Flavour material for use in an aerosol-generating article with enhanced early flavour release

Abstract

The present invention relates to a flavour material (50) for use in an aerosol-generating article (10). The flavour material (50) comprises: a polysaccharide matrix structure; a flavourant formulation dispersed within the polysaccharide matrix structure, wherein the flavourant formulation is at least partly trapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavour material (50); and an elongate susceptor element structurally coupled with the polysaccharide matrix structure and the flavourant formulation. The elongate susceptor element is a metal fibre element or a metal wire element or a metal thread element. The present invention further relates to an aerosol-generating article comprising a flavour material in line with the foregoing description, preferably at a peripheral location in a rod of aerosol-generating substrate (12) of the aerosol-generating article.

Description

[0001] P / 90908.W001

[0002] - 1 - FLAVOUR MATERIAL FOR USE IN AN AEROSOL-GENERATING ARTICLE WITH ENHANCED EARLY FLAVOUR RELEASE

[0003] The present disclosure relates to a flavour material for use in an aerosol-generating article. Further, the present disclosure relates to aerosol-generating articles comprising one such flavour material and to aerosol-generating systems comprising said aerosol-generating articles.

[0004] Aerosol-generating articles in which an aerosol-generating substrate, such as for example a tobacco-containing substrate or a non-tobacco, nicotine-containing substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0005] Several aerosol-generating devices for consuming aerosol-generating articles have been disclosed in the art. Such devices include, for example, electrically heated aerosol-generating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of an aerosolgenerating article. For example, electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosolgenerating substrate. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor arranged within the aerosolgenerating substrate have been proposed by WO 2015 / 176898 A1.

[0006] It has been proposed to include in aerosol-generating articles a source of flavour in addition to the aerosol-generating substrate. In effect, this practice was relatively common with conventional filter cigarettes, and a number of solutions have been described in the art for providing a flavourant at a location in a mouthpiece filter or in the rod of tobacco cut filler.

[0007] However, given how the aerosol is generated and delivered to the consumer in aerosolgenerating articles, ensuring a consistent flavour delivery of aerosol and flavour species during use may be difficult, and so a consumer may perceive fluctuations or a decrease in flavour intensity over time. Additionally, even prior to the aerosol-generating articles being used, some flavour species may be lost during certain production steps or during transportation and storage of the aerosol-generating articles.

[0008] It has previously been proposed to reduce the loss of volatile flavourants from conventional filter cigarettes during storage through the encapsulation of the flavourant, forP / 90908.W001

[0009] - 2 -example in the form of a capsule or microcapsule containing a flavour formulation. The encapsulated flavour species can be released prior to or during smoking of the filter cigarette by breaking open the encapsulating structure, for example by manually crushing the structure. However, the encapsulated flavourant is typically released from the encapsulating structure in a single burst, and so one such solution might fail to provide a consistently intense flavour delivery during use of the article.

[0010] In other examples, wherein an encapsulated flavourant has been provided in a rod of aerosol-generating substrate of an aerosol-generating article, such as for example a rod of aerosol-generating substrate in which the encapsulated flavourant is embedded, release of the encapsulated flavourant from the encapsulating structure has been observed to require the achievement of a predetermined temperature in the rod of aerosol-generating substrate. Depending on how heat is supplied to the aerosol-generating substrate and the encapsulated flavourant, reaching the predetermined minimum temperature may require some time, such that the flavour species only begin to be delivered to the consumer after a few puffs in the usage cycle. Some consumers may find this delay, to an extent, undesirable. Besides, it may more generally be desirable to provide new aerosol-generating articles that are configured to release aerosol and flavour species to the consumer according to a wider range of delivery profiles, and preferably more consistently during a usage cycle.

[0011] Therefore, a need is felt to provide flavour materials, as well as aerosol-generating articles containing flavour materials, that are associated with an enhanced flavour perception for the consumer, particularly towards the start of the usage session of the aerosol-generating article, preferably whilst continuing to make flavour species available over the remainder of the usage session.

[0012] The present disclosure relates to a flavour material for use in an aerosol-generating article, wherein a flavourant formulation is releasable from the flavour material upon heating the flavour material.

[0013] The flavour material may comprise a polysaccharide matrix structure and a flavourant formulation dispersed within the polysaccharide matrix structure. The flavourant formulation may at least partly be trapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavour material.

[0014] The flavour material may further comprise an elongate susceptor element structurally coupled with the polysaccharide matrix structure and the flavourant formulation.

[0015] The elongate susceptor element may be a metal fibre element or a metal wire element or a metal thread element.

