Novel aerosol generating material containing a cellulose-based filler

Abstract

An aerosol generating substrate (40)(114) for use in an aerosol generating article or system comprises at least 10 weight percent of an aerosol forming agent based on dry weight; at least 30 weight percent of a cellulose-based filler based on dry weight; one or more hydrocolloid binders—the total amount of hydrocolloid binders is at most 5 weight percent of the aerosol generating substrate (40)(114) based on dry weight—and at least one of an activator or a flavoring agent. The weight ratio of the cellulose-based filler to the aerosol forming agent within the aerosol generating substrate (40)(114) is at least 1. The aerosol generating substrate (40)(114) is in the form of a plurality of beads.

Description

Technology Field

[0001] The present invention relates to a novel aerosol generating substrate, an article comprising an aerosol generating substrate, and a method for producing an aerosol generating substrate. Background Technology

[0002] A number of aerosol generating articles are proposed in the art in which an aerosol generating material, such as a cigarette, is heated rather than combusted. In these aerosol generating articles, the aerosol is typically generated by heating the aerosol generating material to a predetermined temperature. For example, smoking articles are disclosed in which an aerosol is generated by electric heating, or by transferring heat from a combustible fuel element or a heat source to a cigarette-containing aerosol generating material. During smoking, volatile compounds are released from the aerosol generating material by heat transfer from the heat source and are entrained in droplets into the air inhaled through the smoking article. As the released compounds cool, they condense to form an aerosol inhaled by the consumer.

[0003] Typically, an aerosol generating article in which tobacco is heated rather than burned further comprises one or more elements paired with an aerosol generating substrate. For example, an aerosol generating article is proposed comprising one or more of a load of the aerosol generating substrate and a support element made suitable for imparting increased structural strength to the aerosol generating article, an aerosol cooling element configured to lower the temperature of the aerosol before it reaches the mouth end of the aerosol generating article, and a mouthpiece element.

[0004] It is common to produce aerosol generating articles in which the aerosol generating substrate is formed from cylindrical rods of tobacco materials, such as cigarettes or homogenized tobacco materials. However, it has been shown that these cylindrical rods of tobacco materials do not provide optimal aerosol generation when heated rather than combusted. Cigarette rods typically possess relatively high density and relatively low porosity due to the way the tobacco material is compressed during manufacturing. This can lead to difficulties in heating the tobacco material uniformly, and indeed, studies have shown that a significant portion of the cylindrical rod may not heat up sufficiently to form an aerosol during use. Consequently, this portion of the rod is effectively wasted. Additionally, the fixed size and shape of the cylindrical rods of tobacco material provide little flexibility to adapt the aerosol generating substrate for use in new and more efficient designs of aerosol generating articles and devices. The problem to be solved

[0005] It would be desirable to provide a novel substrate for a heated aerosol generating article that can achieve more efficient aerosol generation and provide an improved experience to consumers. It would be particularly desirable to provide such a novel substrate that offers greater flexibility for use in different shapes and forms, and can be adjusted to be suitable for use with a wider variety of aerosol generating articles and devices. means of solving the problem

[0006] According to the present disclosure, an aerosol generating substrate for use in an aerosol generating article or system is provided. The aerosol generating substrate may comprise at least 30 weight percent of a cellulose-based filler based on dry weight. The aerosol generating substrate may comprise at least 10 weight percent of an aerosol forming agent based on dry weight. The aerosol generating substrate may comprise one or more hydrocolloidal binders, and the total amount of hydrocolloidal binders is 5 weight percent or less of the aerosol generating substrate based on dry weight. The aerosol generating substrate may comprise at least one of an activator and a flavoring agent. The weight ratio of the cellulose-based filler to the aerosol forming agent within the aerosol generating substrate may be at least 1. The aerosol generating substrate may be in the form of a plurality of beads or granules.

[0007] According to the present invention, an aerosol generating substrate for use in an aerosol generating article or system is provided, wherein the aerosol generating substrate comprises at least 30 weight percent of a cellulose-based filler based on dry weight; at least 10 weight percent of an aerosol forming agent based on dry weight; one or more hydrocolloidal binders—the total amount of hydrocolloidal binders is 5 weight percent or less of the aerosol generating substrate based on dry weight—and at least one of an activator and a flavoring agent. The weight ratio of the cellulose-based filler to the aerosol forming agent within the aerosol generating substrate is at least 1. The aerosol generating substrate is in the form of a plurality of beads or granules.

[0008] According to the present invention, as defined above, an aerosol generating article comprising an aerosol generating substrate according to the present invention is also provided.

[0009] According to the present disclosure, a method for producing an aerosol-generating substrate according to the present disclosure is further provided as defined above. The method may include the step of forming a mixture of a cellulose-based filler and an aerosol-forming agent. The method may include the step of forming a dough by mixing the combined cellulose-based filler and aerosol-forming agent with a binder solution comprising one or more hydrocolloid binders. The method may include the step of forming a plurality of beads or granules from the dough.

[0010] According to the present invention, as defined above, a method for producing an aerosol generating substrate according to the present invention is provided, comprising the steps of: forming a mixture of a cellulose-based filler and an aerosol-forming agent; mixing the combined cellulose-based filler and aerosol-forming agent with a binder solution comprising one or more hydrocolloid binders to form a dough; and forming a plurality of beads or granules from the dough.

[0011] As used herein, the term “aerosol generating article” refers to an aerosol generating article for producing an aerosol comprising an aerosol generating material intended to be heated rather than burned in order to release a volatile compound capable of forming an aerosol.

[0012] As used herein, the term "aerosol generating material" refers to a material capable of forming an aerosol and emitting a volatile compound upon heating.

[0013] As used herein, the term “granule” refers to a distinct solid particle formed from an aerosol generating substrate as defined above. The granules may have a regular or irregular shape.

[0014] As used herein, the term "bead" refers to a distinct solid particle formed from an aerosol generating substrate as defined above and having a round, typically spherical shape.

[0015] The present invention provides a novel and improved form of an aerosol generating substrate for an aerosol generating article. The aerosol generating substrate is in the form of a plurality of beads or granules formed from a material comprising a cellulose-based filler, an aerosol forming agent, a hydrocolloid binder, and an activator or flavoring agent. It has been found that a combination of the aerosol forming agent in the relative proportions defined above and a relatively small amount of hydrocolloid binder and cellulose-based filler advantageously provides an aerosol generating substrate that can be stably formed into beads or granules, which can maintain its shape and be used directly in an aerosol generating article. In particular, due to the consistency and stability of the aerosol generating substrate used to form the beads or granules, the beads or granules can be used without requiring an additional coating layer. This simplifies the production process and further optimizes the release of aerosols from the beads or granules upon heating.

[0016] The granular or bead form of the aerosol generating substrate enables its use in a wide variety of different types of aerosol generating articles because the size and number of beads or granules can be easily adjusted to suit the space in which they are integrated. Accordingly, the aerosol generating substrate offers improved flexibility and versatility. The aerosol generating substrate is particularly applicable to planar or flat aerosol generating articles, which provide more efficient heating and generation of aerosols due to the flat structure of the substrate.

[0017] Providing aerosol generating substrates in the form of multiple beads or granules also advantageously provides a substrate having a high surface-to-volume ratio, which optimizes the release of aerosols from the substrate upon heating.

[0018] Additionally, the aerosol generating material of the present invention, comprising nicotine as an activator, surprisingly provides a significant improvement in the consistency of the nicotine-to-aerosol-forming agent ratio in the aerosol generated upon heating compared to known materials comprising a load of tobacco material, as described above. In particular, the aerosol generating material of the present invention allows the nicotine-to-aerosol-forming agent ratio in the aerosol per puff to be more consistent throughout the entire heating duration. This provides an optimized sensory experience for the consumer.

[0019] The aerosol generating substrate according to the present invention can be advantageously produced using known apparatus and methods with relatively minimal modifications. The aerosol generating substrate can be additionally produced using a relatively small amount of water compared to the process for manufacturing other substrates, such as homogenized tobacco materials, which not only reduces time and energy requirements but also reduces environmental impact.

[0020] The aerosol generating substrate of the present invention comprises at least 30 weight percent of a cellulose-based filler based on dry weight. The cellulose-based filler serves as a carrier for an activator or flavoring agent and also provides a plurality of beads or granules having sufficient structural integrity and hardness to be used in an aerosol generating article.

[0021] Preferably, the aerosol generating substrate comprises at least 35 weight percent of a cellulose-based filler based on dry weight, more preferably at least 40 weight percent of a cellulose-based filler.

[0022] Preferably, the aerosol generating substrate comprises 70 weight percent or less of a cellulose-based filler based on dry weight, more preferably 65 weight percent or less of a cellulose-based filler, and more preferably 60 weight percent or less of a cellulose-based filler.

