contained in an amount greater than 2% by weight and less than 12% by weight, by weight of the aerosol-emitting substrate.

19. The substrate 4 according to any one of claims 11 to 18, characterized in that the anti-disintegrant and / or thickening stabilizer is contained in an amount of more than 8% by weight and less than 30% by weight of the aerosol-releasing substrate.

20. Use of a substrate 4 according to any one of claims 11 to 19 to deliver an aerosol when heated by an oven at the volatilisation temperature of the aerosol forming agent in a heated device.

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