[0016] The elongate susceptor element may be a metal rod element.P / 90908.W001

[0017] - 3 - The flavour material may be incorporated in an aerosol-generating article. The aerosolgenerating article may comprise a rod of aerosol-generating substrate extending along a longitudinal axis. The aerosol-generating article may comprise a downstream section located downstream of the rod of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article.

[0018] The aerosol-generating article may comprise an upstream section located upstream of the rod of aerosol-generating substrate and extending to a distal end of the aerosol-generating article.

[0019] The flavour material may be located in at least one of the rod of aerosol-generating substrate; the downstream section; and the optional upstream section.

[0020] For example, the flavour material may be located in the rod of aerosol-generating substrate, and a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be at least 0.25 times a diameter of the rod of aerosolgenerating substrate.

[0021] According to a first aspect of the present invention, there is provided a flavour material for use in an aerosol-generating article, the flavour material comprising: a polysaccharide matrix structure; a flavourant formulation dispersed within the polysaccharide matrix structure, wherein the flavourant formulation is at least partly trapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavour material; and an elongate susceptor element structurally coupled with the polysaccharide matrix structure and the flavourant formulation, wherein the elongate susceptor element is a metal fibre element or a metal wire element or a metal thread element.

[0022] According to a second aspect of the present invention, there is provided an aerosolgenerating article comprising a rod of aerosol-generating substrate extending along a longitudinal axis, the article further comprising at least one of a downstream section located downstream of the rod of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article and an upstream section located upstream of the rod of aerosol-generating substrate and extending to a distal end of the aerosol-generating article. The aerosol-generating article comprises a flavour material according to the first aspect of the present invention, the flavour material located in the rod of aerosol-generating substrate, wherein a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.25 times a diameter of the rod of aerosol-generating substrate.

[0023] As used herein with reference to the invention, the term “aerosol-generating article” is used to describe an article comprising an aerosol-generating substrate that is heated to generate an inhalable aerosol for delivery to a user.P / 90908.W001

[0024] - 4 - As used herein with reference to the invention, the term “aerosol-generating substrate” is used to describe a substrate comprising aerosol-generating material that is capable of releasing upon heating volatile compounds that can generate an aerosol.

[0025] As used herein with reference to the invention, the term “aerosol” is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0026] As used herein with reference to the invention, the term “aerosol-generating device” is used to describe a device that interacts with the aerosol-generating substrate of the aerosolgenerating article to generate an aerosol.

[0027] Aerosol-generating articles according to the invention have a proximal end through which, in use, an aerosol exits the aerosol-generating article for delivery to a user. The proximal end of the aerosol-generating article may also be referred to as the downstream end or mouth end of the aerosol-generating article. In use, a user draws directly or indirectly on the proximal end of the aerosol-generating article in order to inhale an aerosol generated by the aerosol-generating article.

[0028] Aerosol-generating articles according to the invention have a distal end. The distal end is opposite the proximal end. The distal end of the aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0029] Components of aerosol-generating articles according to the invention may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the aerosol-generating article and the distal end of the aerosol-generating article.

[0030] As used herein with reference to the invention, the term “longitudinal” is used to describe the direction between the upstream end and the downstream end of the aerosol-generating article. During use, air is drawn through the aerosol-generating article in the longitudinal direction.

[0031] As used herein with reference to the invention, the term “length” is used to describe the maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in the longitudinal direction.

[0032] As used herein with reference to the invention, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or a component of the aerosol-generating article refer to the transverse cross-section.

[0033] As used herein with reference to the invention, the term “width” denotes the maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in a transverse direction. Where the aerosol-generating article has a substantially circular cross-P / 90908.W001

[0034] - 5 -section, the width of the aerosol-generating article corresponds to the diameter of the aerosolgenerating article. Where a component of the aerosol-generating article has a substantially circular cross-section, the width of the component of the aerosol-generating article corresponds to the diameter of the component of the aerosol-generating article.

[0035] As used herein with reference to the present invention, the term “susceptor” refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents induced in the susceptor cause heating of the susceptor.

[0036] As used herein with reference to the invention, the term “elongate susceptor element” is used to denote a susceptor element having a greater extent in one predominant dimension than in the two remaining dimensions perpendicular to the predominant dimension. As such, the elongate susceptor element may also be denoted as a quasi-one-dimensional susceptor element or quasi- 1 D susceptor element. In particular, the term "elongate susceptor element" may refer to a susceptor element that has a length dimension greater than any transverse dimension perpendicular to the length dimension. More particularly, the susceptor element may be an elongate or a prolate susceptor element.