[0023] For example, the aerosol generating substrate may comprise 30 to 70 weight percent of a cellulose-based filler based on dry weight, or 35 to 70 weight percent of a cellulose-based filler, or 40 to 70 weight percent of a cellulose-based filler.

[0024] For example, the aerosol generating substrate may comprise 30 to 65 weight percent of a cellulose-based filler based on dry weight, or 35 to 65 weight percent of a cellulose-based filler, or 40 to 65 weight percent of a cellulose-based filler.

[0025] For example, the aerosol generating substrate may comprise 30 to 60 weight percent of a cellulose-based filler based on dry weight, or 35 to 60 weight percent of a cellulose-based filler, or 40 to 60 weight percent of a cellulose-based filler.

[0026] Therefore, cellulose-based fillers become an important component of the aerosol generating substrate. By adjusting the amount of cellulose-based fillers within the aerosol generating substrate, it may be advantageously possible to adjust the viscosity and density of the aerosol generating substrate. Additionally, by adjusting not only the amount of cellulose-based fillers within the aerosol generating substrate but also the relative ratio of cellulose-based fillers to aerosol-forming agents, it may be possible to control the delivery of specific compounds, such as flavor compounds, into the aerosol generated from the aerosol generating substrate upon heating.

[0027] Cellulose-based fillers may include microcrystalline cellulose (MCC). Advantageously, the inventors have discovered that the use of MCC as a cellulose-based filler optimizes the physical properties of granules or beads of an aerosol-generating substrate, such as homogeneity, hardness, and structural integrity.

[0028] The aerosol generating substrate may have a microcrystalline cellulose content of at least 30 weight percent, preferably at least 40 weight percent, based on dry weight. The aerosol generating substrate may have a microcrystalline cellulose content of up to 70 weight percent, more preferably up to 65 weight percent, based on dry weight.

[0029] For example, the aerosol generating substrate may comprise 30 to 70 weight percent of microcrystalline cellulose based on dry weight, or 40 to 70 weight percent of microcrystalline cellulose, or 30 to 65 weight percent of microcrystalline cellulose, or 40 to 65 weight percent of microcrystalline cellulose.

[0030] As an alternative to or in addition to MCC, the cellulose-based filler may comprise at least one of cellulose powder and cellulose fibers.

[0031] The aerosol generating substrate may have a cellulose fiber content of at least 1 weight percent, preferably at least 5 weight percent, based on dry weight. The aerosol generating substrate may have a cellulose fiber content of up to 15 weight percent, more preferably up to 10 weight percent, based on dry weight.

[0032] For example, the aerosol generating substrate may comprise 1 weight percent to 15 weight percent of cellulose fibers based on dry weight, or 1 weight percent to 10 weight percent of cellulose fibers, or 5 weight percent to 15 weight percent of cellulose fibers, or 5 weight percent to 10 weight percent of cellulose fibers.

[0033] The aerosol generating substrate may have a cellulose powder content of at least 5 weight percent, preferably at least 10 weight percent, based on dry weight. The aerosol generating substrate may have a cellulose powder content of up to 25 weight percent, more preferably up to 20 weight percent, based on dry weight.

[0034] For example, the aerosol generating substrate may comprise 5 to 25 weight percent of cellulose powder based on dry weight, or 5 to 20 weight percent of cellulose powder, or 10 to 25 weight percent of cellulose fibers, or 10 to 20 weight percent of cellulose powder.

[0035] According to the present invention, the weight ratio of the cellulose-based filler to the aerosol-forming agent is at least 1. Preferably, the weight ratio of the cellulose-based filler to the aerosol-forming agent is at least 1.1, more preferably at least 1.2, and more preferably at least 1.3. This relatively high ratio of solid cellulose-based filler to liquid aerosol-forming agent ensures that beads or granules can be formed with a desired consistency, which balances the need for structural stability with the need to optimize the release of aerosol from the aerosol-generating substrate upon heating.

[0036] The weight ratio of the cellulose-based filler to the aerosol-forming agent is preferably 2 or less, more preferably 1.8 or less, and more preferably 1.6 or less.

[0037] The aerosol generating substrate comprises at least 10 weight percent of an aerosol forming agent based on dry weight. Preferably, the aerosol generating substrate comprises at least 15 weight percent of an aerosol forming agent based on dry weight, more preferably at least 20 weight percent of an aerosol forming agent, more preferably at least 25 weight percent of an aerosol forming agent, more preferably at least 30 weight percent of an aerosol forming agent, and more preferably at least 40 weight percent.

[0038] The aerosol generating material preferably comprises 50 weight percent or less of an aerosol forming agent based on dry weight, more preferably 45 weight percent or less of an aerosol forming agent.

[0039] For example, the aerosol generating substrate comprises, based on dry weight, 10 weight percent to 50 weight percent of an aerosol forming agent, or 10 weight percent to 45 weight percent of an aerosol forming agent, or 15 weight percent to 50 weight percent of an aerosol forming agent, or 15 weight percent to 45 weight percent of an aerosol forming agent, or 20 weight percent to 50 weight percent of an aerosol forming agent, or 20 weight percent to 45 weight percent of an aerosol forming agent, or 25 weight percent to 50 weight percent of an aerosol forming agent, or 25 weight percent to 45 weight percent of an aerosol forming agent, or 30 weight percent to 50 weight percent of an aerosol forming agent, or 30 weight percent to 45 weight percent of an aerosol forming agent, or 40 weight percent to 50 weight percent of an aerosol forming agent, or 40 It may include an aerosol-forming agent in an amount of 1 to 45 weight percent. In one preferred embodiment of the present invention, the aerosol-generating substrate comprises approximately 42 weight percent of an aerosol-forming agent based on dry weight.

[0040] Accordingly, the aerosol generating substrate preferably contains a relatively high level of an aerosol-forming agent. This not only ensures that the aerosol generating substrate can be formed with a desirable consistency and density, but also ensures the optimized delivery of activators or flavor agents into the aerosol generated upon heating of the aerosol generating substrate.

[0041] Aerosol-forming agents suitable for use in aerosol-generating substrates according to the present disclosure include, but are not limited to, glycerin, propylene glycol, and mixtures thereof.

[0042] Preferably, the aerosol generating substrate comprises at least 10 weight percent glycerin based on dry weight, more preferably at least 15 weight percent glycerin, more preferably at least 20 weight percent glycerin, more preferably at least 25 weight percent glycerin, more preferably at least 30 weight percent glycerin, and more preferably at least 40 weight percent glycerin.

[0043] The aerosol generating material preferably contains 50 weight percent or less of glycerin based on dry weight, more preferably 45 weight percent or less of glycerin.

[0044] For example, the aerosol generating substrate may comprise 10 to 50 weight percent glycerin based on dry weight, or 10 to 45 weight percent glycerin, or 20 to 50 weight percent glycerin, or 20 to 45 weight percent glycerin, or 30 to 50 weight percent glycerin, or 30 to 45 weight percent glycerin, or 40 to 50 weight percent glycerin, or 40 to 45 weight percent glycerin. In one preferred embodiment of the present invention, the aerosol generating substrate comprises approximately 42 weight percent glycerin based on dry weight.

[0045] The aerosol generating substrate of the present invention further comprises a hydrocolloidal binder, which serves to improve the binding of cellulose-based fillers within the aerosol generating substrate and optimize the structural integrity of the aerosol generating substrate. According to the present invention, the aerosol generating substrate comprises a hydrocolloidal binder in an amount of up to 5 weight percent or less based on dry weight. It has been found that such a relatively low level of binder provides desired physical advantages without adversely affecting the generation of aerosols from the aerosol generating substrate.

[0046] Preferably, the total amount of hydrocolloid binder is 4 weight percent or less based on dry weight of the aerosol generating substrate, more preferably 3 weight percent or less of the aerosol generating substrate, and more preferably 2 weight percent or less of the aerosol generating substrate.

[0047] Preferably, the total amount of hydrocolloid binder is at least 0.5 weight percent of aerosol generating substrate based on dry weight, more preferably at least 0.6 weight percent of aerosol generating substrate, more preferably at least 0.7 weight percent of aerosol generating substrate, and more preferably at least 0.8 weight percent of aerosol generating substrate.

[0048] For example, the total amount of hydrocolloid binder in the aerosol generating substrate may be 0.5 weight percent to 5 weight percent, or 0.5 weight percent to 4 weight percent, or 0.5 weight percent to 3 weight percent, or 0.5 weight percent to 2 weight percent based on dry weight.

[0049] For example, the total amount of hydrocolloid binder in the aerosol generating substrate may be 0.6 weight percent to 5 weight percent, or 0.6 weight percent to 4 weight percent, or 0.6 weight percent to 3 weight percent, or 0.6 weight percent to 2 weight percent based on dry weight.

[0050] For example, the total amount of hydrocolloid binder in the aerosol generating substrate may be 0.7 weight percent to 5 weight percent, or 0.7 weight percent to 4 weight percent, or 0.7 weight percent to 3 weight percent, or 0.7 weight percent to 2 weight percent based on dry weight.

[0051] For example, the total amount of hydrocolloid binder in the aerosol generating substrate may be 0.8 weight percent to 5 weight percent, or 0.8 weight percent to 4 weight percent, or 0.5 weight percent to 3 weight percent, or 0.8 weight percent to 2 weight percent based on dry weight.

[0052] Preferably, the weight ratio of the cellulose-based filler to the hydrocolloid binder in the aerosol generating substrate is at least 20, more preferably at least 25, more preferably at least 30, more preferably at least 40, more preferably at least 50.

[0053] Preferably, the weight ratio of the cellulose-based filler to the hydrocolloid binder in the aerosol generating substrate is 100 or less, more preferably 80 or less.

[0054] Hydrocolloid binders suitable for use in the aerosol generating substrate of the present invention will be known to those skilled in the art. The aerosol generating substrate may be formed of a single hydrocolloid binder or a combination of two or more hydrocolloid binders.

[0055] Preferably, one or more hydrocolloid binders are selected from the group consisting of starch, modified starch, dextrin, alginate, pectin, cellulose, cellulose derivatives (e.g., carboxymethyl cellulose), agar, carrageenan, gelatin, natural gums (e.g., tragacanth gum, konjac gum, guar gum, or xanthan gum) and combinations thereof.

[0056] Preferably, one or more hydrocolloid binders are selected from the group consisting of carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), guar gum, or alginate.

[0057] In a specific preferred embodiment of the present invention, the hydrocolloidal binder comprises a cellulose binder. Preferably, the hydrocolloidal binder comprises a cellulose derivative. Particularly preferably, the hydrocolloidal binder comprises hydroxypropyl methylcellulose (HPMC).

[0058] Preferably, the aerosol generating substrate comprises 0.5 weight percent to 2 weight percent of HPMC based on dry weight, more preferably 0.5 weight percent to 1.5 weight percent of HPMC.

[0059] Preferably, the hydrocolloid binder is selected such that a 2 weight percent aqueous solution of the hydrocolloid binder has a viscosity of at least 50 cps. Preferably, the hydrocolloid binder is selected such that a 2 weight percent aqueous solution of the hydrocolloid binder has a viscosity of 5600 cps or less.

[0060] In a preferred embodiment in which the hydrocolloid binder comprises HPMC, a 2 weight percent aqueous solution of HPMC has a viscosity of 50 cps to 5600 cps.

[0061] The term “viscosity” is used herein to denote a measure of the internal resistance of a fluid to deformation under shear stress. More specifically, the term “viscosity” as used herein refers to the dynamic viscosity (μ) of a fluid. In the centigram-second (cgs) unit system, the physical unit of dynamic viscosity is the poise (P). 1 poise = 100 centipoise (cP) = 0.1 Pa·s.

[0062] More specifically, the term "viscosity" refers to the dynamic viscosity of a binder solution as measured at a shear rate of 100 inverse seconds (1 / s) at 23 degrees Celsius for a linear ramp of 1 to 200 inverse seconds using an MCR302 Anton Paar rheometer having a PP25 geometry, and the rheometer is equipped with a Peltier module P-PTD2000 with a VT2 cooling system. As defined above, to measure the viscosity of a hydrocolloidal binder solution, a solution containing 2 weight percent of hydrocolloidal binder in water is used.

[0063] The use of hydrocolloid binders that provide binder solutions with viscosity within this range has been found to advantageously optimize both the formulation of the aerosol generating substrate and the production process of the aerosol generating substrate.

[0064] The aerosol generating substrate according to the present invention further comprises at least one activator or flavoring agent. For example, the aerosol generating substrate may comprise nicotine as an activator. As used herein with reference to the present invention, the term “nicotine” comprises nicotine, nicotine base, or nicotine salt. In an embodiment in which the aerosol generating substrate comprises a nicotine base or a nicotine salt, the amount of nicotine cited herein is, respectively, an amount of free base nicotine or an amount of protonated nicotine.

[0065] The aerosol generating material may include natural nicotine extracted or isolated from natural tobacco materials or other natural sources. The aerosol generating material may include chemically synthesized synthetic nicotine.

[0066] The aerosol generating material may have a nicotine content of at least 0.5 weight percent, preferably at least 1 weight percent, and more preferably at least 2 weight percent based on dry weight.

[0067] The aerosol generating material may have a nicotine content of 10 weight percent or less based on dry weight, preferably 8 weight percent or less, more preferably 5 weight percent or less.

[0068] For example, the aerosol generating material may have a nicotine content of 0.5 weight percent to 10 weight percent, or 1 weight percent to 8 weight percent, or 2 weight percent to 5 weight percent based on dry weight.

[0069] Alternatively or additionally, the aerosol generating substrate of the present invention may comprise one or more cannabinoid compounds selected from the group consisting of tetrahydrocannabinol (THC), tetrahydrocannabinol acid (THCA), cannabidiol (CBD), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabigerol monomethyl ether (CBGM), cannabivarin (CBV), cannabidivarin (CBDV), tetrahydrocannabivarin (THCV), cannabichromene (CBC), cannabicyclorol (CBL), cannabicrombarin (CBCV), cannabigerovarin (CBGV), cannabielsoin (CBE), cannabicitran (CBT), and combinations thereof. Preferably, one or more cannabinoid compounds are selected from CBD, THC, and combinations thereof. Particularly preferably, one or more cannabinoid compounds comprise CBD.

[0070] Alternatively or additionally, the aerosol generating material of the present invention may further comprise one or more flavoring agents. Suitable flavoring agents will be known to those skilled in the art. One or more flavoring agents may comprise one or more essential oils such as eugenol, peppermint oil, and spearmint oil; one or both of menthol and eugenol; and one or more of anethole and linalool.

[0071] The aerosol generating material may have a flavoring agent content of at least 0.5 weight percent, preferably at least 1 weight percent, and more preferably at least 2 weight percent based on dry weight.

[0072] The aerosol generating material may have a flavoring agent content of 10 weight percent or less based on dry weight, preferably 8 weight percent or less, more preferably 5 weight percent or less.

[0073] For example, the aerosol generating substrate may have a flavoring agent content of 0.5 weight percent to 10 weight percent, or 1 weight percent to 8 weight percent, or 2 weight percent to 5 weight percent based on dry weight.

[0074] The aerosol generating substrate may additionally include one or more carboxylic acids. Advantageously, when the activator includes nicotine, including one or more carboxylic acids in the aerosol generating substrate may produce a nicotine salt. The carboxylic acid may include one or more of lactic acid, levulinic acid, benzoic acid, fumaric acid, or acetic acid. Preferably, the carboxylic acid is at least one of lactic acid or levulinic acid.

[0075] The aerosol generating material may have a carboxylic acid content of at least 0.5 weight percent, preferably at least 1 weight percent, and more preferably at least 2 weight percent based on dry weight.

[0076] The aerosol generating material may have a carboxylic acid content of 10 weight percent or less based on dry weight, preferably 8 weight percent or less, more preferably 8 weight percent or less.

[0077] For example, the aerosol generating material may contain about 0.5 weight percent to about 10 weight percent of acid, or about 1 weight percent to about 8 weight percent of acid, or about 2 weight percent to about 6 weight percent of acid.

[0078] The aerosol generating material preferably has a total water content of 30 weight percent or less, more preferably 20 weight percent or less, and more preferably 15 weight percent or less.

[0079] The aerosol generating material preferably has a total water content of at least 1 weight percent, more preferably at least 2 weight percent, and more preferably at least 5 weight percent.

[0080] For example, the aerosol generating material may have a total water content of 1 weight percent to 30 weight percent, or 2 weight percent to 20 weight percent, or 5 weight percent to 15 weight percent.

[0081] Preferably, the aerosol generating material has a moisture content of 30 percent or less of oven volatilization (OV), more preferably 20 percent or less of oven volatilization (OV), and more preferably 15 percent or less of oven volatilization (OV).

[0082] Preferably, the aerosol generating substrate has a moisture content of at least 1 percent oven volatile matter (OV), more preferably at least 2 percent oven volatile matter (OV), and more preferably at least 5 percent oven volatile matter (OV).

[0083] For example, the aerosol generating material may have a moisture content of 1 OV percent to 30 OV percent, or 2 OV percent to 20 OV percent, or 5 OV percent to 15 OV percent.