[0037] As used herein with reference to the invention, the term "hollow tubular element" is used to denote a generally cylindrical element having a lumen along a longitudinal axis thereof. The tubular portion may have a substantially circular, oval or elliptical cross-section. The lumen may have a substantially circular, oval or elliptical cross-section. In particular, the term "hollow tubular element" is used to denote an element defining at least one airflow conduit establishing an uninterrupted fluid communication between an upstream end of the hollow tubular element and a downstream end of the tubular element.

[0038] Unless otherwise stated, the resistance to draw (RTD) of the aerosol-generating article or a component of the aerosol-generating article is measured in accordance with ISO 6565-2015 at a volumetric flow rate of 17.5 millilitres per second at the proximal end of the aerosol-generating article or the component thereof at a temperature of 22 degrees Celsius, a pressure of 101 kPa (760 Torr) and a relative humidity of 60%.

[0039] As used herein, the resistance to draw (RTD) per unit length of the aerosol-generating article or a component of the aerosol-generating article is equal to the resistance to draw (RTD) of the aerosol-generating article divided by the length of the aerosol-generating article or the resistance to draw (RTD) of the component divided by the length of the component, respectively.

[0040] Structurally coupling a flavourant formulation immobilised within a polysaccharide matrix structure with an elongate susceptor element in the form of a metal fibre element or a metal wire element or a metal thread element or a metal rod element in accordance with the present invention has been found to have a desirable impact on the overall flavour delivery profile. In fact, the inventors have observed that with the first puffs of the usage session of an aerosol-generatingP / 90908.W001

[0041] - 6 -article including a flavour material according to the present invention considerably higher amounts of flavour species are delivered to the consumer, compared with an aerosol-generating article comprising a similarly immobilised flavour formulation that is not coupled with an elongate susceptor of the type described here. Further, throughout a usage session, an aerosol-generating article including a flavour material according to the present invention has generally been found to deliver higher levels of flavour species to the consumer.

[0042] Accordingly, the present invention provides aerosol-generating articles with a new flavour material arrangement that is associated with a desirable and distinctive flavour delivery profile, such that a sudden burst of flavour may be perceived by the consumer with the very first puffs at the beginning of a usage session. Without wishing to be bound by theory, it is understood that, because of its high conductivity, the metal fibre element or a metal wire element or a metal thread element is heated very rapidly and can efficiently transfer heat by conduction to the immobilised flavourant formulation and polysaccharide matrix it is coupled with. As a consequence, the flavourant formulation reaches the threshold temperature required for its release much faster than in existing aerosol-generating articles. In fact, as has been observed experimentally, release of the flavourant formulation may triggered so promptly that the very first puff of a usage session is associated with a highly enhanced release and delivery of flavour species to the consumer.

[0043] Furthermore, because the delivery of flavour species is generally enhanced over the whole usage session, aerosol-generating articles in accordance with the present invention have been found to consistently provide highly satisfactory flavour delivery even after the initial flavour burst has subsided. Therefore, the present invention may also typically help provide aerosolgenerating articles that are perceived as being associated with a more prolonged or more consistent flavour release during use. In general terms, when a flavour material in accordance with the invention is incorporated in an aerosol-generating article, such as for example a heat-not-burn article configured to generate an aerosol upon heating a tobacco-containing aerosolgenerating substrate, puff-by-puff flavour release has been found to be generally more efficient.

[0044] The inventors have also observed that by adjusting the relative proportions of the various ingredients in the flavour formulation or by altering the composition of the matrix - for example, by selecting certain combinations of polysaccharides forming the matrix - or by doing both, it may advantageously be possible to finely tailor certain characteristics of the flavour material to specific needs associated with use in an aerosol-generating article. For example, the flavour release profile may be adjusted, such as to have the flavour released in more successive “waves” during use. As a result, the consumer may perceive flavour notes as more intense or lingering for longer during use. Thus, flavour materials in accordance with the present invention may offer a wider breadth of flavour profiles that were not accessible with the known flavour materials.P / 90908.W001

[0045] - 7 - Because the flavourant formulation is at least partly trapped within the matrix until it is released upon heating, flavour materials in accordance with the present invention have been found to exhibit increased stability. For example, a significant reduction in losses of flavour species during storage, transportation, and so forth, has been observed, even under stress conditions. Coupled with the enhancement in flavour release at the start of a usage session, this makes for a particularly effective use of flavourants and other ingredients of the flavour formulation.

[0046] As described briefly above, in a flavour material according to the present invention an elongate susceptor element is structurally coupled with a polysaccharide matrix structure and a flavourant formulation which is at least partly trapped within the polysaccharide matrix structure and which is releasable from the polysaccharide matrix structure upon heating of the flavour material. The elongate susceptor element is a metal fibre element or a metal wire element or a metal thread element.

[0047] In certain examples, the elongate susceptor element may be partly enveloped by the polysaccharide matrix structure. For example, this may be achieved by casting a mixture containing the ingredients from which the polysaccharide matrix structure and the flavourant formulation are formed onto a supporting surface (e.g. a metallic tray) on which metal fibre elements or metal wire elements or metal thread elements or metal rod elements have previously been arranged according to a predetermined array. Thus, when the mixture gels, the polysaccharide matrix structure trapping the flavourant formulation is formed on and around the metal fibre elements or metal wire elements or metal thread elements or metal rod elements.

[0048] In other examples, the flavour material further comprises a carrier sheet material, wherein the polysaccharide matrix structure and the flavourant formulation are supported by the carrier sheet material, and the elongate susceptor element is embedded within the carrier sheet material.

[0049] For example, this may be achieved by casting a mixture containing the ingredients from which the polysaccharide matrix structure and the flavourant formulation are formed onto a carrier sheet material in which metal fibre elements or metal wire elements or metal thread elements or metal rod elements are embedded, for example so that they formed a predetermined array across the carrier sheet material.

[0050] In alternative examples, the flavour material further comprises a carrier sheet material, wherein the polysaccharide matrix structure and the flavourant formulation are supported by the carrier sheet material, and the elongate susceptor element is secured to the carrier sheet material.

[0051] Where the metal wire is secured to the carrier sheet material, the elongate susceptor element may be secured to the same side of the carrier sheet material which is in direct contact with the polysaccharide matrix structure and the flavourant formulation.P / 90908.W001

[0052] - 8 - For example, this may be achieved by casting a mixture containing the ingredients from which the polysaccharide matrix structure and the flavourant formulation are formed onto a surface of carrier sheet material to which metal fibre elements or metal wire elements or metal thread elements or metal rod elements have previously been secured (for example, glued). The lengths of metal wire may form a predetermined array across the surface of the carrier sheet material.

[0053] As an alternative, where the elongate susceptor element is secured to the carrier sheet material, the elongate susceptor element may be secured to the side of the carrier sheet material opposite the one which is in direct contact with the polysaccharide matrix structure and the flavourant formulation.

[0054] For example, this may be achieved by casting a mixture containing the ingredients from which the polysaccharide matrix structure and the flavourant formulation are formed onto a surface of a carrier sheet material and subsequently securing (for example, gluing) metal fibre elements or metal wire elements or metal thread elements or metal rod elements to the opposite surface of the carrier sheet material. The metal fibre elements or metal wire elements or metal thread elements or metal rod elements may form a predetermined array across the surface of the carrier sheet material.

[0055] As used herein, the term “sheet material” denotes a laminar material having a width and length substantially greater than the thickness thereof. For example, the carrier sheet material may be a sheet of homogenised tobacco material or a sheet of a paper material. Use of a homogenised tobacco material for manufacturing a flavour material in accordance with the present invention will be described in more detail below.

[0056] Having the polysaccharide matrix structure and the flavourant formulation trapped therein supported by the carrier sheet material is advantageous in that the structural strength of the flavour material is improved by virtue of the carrier sheet material serving a support function. This may be especially beneficial from a manufacturing viewpoint, as handling of the flavour material reinforced by the carrier sheet material may generally be easier.

[0057] For example, where the flavour material comprises a carrier sheet material, the polysaccharide matrix structure and the flavourant formulation trapped therein may be formed directly on the carrier sheet material to form a flavour material that can, as such, be easily cut into pieces having a predetermined average size (for example, a predetermined cut width or a predetermined cut length or both). This makes it easy to combine the flavour material with an aerosol-generating substrate containing pieces of a similar size.

[0058] In other examples, the carrier sheet material may be in the form of a plurality of pieces cut from a sheet material, the pieces having a predetermined average size (for example, a predetermined cut width or a predetermined cut length or both). As an alternative, the carrierP / 90908.W001

[0059] - 9 -sheet material may comprise a plurality of pieces cut from a naturally occurring plant material, preferably a plant leaf material (for example, tobacco lamina). In some embodiments, the carrier sheet material may be tobacco cut filler.

[0060] Use of a carrier sheet material supporting polysaccharide matrix structure and the trapped flavourant formulation may have the added benefit that, by selecting and adjusting certain properties of the carrier sheet material (for example, its thickness) one may obtain a flavour material that is easier to form into a bobbin, and which can therefore be handled and processed more easily when the flavour material is incorporated into an aerosol-generating article. In view of a high speed automated manufacturing process, the increased structural strength provided by the carrier sheet material may be particularly beneficial.

[0061] As mentioned previously, in some preferred embodiments, the carrier sheet material may be in the form of a sheet of a homogenised tobacco material.