[0084] The term "oven volatile matter percentage (OV percent)" is used to refer to the moisture content of a material. It is determined by measuring the percentage of weight loss from the material being tested during drying of a material sample in an oven at 100 ± 1°C for 3 hours ± 0.5 minutes. In practice, a significant portion of the weight loss from plant materials is estimated to be due to the evaporation of moisture. It should be noted that, in absolute terms, the moisture content value determined by oven drying may be greater than the result of water content analysis when using specific methods such as ISO 6488 (the Karl Fischer method). The difference depends on the sample type, which is attributed to the loss of volatile materials other than water (e.g., aerosol-forming agents) from the material being tested during oven drying.

[0085] As discussed above, the beads or granules of the aerosol generating substrate of the present invention can advantageously be used without requiring an external coating layer. However, in some embodiments, it may be beneficial to provide an aerosol generating substrate in which a plurality of beads or granules are at least partially coated, for example, with powder.

[0086] Preferably, a plurality of beads or granules are at least partially coated with powder. For example, a plurality of beads or granules may be at least partially coated with tobacco powder. Alternatively or additionally, a plurality of beads or granules may be at least partially coated with a cellulose material, for example, microcrystalline cellulose (MCC).

[0087] The provision of a powder coating can advantageously prevent beads or granules from sticking together, which can facilitate the handling of the aerosol generating substrate, for example, during the production of an aerosol generating article containing the aerosol generating substrate. In addition, the powder coating can provide a moisture barrier to protect the aerosol generating substrate from environmental moisture.

[0088] The aerosol generating material preferably has a density of at least 0.75 grams / cubic centimeter, more preferably at least 0.8 grams / cubic centimeter, more preferably at least 0.9 grams / cubic centimeter, more preferably at least 1 gram / cubic centimeter, more preferably at least 1.1 grams / cubic centimeter, and more preferably at least 1.2 grams / cubic centimeter.

[0089] The aerosol generating material preferably has a density of 2 grams / cubic centimeter or less, more preferably 1.95 grams / cubic centimeter or less, more preferably 1.9 grams / cubic centimeter or less, more preferably 1.85 grams / cubic centimeter or less, and more preferably 1.8 grams / cubic centimeter or less.

[0090] For example, the density of the aerosol generating material may be 0.75 grams / cubic centimeter to 2 grams / cubic centimeter, or 0.75 grams / cubic centimeter to 1.95 grams / cubic centimeter, or 0.75 grams / cubic centimeter to 1.9 grams / cubic centimeter, or 0.75 grams / cubic centimeter to 1.85 grams / cubic centimeter, or 0.75 grams / cubic centimeter to 1.8 grams / cubic centimeter.

[0091] For example, the density of the aerosol generating material may be 0.8 grams / cubic centimeter to 2 grams / cubic centimeter, or 0.8 grams / cubic centimeter to 1.95 grams / cubic centimeter, or 0.8 grams / cubic centimeter to 1.9 grams / cubic centimeter, or 0.8 grams / cubic centimeter to 1.85 grams / cubic centimeter, or 0.8 grams / cubic centimeter to 1.8 grams / cubic centimeter.

[0092] For example, the density of the aerosol generating material may be 0.9 grams / cubic centimeter to 2 grams / cubic centimeter, or 0.9 grams / cubic centimeter to 1.95 grams / cubic centimeter, or 0.9 grams / cubic centimeter to 1.9 grams / cubic centimeter, or 0.9 grams / cubic centimeter to 1.85 grams / cubic centimeter, or 0.9 grams / cubic centimeter to 1.8 grams / cubic centimeter.

[0093] For example, the density of the aerosol generating material may be 1 gram / cubic centimeter to 2 grams / cubic centimeter, or 1 gram / cubic centimeter to 1.95 grams / cubic centimeter, or 1 gram / cubic centimeter to 1.9 grams / cubic centimeter, or 1 gram / cubic centimeter to 1.85 grams / cubic centimeter, or 1 gram / cubic centimeter to 1.8 grams / cubic centimeter.

[0094] For example, the density of the aerosol generating material may be 1.1 gram / cubic centimeter to 2 gram / cubic centimeter, or 1.1 gram / cubic centimeter to 1.95 gram / cubic centimeter, or 1.1 gram / cubic centimeter to 1.9 gram / cubic centimeter, or 1.1 gram / cubic centimeter to 1.85 gram / cubic centimeter, or 1.1 gram / cubic centimeter to 1.8 gram / cubic centimeter.

[0095] For example, the density of the aerosol generating material may be 1.2 grams / cubic centimeter to 2 grams / cubic centimeter, or 1.2 grams / cubic centimeter to 1.95 grams / cubic centimeter, or 1.2 grams / cubic centimeter to 1.9 grams / cubic centimeter, or 1.2 grams / cubic centimeter to 1.85 grams / cubic centimeter, or 1.2 grams / cubic centimeter to 1.8 grams / cubic centimeter.

[0096] The density of the aerosol generating material can be measured using a densitometer, such as the Density meter Excellence available from Mettler Toledo®. Using this meter, the beads of the aerosol generating material granules are first weighed to determine their weight. Then, the beads or granules are placed in a container of sunflower oil (depth 2 to 3 cm) and allowed to sink. The density of the sunflower oil is entered into the meter (0.9188), and then the density value of the beads is calculated by the meter. This calculation is based on Archimedes' principle and uses the following equation, where the object is the beads or granules of the aerosol generating material and the fluid is sunflower oil:

[0097]

[0098] The size of the beads or granules can be adjusted according to the desired use of the aerosol generating material. The average weight of the plurality of beads or granules is preferably at least 0.6 mg, more preferably at least 2 mg, more preferably at least 10 mg, and more preferably at least 20 mg. Preferably, the average weight of the plurality of beads or granules is 80 mg or less, more preferably 60 mg or less, and more preferably 40 mg or less.

[0099] For example, the average weight of a plurality of beads or granules may be 0.6 mg to 80 mg, or 2 mg to 60 mg, or 10 mg to 40 mg, or 20 mg to 40 mg.

[0100] The average weight of a plurality of beads or granules is defined as the value obtained by dividing the total weight of a plurality of beads by the total number of beads or granules. Thus, the average weight represents the weight of individual beads or granules.

[0101] The total weight of the plurality of beads or granules is preferably at least 50 mg, more preferably at least 100 mg, more preferably at least 125 mg, and more preferably at least 150 mg. Preferably, the total weight of the plurality of beads or granules is 350 mg or less, more preferably 300 mg or less, more preferably 250 mg or less, and more preferably 200 mg or less.

[0102] For example, the total weight of the plurality of beads or granules may be 50 mg to 350 mg, or 100 mg to 300 mg, or 125 mg to 250 mg, or 150 mg to 200 mg.

[0103] The bulk density of the plurality of beads or granules is preferably at least 200 mg / cubic centimeter, more preferably at least 210 mg / cubic centimeter, more preferably at least 225 mg / cubic centimeter, more preferably at least 240 mg / cubic centimeter, and more preferably at least 250 mg / cubic centimeter. Preferably, the bulk density of the plurality of beads or granules is 500 mg / cubic centimeter or less, more preferably 485 mg / cubic centimeter or less, more preferably 475 mg / cubic centimeter or less, more preferably 465 mg / cubic centimeter or less, and more preferably 450 mg / cubic centimeter or less.

[0104] For example, the bulk density of a plurality of beads or granules may be 200 mg / cubic centimeter to 500 mg / cubic centimeter, or 210 mg / cubic centimeter to 485 mg / cubic centimeter, or 225 mg / cubic centimeter to 475 mg / cubic centimeter, or 240 mg / cubic centimeter to 465 mg / cubic centimeter, or 250 mg / cubic centimeter to 450 mg / cubic centimeter.

[0105] The bulk density of a plurality of beads or granules is defined as the value obtained by dividing the total weight of the plurality of beads or granules by the volume of the space occupied by the plurality of beads or granules.

[0106] The bulk density of a plurality of beads or granules is defined as the value obtained by dividing the total weight of the plurality of beads or granules by the volume of the space occupied by the plurality of beads or granules.

[0107] The average surface area of ​​a plurality of beads or granules is preferably at least 3 square millimeters, more preferably at least 5 square millimeters, more preferably at least 8 square millimeters, more preferably at least 10 square millimeters, more preferably at least 12 square millimeters, more preferably at least 15 square millimeters, more preferably at least 18 square millimeters, and more preferably at least 20 square millimeters. Preferably, the average surface area of ​​a plurality of beads is 80 square millimeters or less, more preferably 75 square millimeters or less, more preferably 70 square millimeters or less, more preferably 65 square millimeters or less, more preferably 60 square millimeters or less, more preferably 50 square millimeters or less, and more preferably 40 square millimeters or less.

[0108] For example, a plurality of beads or granules may have an average surface area of ​​3 square millimeters to 80 square millimeters, or 5 square millimeters to 75 square millimeters, or 8 square millimeters to 70 square millimeters, or 10 square millimeters to 65 square millimeters, or 12 square millimeters to 60 square millimeters, or 15 square millimeters to 50 square millimeters, or 18 square millimeters to 40 square millimeters, or 20 square millimeters to 40 square millimeters.

[0109] The average surface area of ​​a plurality of beads or granules is defined as the value obtained by dividing the total surface area of ​​the plurality of beads or granules by the total number of beads or granules.

[0110] The total surface area of ​​the plurality of beads or granules is preferably at least 120 square millimeters, more preferably at least 200 square millimeters, and more preferably at least 300 square millimeters. Preferably, the total surface area of ​​the plurality of beads is 650 square millimeters or less, more preferably 500 square millimeters or less, and more preferably 400 square millimeters or less.

[0111] For example, a plurality of beads or granules may have a total surface area of ​​120 square millimeters to 650 square millimeters, or 200 square millimeters to 500 square millimeters, or 300 square millimeters to 400 square millimeters.

[0112] The average diameter of the plurality of beads or granules is preferably at least 0.5 millimeters, more preferably at least 0.75 millimeters, more preferably at least 1 millimeter, and more preferably at least 1.5 millimeters. Preferably, the average diameter of the plurality of beads or granules is 10 millimeters or less, more preferably 8 millimeters or less, more preferably 6 millimeters or less, more preferably 4 millimeters or less, and more preferably 2.5 millimeters or less.

[0113] For example, the average diameter of a plurality of beads or granules is 0.5 to 10 millimeters, or 0.5 to 8 millimeters, or 0.5 to 6 millimeters, or 0.5 to 4 millimeters, or 0.5 to 2.5 millimeters, or 0.75 to 10 millimeters, or 0.75 to 8 millimeters, or 0.75 to 6 millimeters, or 0.75 to 4 millimeters, or 0.75 to 2.5 millimeters, or 1 millimeter to 10 millimeters, or 1 millimeter to 8 millimeters, or 1 millimeter to 6 millimeters, or 1 millimeter to 4 millimeters, or 1 millimeter to 2.5 millimeters, or 1.5 to 10 millimeters, or 1.5 to 8 millimeters, or 1.5 millimeters It may be up to 6 millimeters, or 1.5 millimeters to 4 millimeters or 1.5 millimeters to 2.5 millimeters.

[0114] The average diameter of a plurality of beads or granules is defined as the sum of the diameters of the plurality of beads or granules divided by the total number of beads or granules. To avoid doubt, as used herein with reference to the present invention, the term 'diameter' is used to describe the maximum dimension of a bead or granule. For a bead having a substantially circular cross-section or a substantially spherical shape, the term 'diameter' refers to the diameter of the circular cross-section or the diameter of the sphere, respectively. However, where a bead or granule has a shape that is not substantially spherical, the term 'diameter' is used to refer to the maximum dimension of the bead or granule.

[0115] Beads or granules forming the aerosol generating substrate may have any suitable shape. If the aerosol generating substrate is in the form of multiple granules, the granules may have a regular shape, such as a cylinder, or an irregular shape. The granules may have the same shape from one another, or the multiple granules may alternatively include granules of different shapes.

[0116] Preferably, the granules have a length greater than their width, and accordingly, the granules are elongated, for example, in the shape of a cylinder, a rectangular prism, or a filament.

[0117] It has been found that the shape of the granules affects the rate at which an active agent, such as nicotine, is released from the granules. For example, the inventors surprisingly discovered that the higher the ratio between the length and width of the granules, the slower the rate of release of the active agent. Therefore, the shape of the granules can be adjusted to provide a desired rate of release of the active agent. Multiple granules may comprise a combination of granules having different shapes or sizes (or both). This can advantageously provide greater control over the release of the active agent from multiple granules.

[0118] Preferably, the aerosol generating substrate is in the form of a plurality of rounded beads, such as spherical, oval, or elliptical beads. In a particularly preferred embodiment of the present invention, the aerosol generating substrate is in the form of a plurality of substantially spherical beads of the aerosol generating substrate.

[0119] Multiple beads may include a combination of beads having different diameters. As previously mentioned in relation to granules, bead size can affect the release profile of the activator from the beads, and the use of combinations of bead sizes can advantageously provide greater control over the release of the activator from the beads.

[0120] In a specific embodiment of the present invention, a plurality of beads may be combined with a plurality of granules to provide a combination of different size and shape elements.

[0121] As defined above, the present invention further provides a method for producing an aerosol generating substrate according to the present invention. The method according to the present invention comprises the steps of: forming a mixture of a cellulose-based filler and an aerosol-forming agent; mixing the combined cellulose-based filler and aerosol-forming agent with a binder solution comprising one or more hydrocolloid binders to form a dough; and forming a plurality of beads or granules from the dough.

[0122] As mentioned above, cellulose-based fillers may include microcrystalline cellulose (MCC).

[0123] The binder solution is preferably a solution of a binder in water or glycerin, or a combination thereof.

[0124] The step of forming a plurality of beads or granules from the dough can be performed using any suitable means including, for example, extrusion (e.g., high-shear extrusion), spray granulation, or molding.

[0125] Preferably, the step of forming a plurality of beads or granules includes the step of extruding a dough to form a plurality of distinct elements. For a preferred embodiment in which the aerosol generating substrate comprises a plurality of spherical beads, the step of forming a plurality of beads may further include the step of sphericalizing the extruded distinct elements to form spherical beads.

[0126] A suitable device for forming distinct elements by extrusion is the Caleva® Model 20 Extruder. A suitable device for performing sphericization of distinct elements is the Caleva® Multi Bowl Spheronizer 250.

[0127] The method according to the present invention may further include a step of drying a plurality of beads or granules to a desired water content. The drying step may be performed using any suitable means including, but not limited to, heating and freeze-drying.

[0128] The method according to the present invention may further include the step of applying a powder coating to a plurality of beads or granules. As described above, the powder coating may include at least one of tobacco powder or cellulose powder such as microcrystalline cellulose (MCC).

[0129] Advantageously, the method according to the present invention uses a relatively small amount of water through the production of a non-slurry dough containing a cellulose-based filler. Accordingly, the amount of water that needs to be evaporated from the substrate during the production method is relatively low. This reduces the duration and energy requirements for the drying step or steps, so that the aerosol generating substrate can be produced in a more sustainable manner than alternative aerosol generating substrates.

[0130] The aerosol generating substrate according to the present invention can be used in a wide variety of different aerosol generating articles. As defined below, the present invention provides an aerosol generating article comprising the aerosol generating substrate according to the present invention as described above.

[0131] The aerosol generating material may be combined with one or more elements located upstream or downstream of the aerosol generating material.

[0132] The aerosol generating article according to the present invention may comprise at least two beads or granules of an aerosol generating substrate, more preferably at least five beads or granules of an aerosol generating substrate, more preferably at least ten beads or granules of an aerosol generating substrate, more preferably at least twenty beads or granules of an aerosol generating substrate, more preferably at least thirty beads or granules of an aerosol generating substrate, and more preferably at least forty beads or granules of an aerosol generating substrate.

[0133] The aerosol generating article according to the present invention may include 200 or fewer beads or granules of an aerosol generating substrate, more preferably 100 or fewer beads of granules of an aerosol generating substrate, more preferably 75 or fewer beads of granules of an aerosol generating substrate, and more preferably 50 or fewer beads of granules of an aerosol generating substrate.

[0134] For example, an aerosol generating article according to the present invention may comprise 2 to 200 beads or granules of an aerosol generating substrate, or 5 to 200 beads or granules of an aerosol generating substrate, or 10 to 100 beads or granules of an aerosol generating substrate, or 20 to 75 beads or granules of an aerosol generating substrate, or 30 to 50 beads or granules of an aerosol generating substrate, or 40 to 50 beads or granules of an aerosol generating substrate.

[0135] An aerosol generating article according to the present invention may comprise a total weight of at least 50 mg of beads or granules of an aerosol generating substrate, preferably at least 100 mg of beads or granules of an aerosol generating substrate, more preferably at least 125 mg of beads or granules of an aerosol generating substrate, and more preferably at least 150 mg of beads or granules of an aerosol generating substrate. Preferably, the total weight of a plurality of beads or granules within the aerosol generating article is 350 mg or less, more preferably 300 mg or less, more preferably 250 mg or less, and more preferably 200 mg or less.

[0136] For example, the total weight of a plurality of beads or granules in an aerosol-generating article may be 50 mg to 350 mg, or 100 mg to 300 mg, or 125 mg to 250 mg, or 150 mg to 200 mg.

[0137] Preferably, the aerosol generating article according to the present invention is substantially flat or substantially planar. This means that the article has a base area that is relatively large relative to the volume of the article. As previously mentioned, the aerosol generating substrate of the present invention has been found to be particularly suitable for use in flat aerosol generating articles because it can be easily adjusted to fill the space within an article having a relatively large flat shape with an opposing surface. This form optimizes the heating of the aerosol generating substrate and the generation of aerosols.