[0062] As used in the present specification, the term “homogenised tobacco material” encompasses any tobacco material formed by the agglomeration of particles of tobacco material. Sheets or webs of homogenised tobacco material are formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering of one or both of tobacco leaf lamina and tobacco leaf stems. In addition, homogenised tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. The sheets of homogenised tobacco material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0063] Sheets or webs of homogenised tobacco material for use in the invention may have a tobacco content of at least about 40 percent by weight on a dry weight basis, more preferably of at least about 60 percent by weight on a dry weight basis, more preferably or at least about 70 percent by weight on a dry basis and most preferably at least about 90 percent by weight on a dry weight basis.

[0064] Sheets or webs of homogenised tobacco material for use as the carrier sheet material may comprise one or more intrinsic binders, that is tobacco endogenous binders, one or more extrinsic binders, that is tobacco exogenous binders, or a combination thereof to help agglomerate the particulate tobacco. Alternatively, or in addition, sheets of homogenised tobacco material for use as the carrier sheet material may comprise other additives including, but not limited to, tobacco and non-tobacco fibres, aerosol-formers, humectants, plasticisers, flavourants, fillers, aqueous and non-aqueous solvents and combinations thereof.

[0065] Suitable extrinsic binders for inclusion in sheets or webs of homogenised tobacco material for use as the carrier sheet material are known in the art and include, but are not limited to: gums such as, for example, guar gum, xanthan gum, arabic gum and locust bean gum; cellulosicP / 90908.W001

[0066] - 10 -binders such as, for example, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as, for example, starches, organic acids, such as alginic acid, conjugate base salts of organic acids, such as sodiumalginate, agar and pectins; and combinations thereof.

[0067] Suitable non-tobacco fibres for inclusion in sheets or webs of homogenised tobacco material for use as the carrier sheet material are known in the art and include, but are not limited to: cellulose fibres; soft-wood fibres; hard-wood fibres; jute fibres and combinations thereof. Prior to inclusion in sheets of homogenised tobacco material for use as the carrier sheet material, nontobacco fibres may be treated by suitable processes known in the art including, but not limited to: mechanical pulping; refining; chemical pulping; bleaching; sulphate pulping; and combinations thereof.

[0068] Preferably, the sheets or webs of homogenised tobacco material comprise an aerosol former. As used herein, the term “aerosol former” describes any suitable known compound or mixture of compounds that, in use, facilitates formation of an aerosol and that is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article.

[0069] Suitable aerosol-formers are known in the art and include, but are not limited to: polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0070] Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol and, most preferred, glycerine.

[0071] The sheets or webs of homogenised tobacco material may comprise a single aerosol former. Alternatively, the sheets or webs of homogenised tobacco material may comprise a combination of two or more aerosol formers.

[0072] The sheets or webs of homogenised tobacco material have an aerosol former content of greater than 10 percent on a dry weight basis. Preferably, the sheets or webs of homogenised tobacco material have an aerosol former content of greater than 12 percent on a dry weight basis. More preferably, the sheets or webs of homogenised tobacco material have an aerosol former content of greater than 14 percent on a dry weight basis. Even more preferably the sheets or webs of homogenised tobacco material have an aerosol former content of greater than 16 percent on a dry weight basis.

[0073] The sheets of homogenised tobacco material may have an aerosol former content of between approximately 10 percent and approximately 30 percent on a dry weight basis. Preferably, the sheets or webs of homogenised tobacco material have an aerosol former content of less than 25 percent on a dry weight basis.P / 90908.W001

[0074] - 11 - In a preferred embodiment, the sheets of homogenised tobacco material have an aerosol former content of approximately 20 percent on a dry weight basis.

[0075] Sheets or webs of homogenised tobacco for use as the carrier sheet material in the flavour material of the present invention may be made by methods known in the art, for example the methods disclosed in International patent application WO-A-2012 / 164009 A2. In a preferred embodiment, sheets of homogenised tobacco material for use as the carrier sheet material are formed from a slurry comprising particulate tobacco, guar gum, cellulose fibres and glycerine by a casting process.

[0076] In other embodiments, the carrier sheet material may be in the form of a sheet of a nontobacco aerosol-generating material. For example, the carrier sheet material may be a sheet of sorbent non-tobacco material loaded with nicotine (for example, in the form of a nicotine salt) and an aerosol-former. Examples of such rods are described in the international application WO-A-2015 / 052652. In addition, or as an alternative, the carrier sheet material may be a sheet of a homogenised non-tobacco plant material, such as an aromatic non-tobacco plant material. In certain embodiments, the carrier sheet material may be in the form of a paper wrapper material. This has the benefit that the flavour material may be used as an alternative or in addition to conventional paper wrapper materials in the manufacture of an aerosol-generating article. Thus, the flavour material may be incorporated into the aerosol-generating article without significantly altering existing manufacturing processes and without requiring significant modifications of existing manufacturing apparatus.

[0077] In further examples, the flavour material may be in the form of a flavour sheet comprising the polysaccharide matrix structure and the flavourant formulation, wherein the elongate susceptor element is secured to the flavour sheet. This may be achieved by casting a mixture containing the ingredients from which the polysaccharide matrix structure and the flavourant formulation are formed onto a supporting surface (e.g. a metallic tray) to form the flavour sheet through gelling of the mixture. Metal fibre elements or metal wire elements or metal thread elements or metal rod elements may subsequently be secured (for example, glued) to the flavour sheet. The metal fibre elements or metal wire elements or metal thread elements or metal rod elements may form a predetermined array across the surface of the flavour sheet.

[0078] Preferably, the elongate susceptor element has a diameter of at least 5 micrometres. More preferably, the elongate susceptor element has a diameter of at least 10 micrometres. Even more preferably, the elongate susceptor element has a diameter of at least 15 micrometres.

[0079] The elongate susceptor element preferably has a diameter of less than or equal to 100 micrometres. More preferably, the elongate susceptor element has a diameter of less than or equal to 90 micrometres. Even more preferably, the elongate susceptor element has a diameter of less than or equal to 80 micrometres.P / 90908.W001

[0080] - 12 - In some examples, the elongate susceptor element has a diameter of from 5 micrometres to 100 micrometres, preferably from 10 micrometres to 100 micrometres, more preferably from 15 micrometres to 100 micrometres. In other examples, the elongate susceptor element has a diameter of from 5 micrometres to 90 micrometres, preferably from 10 micrometres to 90 micrometres, more preferably from 15 micrometres to 90 micrometres. In further examples, the elongate susceptor element has a diameter of from 5 micrometres to 80 micrometres, preferably from 10 micrometres to 80 micrometres, more preferably from 15 micrometres to 80 micrometres.

[0081] In a flavour material according to the present invention, the elongate susceptor element may for example have a length of at least 100 micrometres. Preferably, the elongate susceptor element has a length of at least 500 micrometres. More preferably, the elongate susceptor element has a length of at least 1 millimetre. Even more preferably, the elongate susceptor element has a length of at least 1.5 millimetres.

[0082] A length of the elongate susceptor element may for example be of up to 15 millimetres. Preferably, a length of the elongate susceptor element is of less than or equal to 12 millimetres. More preferably, a length of the elongate susceptor element is of less than or equal to 10 millimetres. Even more preferably, a length of the elongate susceptor element is of less than or equal to 5 millimetres.

[0083] In some examples, the elongate susceptor element may have a length from 100 micrometres to 15 millimetres, preferably from 500 micrometres to 15 millimetres, more preferably from 1 millimetre to 15 millimetres, even more preferably from 1.5 millimetres to 15 millimetres. In other example, the elongate susceptor element may have a length from 100 micrometres to 10 millimetres, preferably from 500 micrometres to 10 millimetres, more preferably from 1 millimetre to 10 millimetres, even more preferably from 1.5 millimetres to 10 millimetres. In further examples, the metal wire may have a length from 100 micrometres to 5 millimetres, preferably from 500 micrometres to 5 millimetres, more preferably from 1 millimetre to 5 millimetres, even more preferably from 1.5 millimetres to 5 millimetres. In yet further examples, the elongate susceptor element may have a length from 100 micrometres to 5 millimetres, preferably from 500 micrometres to 5 millimetres, more preferably from 1 millimetre to 5 millimetres, even more preferably from 1.5 millimetres to 5 millimetres.

[0084] Preferably, in a flavour material according to the present invention the polysaccharide matrix structure comprises gellan gum and emulsifier.

[0085] The term “gellan gum” is used to identify a water-soluble anionic polysaccharide, which is produced by the bacterium Sphingomonas elodea. The repeating unit of the polymer is a tetrasaccharide, which consists of two residues of D-glucose and one of each residues of L-rhamnose and D-glucuronic acid. Gellan gum has been approved for food, non-food, cosmeticP / 90908.W001

[0086] - 13 -and pharmaceutical uses by authorities in many jurisdictions, such as Japan, USA, Canada, China, South Korea and the EU.

[0087] Two forms of gellan gum are known - namely, high acyl gellan gum and low acyl gellan gum - which differ by way of the degree / percent of substitution by O-acyl groups.