[0138] In a specific preferred embodiment of the present invention, the aerosol generating article comprises: a first planar outer surface; a second planar outer surface; a cavity; a frame positioned between the first planar outer surface and the second planar outer surface, the frame defining at least partially the cavity; an air inlet and an air outlet; and an airflow passage extending between the air inlet and the air outlet through the cavity. A plurality of beads or granules of the aerosol generating material are positioned between the first planar outer surface and the second planar outer surface, typically within the cavity.

[0139] The cavity may have a length of at least 10 millimeters, or at least 12 millimeters. The cavity may have a length of 20 millimeters or less, or 15 millimeters or less. For example, the cavity may have a length of 10 to 20 millimeters or 12 to 15 millimeters.

[0140] The cavity may have a width of at least 5 millimeters, or at least 6 millimeters. The cavity may have a width of 10 millimeters or less, or 8 millimeters or less. For example, the cavity may have a width of 5 to 10 millimeters or 6 to 8 millimeters.

[0141] The cavity may have a depth of at least 2 millimeters, or at least 3 millimeters. The cavity may have a depth of 5 millimeters or less, or 4 millimeters or less. For example, the cavity may have a depth of 2 to 5 millimeters or 3 to 4 millimeters.

[0142] The cavity may have a volume of at least 200 square millimeters, or at least 250 square millimeters. The cavity may have a volume of 400 square millimeters or less, or 350 square millimeters or less. For example, the cavity may have a volume of 200 square millimeters to 400 square millimeters, or 250 square millimeters to 350 square millimeters.

[0143] In an alternative preferred embodiment of the present invention, the aerosol generating article comprises a container, the container comprises a first wall and a second wall that together define a substrate compartment, and a plurality of beads or granules are provided within the substrate compartment.

[0144] The first wall may comprise a material different from that of the second wall. This provision advantageously enables the first and second walls to have different properties for various functions. For example, the first and second walls may be configured to have different porosity, different thermal conductivity, or different stiffness.

[0145] The first wall may include a flexible material, such as a flexible cellulose material. The second wall may have higher rigidity than the first wall.

[0146] At least a portion of the first or second wall may be porous.

[0147] The container defined above may be in the form of a pouch.

[0148] A non-limiting, non-comprehensive list of embodiments is provided below. Any one or more of the features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0149] EX1. As an aerosol generating material for use in an aerosol generating article or system, the aerosol generating material is

[0150] Cellulose-based filler;

[0151] Aerosol forming agent;

[0152] One or more hydrocolloid binders;

[0153] It includes at least one of an active agent and a flavoring agent, and

[0154] The aerosol generating material is in the form of a plurality of beads or granules.

[0155] EX2. In Example EX1, the aerosol generating substrate comprises at least 30 weight percent of a cellulose-based filler based on dry weight.

[0156] EX3. In Example EX1 or EX2, the aerosol generating substrate comprises at least 35 weight percent of a cellulose-based filler, for example, at least 40 weight percent of a cellulose-based filler, based on dry weight.

[0157] EX4. In any prior embodiment, the aerosol generating substrate comprises a cellulose-based filler of 70 weight percent or less based on dry weight, for example, a cellulose-based filler of 65 weight percent or less, for example, a cellulose-based filler of 60 weight percent or less.

[0158] EX5. In any prior embodiment, the cellulose-based filler comprises microcrystalline cellulose (MCC), an aerosol generating substrate.

[0159] EX6. In Example Ex5, the aerosol generating substrate comprises, based on dry weight, 30 weight percent to 70 weight percent microcrystalline cellulose, for example, 35 weight percent to 70 weight percent microcrystalline cellulose, for example, 40 weight percent to 65 weight percent microcrystalline cellulose.

[0160] EX7. In any prior embodiment, the cellulose-based filler comprises at least one of cellulose powder and cellulose fiber, an aerosol generating substrate.

[0161] EX8. In any prior embodiment, an aerosol generating substrate in which the weight ratio of a cellulose-based filler to an aerosol forming agent in the aerosol generating substrate is at least 1.

[0162] EX9. In any prior embodiment, an aerosol generating substrate in which the weight ratio of a cellulose-based filler to an aerosol forming agent in the aerosol generating substrate is at least 1.1, for example at least 1.2, for example at least 1.3.

[0163] EX10. In any prior embodiment, an aerosol generating substrate in which the weight ratio of the cellulose-based filler to the aerosol forming agent within the aerosol generating substrate is at most 2, for example at most 1.8, for example at most 1.6.

[0164] EX11. In any prior embodiment, the weight ratio of the cellulose-based filler to the hydrocolloid binder in the aerosol generating substrate is at least 20, for example, at least 25, for example, at least 30, for example, at least 40, for example, at least 50.

[0165] EX12. In any prior embodiment, an aerosol generating substrate in which the weight ratio of the cellulose-based filler to the hydrocolloid binder in the aerosol generating substrate is up to 100, e.g. up to 80.

[0166] EX13. In any prior embodiment, the aerosol generating substrate comprises at least 10 weight percent of an aerosol forming agent based on dry weight.

[0167] EX14. In any prior embodiment, the aerosol generating substrate comprises, based on dry weight, at least 20 weight percent of an aerosol forming agent, for example, at least 30 weight percent of an aerosol forming agent, for example, at least 40 weight percent of an aerosol forming agent.

[0168] EX15. In any prior embodiment, the aerosol generating substrate comprises an aerosol forming agent of up to 50 weight percent, for example, up to 45 weight percent, based on dry weight.

[0169] EX16. In any prior embodiment, the aerosol generating substrate comprises an aerosol forming agent comprising glycerin, propylene glycol, or a combination thereof.

[0170] EX17. An aerosol generating substrate, wherein in any prior embodiment, the total amount of hydrocolloid binder is 5 weight percent or less of the aerosol generating substrate based on dry weight.

[0171] EX18. In any prior embodiment, the total amount of hydrocolloid binder is 4 weight percent or less of the aerosol generating substrate based on dry weight, for example 3 weight percent or less of the aerosol generating substrate, for example 2 weight percent or less of the aerosol generating substrate.

[0172] EX19. An aerosol generating substrate, wherein, in any prior embodiment, the total amount of hydrocolloid binder is at least 0.5 weight percent, for example, at least 0.6 weight percent, for example, at least 0.7 weight percent, for example, at least 0.8 weight percent based on dry weight.

[0173] EX20. In any prior embodiment, the hydrocolloid binder comprises a cellulose binder, an aerosol generating substrate.

[0174] EX21. In Example EX20, the aerosol generating substrate comprises a cellulose binder containing a cellulose derivative.

[0175] EX22. In Example EX20 or EX21, the aerosol generating substrate comprises a cellulose binder comprising hydroxypropyl methylcellulose (HPMC).

[0176] EX23. In Example EX22, the aerosol generating substrate comprises 0.5 weight percent to 2 weight percent of HPMC.

[0177] EX24. An aerosol generating substrate further comprising an activator containing nicotine in any prior embodiment.

[0178] EX25. In Example EX24, the aerosol generating substrate has a nicotine content of at least 0.5 weight percent, for example, at least 1 weight percent, for example, at least 2 weight percent based on dry weight.

[0179] EX26. In Example EX24 or EX25, the aerosol generating substrate has a nicotine content of up to 10 weight percent, for example, up to 8 weight percent, for example, up to 5 weight percent based on dry weight.

[0180] EX27. In any prior embodiment, the aerosol generating substrate comprises one or more flavoring agents.

[0181] EX28. In any prior embodiment, the aerosol generating substrate further comprises one or more carboxylic acids.

[0182] EX29. In Example EX28, the aerosol generating substrate comprises, based on dry weight, 0.5 weight percent to 10 weight percent of a carboxylic acid, for example, 1 weight percent to 8 weight percent of a carboxylic acid, for example, 2 weight percent to 6 weight percent of a carboxylic acid.

[0183] EX30. In any prior embodiment, the total water content of the aerosol generating substrate is 20 weight percent or less, for example 15 weight percent or less, for example 12 weight percent or less.

[0184] EX31. In any prior embodiment, the aerosol generating substrate has a moisture content of 20 percent or less of oven volatile matter, for example 15 percent or less of oven volatile matter, for example 12 percent or less of oven volatile matter.

[0185] EX32. In any prior embodiment, an aerosol generating substrate in which a plurality of beads are at least partially coated with powder.

[0186] EX33. In Example EX32, the powder is an aerosol generating substrate comprising tobacco powder.

[0187] EX34. In Example EX32, the powder is an aerosol generating substrate comprising microcrystalline cellulose (MCC).