[0088] In flavour materials in accordance with the present invention, the gellan gum is preferably low acyl gellan gum. This is a gellan gum that is partly deacylated or fully deacylated. Its most common form is the fully deacylated one, with no detectable acyl groups, which is also called deacetylated gellan gum.

[0089] Use of low acyl gellan gum to form the polysaccharide matrix of a flavour material in accordance with the present invention is preferred because low acyl gellan gum is capable of forming gels at very low concentrations. Additionally, the texture of gellan gum based gels varies with the acyl content, low acyl gellan gum typically forming firmer, less elastic and more brittle gels compared with high acyl gellan gum.

[0090] Where the polysaccharide matrix structure comprises gellan gum and an emulsifier, a flavour material may advantageously be provided wherein a substantial fraction of the flavourant formulation is effectively trapped within the polysaccharide matrix structure. This is beneficial in that it improves the stability of the flavour material. Further, as it will be discussed in more detail below, it has an impact on how flavour species are released upon heating the flavour material, and so it may help tune a flavourant release profile during use.

[0091] Additionally, from a manufacturing viewpoint, a stable polysaccharide matrix structure comprising gellan gum and an emulsifier can be formed by supplying heat to the starting reagents without requiring the use of cross-linking agents. In fact, by kneading and emulsifying the flavour formulation and gellan gum in a heated aqueous bath, the polysaccharide-coated flavourant can be brought to an emulsified state which is then substantially preserved after drying and cooling. Advantageously, this allows for a significant amount of flavourant to be provided in an immobilised state within the polysaccharide matrix, and so a flavour material with a high flavourant content may be provided.

[0092] Preferably, the emulsifier is lecithin. Use of lecithin as the emulsifier is advantageous in that it is commonly available and generally recognised as being non-toxic. Like gellan gum, lecithin is commonly used in the food industry as an additive, and has been approved for such use by both the USA Food and Drug Administration and the EU authorities. As such, the pairing of gellan gum and lecithin is especially adapted to be included in a flavour material destined for human use.

[0093] Preferably, where the polysaccharide matrix comprises gellan gum and an emulsifier, the gellan gum makes up from 5 percent by weight to 99.9 percent by weight of the flavour material on a dry weight basis.P / 90908.W001

[0094] - 14 - More preferably, the gellan gum makes up at least 7 percent by weight of the flavour material on a dry weight basis, even more preferably at least 10 percent by weight of the flavour material on a dry weight basis.

[0095] The gellan gum preferably makes up for up to 80 percent by weight of the flavour material on a dry weight basis, more preferably up to 60 percent by weight of the flavour material on a dry weight basis, even more preferably up to 40 percent by weight of the flavour material on a dry weight basis, particularly preferably up to 30 percent by weight of the flavour material on a dry weight basis.

[0096] In some embodiments, the gellan gum makes up from 5 percent by weight to 80 percent by weight of the flavour material on a dry weight basis, preferably from 5 percent by weight to 60 percent by weight of the flavour material on a dry weight basis, more preferably from 5 percent by weight to 40 percent by weight of the flavour material on a dry weight basis, even more preferably from 5 percent by weight to 30 percent by weight of the flavour material on a dry weight basis.

[0097] In other embodiments, the gellan gum makes up from 10 percent by weight to 80 percent by weight of the flavour material on a dry weight basis, preferably from 10 percent by weight to 60 percent by weight of the flavour material on a dry weight basis, more preferably from 10 percent by weight to 40 percent by weight of the flavour material on a dry weight basis, even more preferably from 10 percent by weight to 30 percent by weight of the flavour material on a dry weight basis.

[0098] The emulsifier may make up from 0.01 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. Preferably, the emulsifier makes up from 0.02 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. More preferably, the emulsifier makes up from 0.05 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. Even more preferably, the emulsifier makes up from 0.1 percent by weight to 2 percent by weight of the flavour material on a dry weight basis.

[0099] In preferred embodiments, emulsifier is lecithin and makes up from 0.01 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. Preferably, lecithin makes up from 0.02 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. More preferably, lecithin makes up from 0.05 percent by weight to 2 percent by weight of the flavour material on a dry weight basis. Even more preferably, lecithin makes up from 0.1 percent by weight to 2 percent by weight of the flavour material on a dry weight basis.

[0100] In certain embodiments, the polysaccharide matrix structure comprises gellan gum as the sole polysaccharide.

[0101] In other embodiments, the polysaccharide matrix structure comprises gellan gum in combination with at least a further polysaccharide selected from the group consisting of guar,P / 90908.W001

[0102] - 15 -tamarind gum, sodium alginate, xanthan gum, sodium carboxymethyl cellulose, and hydroxypropyl methyl cellulose.