[0188] EX35. In any prior embodiment, the aerosol generating substrate has a density of at least 0.75 grams / cubic centimeter, for example, at least 1 gram / cubic centimeter, for example, at least 1.1 grams / cubic centimeter, for example, at least 1.2 grams / cubic centimeter.

[0189] EX36. In any prior embodiment, the aerosol generating substrate has a density of at least 0.75 grams / cubic centimeter, for example, at least 1 gram / cubic centimeter, for example, at least 1.1 grams / cubic centimeter, for example, at least 1.2 grams / cubic centimeter.

[0190] EX37. In any prior embodiment, the aerosol generating substrate has a density of 2 grams / cubic centimeter or less, for example 1.9 grams / cubic centimeter or less, for example 1.8 grams / cubic centimeter or less.

[0191] EX38. An aerosol generating substrate, wherein in any prior embodiment, the average weight of a plurality of beads or granules is at least 0.6 mg, for example, at least 2 mg, for example, at least 10 mg, for example, at least 20 mg.

[0192] EX39. An aerosol generating substrate, wherein in any prior embodiment, the average weight of a plurality of beads or granules is 80 mg or less, for example 60 mg or less, for example 40 mg or less.

[0193] EX40. An aerosol generating substrate, wherein in any prior embodiment, the total weight of a plurality of beads or granules is at least 50 mg, for example, at least 100 mg, for example, at least 125 mg, for example, at least 150 mg.

[0194] EX41. An aerosol generating substrate, wherein in any prior embodiment, the total weight of a plurality of beads of granules is 350 mg or less, for example 300 mg or less, for example 250 mg or less.

[0195] EX42. An aerosol generating substrate, wherein in any prior embodiment, the bulk density of a plurality of beads or granules is at least 200 mg / cubic centimeter, for example at least 225 mg / cubic centimeter, for example at least 250 mg / cubic centimeter.

[0196] EX43. An aerosol generating substrate, wherein in any prior embodiment, the bulk density of a plurality of beads or granules is 500 mg / cubic centimeter or less, for example 475 mg / cubic centimeter or less, for example 450 mg / cubic centimeter or less.

[0197] EX44. An aerosol generating substrate, wherein in any prior embodiment, the average surface area of ​​a plurality of beads or granules is at least 3 square millimeters, for example at least 10 square millimeters, for example at least 20 square millimeters.

[0198] EX45. An aerosol generating substrate, wherein in any prior embodiment, the average surface area of ​​a plurality of beads or granules is 80 square millimeters or less, for example 60 square millimeters or less, for example 40 square millimeters or less.

[0199] EX46. An aerosol generating substrate, wherein in any prior embodiment, the total surface area of ​​a plurality of beads or granules is at least 120 square millimeters, for example, at least 240 square millimeters.

[0200] EX47. An aerosol generating substrate, wherein in any prior embodiment, the total surface area of ​​a plurality of beads or granules is 650 square millimeters or less, for example 500 square millimeters or less.

[0201] EX48. An aerosol generating substrate, wherein in any prior embodiment, the average diameter of a plurality of beads or granules is at least 0.5 millimeters, for example, at least 1 millimeter, for example, at least 1.5 millimeters.

[0202] EX49. An aerosol generating substrate, wherein in any prior embodiment, the average diameter of a plurality of beads or granules is 4 millimeters or less, for example 3 millimeters or less, for example 2.5 millimeters or less.

[0203] EX50. In any prior embodiment, an aerosol generating substrate comprising a plurality of substantially spherical beads.

[0204] EX51. An aerosol generating article comprising an aerosol generating substrate according to any prior embodiment.

[0205] EX52. In Example Ex51, the aerosol generating article is substantially flat.

[0206] EX53. In Example EX52, the aerosol generating article is

[0207] First planar outer surface;

[0208] Second planar outer surface;

[0209] cavity;

[0210] A frame positioned between a first planar outer surface and a second planar outer surface, wherein the frame at least partially defines a cavity, and a plurality of beads or granules are provided within the cavity between the first planar outer surface and the second planar outer surface;

[0211] Air inlet and air outlet; and

[0212] An aerosol generating article comprising an airflow passage extending between an air inlet and an air outlet through a cavity.

[0213] EX54. In Example EX51, the aerosol generating article includes a container, and the container is

[0214] An aerosol generating article comprising a first wall and a second wall that jointly define a substrate compartment, wherein a plurality of beads or granules are provided within the substrate compartment.

[0215] EX55. A method for producing an aerosol generating substrate according to any one of Examples EX1 to EX50,

[0216] A step of forming a mixture of a cellulose-based filler and an aerosol-forming agent;

[0217] A step of forming a dough by mixing a combined cellulose-based filler and an aerosol-forming agent with a binder solution comprising one or more hydrocolloid binders;

[0218] A method comprising the step of forming a plurality of beads from dough.

[0219] EX56. In Example EX55, the step of forming a plurality of beads comprises the step of extruding dough to form a plurality of distinct elements and the step of sphericalizing the distinct elements to form a plurality of beads.

[0220] EX57. A method according to Example EX55 or EX56, further comprising the step of drying a plurality of beads.

[0221] EX58. A method in any one of Examples EX55 to EX57, further comprising the step of applying a powder coating to a plurality of beads, wherein the powder coating comprises at least one of tobacco and microcrystalline cellulose. Brief explanation of the drawing

[0222] Now, embodiments will be further described with reference to the drawings: FIG. 1 illustrates a perspective view of an aerosol generating article according to a first embodiment of the present invention; FIG. 2 shows an exploded perspective view of the aerosol generating article of FIG. 1; FIG. 3 illustrates a cross-sectional view of the aerosol-generating article of FIG. 1; FIG. 4 illustrates a schematic cross-sectional view of an aerosol generating article according to a second embodiment of the present invention. Specific details for implementing the invention

[0223] FIG. 1 illustrates an aerosol generating article (10) comprising a first planar outer layer (24) forming a first planar outer surface (21), a second planar outer layer (25) forming a second planar outer surface (22), and a frame (50) positioned between the first planar outer layer (24) and the second planar outer layer (25). The first planar outer layer (24) and the second planar outer layer (25) may be formed from a non-aerosol generating material such as paper or card. Alternatively, either the first planar outer layer (24) and the second planar outer layer (25) may comprise an aerosol generating substrate comprising an aerosol generating material, e.g., tobacco.

[0224] The aerosol generating article (10) has a length extending in the x direction, a width extending in the y direction, and a thickness extending in the z direction. The aerosol generating article (10) has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 3.1 millimeters.

[0225] The first planar outer surface (21) and the second planar outer surface (22) extend in the x and y directions. That is, the first planar outer surface (21) and the second planar outer surface (22) extend in the x / y plane. The first planar outer surface (21) is positioned parallel to the second planar outer surface (22), and the first planar outer surface (21) is spaced apart from the second planar outer surface (22) in the z direction or transverse direction. The distance between the first planar outer surface (21) and the second planar outer surface (22) in the z direction or transverse direction corresponds to the thickness of the aerosol generating article (10).

[0226] The aerosol generating article (10) is substantially flat or substantially planar. In particular, the thickness of the aerosol generating article (10) is less than 50 percent of both the length and width of the aerosol generating article. The aerosol generating article (10) has a shape that is generally rectangular and has a laminated structure formed by a first planar outer layer (24), a frame (50), and a second planar outer layer (25). The first planar outer layer (24), the frame (50), and the second planar outer layer (25) are bonded together using an adhesive, in particular guar gum.

[0227] FIG. 2 shows an exploded view of the aerosol generating article (10) of FIG. 1.

[0228] The frame (50) has a length of 30 millimeters, a width of 10 millimeters, and a thickness of 2.7 millimeters. The frame (50) is made of cardboard and defines a frame aperture that extends through the thickness of the frame (50). The frame aperture forms at least partially a cavity (30). The cavity (30) has a length of 15 millimeters, a width of 7 millimeters, and a depth of 3.3 millimeters. Thus, the cavity (30) has a volume of approximately 346.5 cubic millimeters. The cavity (30) is filled with a plurality of beads (schematically illustrated) of an aerosol generating substrate (40). The beads of the aerosol generating substrate (40) fill the entire volume of the cavity (30), and airflow through the cavity (30) is provided by the gaps between adjacent beads. The beads of the aerosol generating substrate (40) will be described in more detail below.

[0229] The first planar outer layer (24) and the second planar outer layer (25) have a thickness of 200 micrometers and are in physical contact with the frame (50). The first planar outer layer (24) and the second planar outer layer (25) are bonded to the frame using an adhesive (15). The first planar outer layer (24) is placed over the end of the cavity (30) and forms the first cavity end wall (31). The second planar outer layer (25) is placed over the opposite end of the cavity (30) and forms the second cavity end wall (32). That is, the frame (50), the first planar outer layer (24), and the second planar outer layer (25) collectively define the cavity (30).

[0230] The frame (50) includes a surrounding wall (51) that surrounds the cavity (30). The surrounding wall (51) has a radial thickness of about 2 millimeters.

[0231] The air inlet (not visible) and the air outlet (12) are defined by and extend through the periphery wall (51) of the frame (50). The air inlet is located on the opposite side of the air outlet (12) on the opposite wall of the frame (50). The air inlet and the air outlet (12) each have a rectangular cross-section, a width of 2 millimeters, and a thickness of 0.9 millimeters. An airflow passage extends through a cavity (30) between the air inlet and the air outlet (12).

[0232] The beads of the aerosol generating substrate (40) have a substantially spherical shape with a diameter of 1.5 millimeters and a density of 1.3 grams / cubic centimeter. The total weight of the beads of the aerosol generating substrate (40) within the cavity (30) is approximately 150 mg. The beads are formed from an aerosol generating substrate comprising a cellulose-based filler, an aerosol forming agent, and a hydrocolloid binder. Examples of suitable compositions of the aerosol generating substrate forming the beads are provided below.

[0233] FIG. 4 illustrates an aerosol generating article (100) according to a second embodiment of the present invention. The aerosol generating article (100) comprises a container (110). The container (110) comprises a first wall (111) and a second wall (112) that together define a substrate compartment (113). A plurality of spherical beads (114) of an aerosol generating substrate (schematically illustrated) are provided within the substrate compartment (113). The substrate compartment (113) has a length of 17 millimeters, a width of 8 millimeters, and a depth of 3.5 millimeters.

[0234] The first wall (111) is formed of a nonwoven cotton material. The first wall (111) comprises 85 to 90 weight percent cellulose, 7 to 16 weight percent hemicellulose, and 1 to 3 weight percent lignin. The first wall (111) is porous.

[0235] The second wall (112) comprises paper. The second wall (112) has a basis weight of about 35 gsm. The second wall is non-porous.

[0236] The second wall (112) may be substantially flat. The second wall (112) has higher rigidity than the first wall (111). In this way, the first wall (111) can generally form a bag shape that is closed by the second wall (112).

[0237] The first wall (111) and the second wall (112) meet at a contact area (116). The contact area (116) extends around the circumference of the container (110). The contact area (116) has a thickness of 3.5 millimeters. The first wall (111) and the second wall (112) are connected at the contact area (116) by an adhesive to form a sealing area. The adhesive is a polyvinyl alcohol adhesive.

[0238] The first wall (111) and the second wall (112) are thermally stable at least 280 degrees Celsius or less.

[0239] The aerosol generating article (100) further comprises a ring element (115) placed over a sealing area. The ring element (115) is formed from paper having a basis weight of 100 gsm. The ring element (115) has a higher rigidity than the first wall (111) and the second wall (112). The ring element (115) is placed over the entire sealing area. The ring element (115) is adhered to the first wall (111). In this way, a portion of the first wall (111) is interposed between the ring element (115) and the second wall (112). The ring element (115) is adhered to the first wall (111) by a polyvinyl alcohol adhesive. The ring element (115) has a thickness of 3.5 millimeters corresponding to the thickness of the contact area (116).

[0240] The spherical beads (114) provided within the substrate compartment (113) have an average diameter of 1.5 millimeters and a density of 1.3 grams / cubic centimeter. The total weight of the beads (114) within the substrate compartment (113) is approximately 150 mg. The beads (114) are formed from an aerosol-generating substrate comprising a cellulose-based filler, an aerosol-forming agent, and a hydrocolloid binder. An example of a suitable composition of the aerosol-generating substrate forming the beads is provided below.

[0241] Examples

[0242] Suitable compositions for forming beads or granules of an aerosol generating substrate according to the present invention are presented in Table 1 below:

[0243] Components Composition A Weight content (%) Composition B Weight content (%) Composition C Weight content (%) Composition D Weight content (%) Microcrystalline cellulose 55.75 74.0 79.6 49.7 glycerin 40.3 23.6 18 48.2 HPMC 0.75 0.9 0.9 0.6 nicotine 1.5 1.5 1.5 1.5 Lactic acid 1.7 0 0 0

[0244] All amounts are presented as weight percentages on a dry weight basis, based on the total weight of the aerosol generating element.

[0245] To manufacture the beads, first, an HPMC binder is dispersed in glycerin, and then water is added to form an aqueous binder solution. A solution of nicotine and acid in glycerin is also produced. The MCC and nicotine solution is added to the binder solution, and all components are mixed to form a dough. The dough is extruded to form multiple distinct elements, and then the distinct elements are spherical at low speed to form spherical beads having an average diameter of 1.5 millimeters. The beads are dried in an oven to a desired moisture content. Then, the dried beads can be incorporated into various aerosol-generating articles as described above.

[0246] As previously described in relation to FIG. 1, an aerosol containing nicotine and glycerin was generated from the aerosol generating substrate when incorporated into an aerosol generating article and heated to a temperature of 200 to 240 degrees Celsius. It was found that the ratio of nicotine to glycerin in each puff of the aerosol remained consistent over the duration of heating. This contrasts with an aerosol generated from an article having a similar composition but in which the aerosol generating substrate is in the form of a tobacco cast leaf. Under the same conditions, the aerosol generated by the tobacco cast leaf substrate was found to have a much more variable ratio of nicotine to glycerin per puff. Providing an aerosol with a more consistent ratio of nicotine to glycerin across the entire puff offers the consumer an optimal sensory experience over the duration of heating.

[0247] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases as being modified by the term “about.” Accordingly, in this context, the number A is understood as 10 percent of A ± A. In this context, the number A may be considered to include numerical values ​​within the general standard error for measuring the characteristic that the number A modifies. In some cases used in the appended claims, the number A may deviate by the percentage listed above, provided that the amount of deviation of A does not significantly affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically listed herein.

Claims

Claim 1 An aerosol generating substrate for use in an aerosol generating article or system, wherein the aerosol generating substrate comprises at least 10 weight percent of an aerosol forming agent based on dry weight; at least 30 weight percent of a cellulose-based filler based on dry weight; one or more hydrocolloid binders - the total amount of the hydrocolloid binders is at most 5 weight percent of the aerosol generating substrate based on dry weight; and at least one of an activator or a flavoring agent, wherein the weight ratio of the cellulose-based filler to the aerosol forming agent within the aerosol generating substrate is at least 1, and the aerosol generating substrate is in the form of a plurality of beads. Claim 2 In claim 1, the cellulose-based filler comprises microcrystalline cellulose, an aerosol generating substrate. Claim 3 An aerosol generating substrate according to claim 1 or 2, wherein the weight ratio of the cellulose-based filler to the aerosol forming agent in the aerosol generating substrate is 2 or less. Claim 4 An aerosol generating substrate according to any one of claims 1 to 3, wherein the weight ratio of the cellulose-based filler to the hydrocolloid binder in the aerosol generating substrate is at least 20. Claim 5 An aerosol generating substrate according to any one of claims 1 to 4, wherein the total amount of the hydrocolloid binder is at least 0.5 weight percent based on dry weight. Claim 6 An aerosol generating substrate according to any one of claims 1 to 5, wherein the hydrocolloid binder comprises a cellulose binder. Claim 7 In claim 6, the aerosol generating substrate comprises a cellulose binder comprising hydroxypropyl methylcellulose (HPMC). Claim 8 An aerosol generating substrate according to any one of claims 1 to 7, wherein the aerosol generating substrate comprises an activator containing nicotine, and the nicotine content of the aerosol generating substrate is at least 0.5 weight percent based on dry weight. Claim 9 In any one of claims 1 to 8, the aerosol generating material is an aerosol generating material having a density of at least 0.75 grams / cubic centimeter. Claim 10 An aerosol generating substrate according to any one of claims 1 to 9, wherein the bulk density of the plurality of beads or granules is at least 200 mg / cubic centimeter. Claim 11 An aerosol generating substrate according to any one of claims 1 to 10, wherein the average diameter of the plurality of beads or granules is at least 0.5 millimeters. Claim 12 In any one of claims 1 to 11, the aerosol generating material is in the form of a plurality of spherical beads. Claim 13 An aerosol generating article comprising an aerosol generating description according to any one of paragraphs 1 to 12. Claim 14 In paragraph 13, the aerosol generating article is a substantially flat aerosol generating article. Claim 15 A method for producing an aerosol generating substrate according to any one of claims 1 to 12, comprising: a step of forming a mixture of a cellulose-based filler and an aerosol-forming agent; a step of mixing the combined cellulose-based filler and aerosol-forming agent with a binder solution comprising one or more hydrocolloid binders to form a dough; and a step of forming a plurality of beads from the dough.

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