[0103] Flavour materials according to the invention wherein the polysaccharide matrix structure comprises gellan gum in combination with one or more of the polysaccharides listed above have been found to provide different flavourant release profiles upon heating. For example, in embodiments wherein the polysaccharide matrix structure comprises gellan gum in combination with another one of the polysaccharides listed above, a flavourant release profile characterised by two distinct peaks at two different temperatures has been observed. Without wishing to be bound by theory, it is hypothesised that this is due to a different strength of interaction between the flavourant and each polysaccharide in the matrix structure, and may also have to do with each polysaccharide undergoing thermal decomposition at slightly different temperatures.

[0104] Because different combinations of polysaccharides in the matrix structure will generally lead to slightly different flavourant release profiles when the flavour material is heated, embodiments wherein gellan gum is combined with one or more of the other polysaccharides listed above may advantageously be used to fine-tune the flavourant release during use of an aerosol-generating article containing the flavour material. Additionally, different flavour materials, each containing a polysaccharide matrix structure comprising a different combination of polysaccharides, may be used in combination in a single aerosol-generating article to further adjust and control flavourant delivery during a whole usage session of the aerosol-generating article. For example, incorporating in a single aerosol-generating article different flavour materials according to the invention, wherein the different flavour materials are adapted to release most of the flavourant at different temperature or at different times during the usage session may help maintain an overall flavour delivery substantially consistent throughout.

[0105] In embodiments of the flavour material wherein the matrix structure comprises gellan gum in combination with at least one of the additional polysaccharides listed above, the at least one additional polysaccharide may make up at least 0.01 percent by weight of the flavourant delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide makes up at least 0.1 percent by weight of the flavourant delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide makes up at least 1.0 percent by weight of the flavourant delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide makes up at least 2.0 percent by weight of the flavourant delivery material on a dry weight basis. In particularly preferred embodiments, the at least one additional polysaccharide makes up at least 5 percent by weight of the flavourant delivery material on a dry weight basis.

[0106] In embodiments of the flavour material wherein the matrix structure comprises gellan gum in combination with at least one of the additional polysaccharides listed above, the at least oneP / 90908.W001

[0107] - 16 -additional polysaccharide may make up 80 percent by weight or less of the flavourant delivery material on a dry weight basis. Preferably, the at least one additional polysaccharide makes up 35 percent by weight or less of the flavourant delivery material on a dry weight basis. More preferably, the at least one additional polysaccharide makes up 25 percent by weight or less of the flavourant delivery material on a dry weight basis. Even more preferably, the at least one additional polysaccharide makes up 15 percent by weight or less of the flavourant delivery material on a dry weight basis.

[0108] In some embodiments, the at least one additional polysaccharide makes up from 1.0 percent to 35 percent by weight or less of the flavourant delivery material on a dry weight basis, preferably from 2.0 percent to 35 percent by weight or less of the flavourant delivery material on a dry weight basis, more preferably from 5.0 percent to 35 percent by weight or less of the flavourant delivery material on a dry weight basis.

[0109] In other embodiments, the at least one additional polysaccharide makes up from 1.0 percent to 25 percent by weight or less of the flavourant delivery material on a dry weight basis, preferably from 2.0 percent to 25 percent by weight or less of the flavourant delivery material on a dry weight basis, more preferably from 5.0 percent to 25 percent by weight or less of the flavourant delivery material on a dry weight basis.

[0110] In further embodiments, the at least one additional polysaccharide makes up from 1.0 percent to 15 percent by weight or less of the flavourant delivery material on a dry weight basis, preferably from 2.0 percent to 15 percent by weight or less of the flavourant delivery material on a dry weight basis, more preferably from 5.0 percent to 15 percent by weight or less of the flavourant delivery material on a dry weight basis.

[0111] The flavour material may comprise at least 0.01 percent by weight of a flavourant on a dry weight basis. Preferably, the flavour material comprises at least 1 percent by weight of a flavourant on a dry weight basis. More preferably, the flavour material comprises at least 5 percent by weight of a flavourant on a dry weight basis. Even more preferably, the flavour material comprises at least 10 percent by weight of a flavourant on a dry weight basis.

[0112] In certain embodiments, the flavour material comprises at least 20 percent by weight of a flavourant on a dry weight basis, preferably at least 25 percent by weight of a flavourant on a dry weight basis, more preferably at least 30 percent by weight of a flavourant on a dry weight basis.

[0113] The flavour material may up to 90 percent by weight of a flavourant on a dry weight basis. Preferably, the flavour material may up to 85 percent by weight of a flavourant on a dry weight basis. More preferably, the flavour material may up to 80 percent by weight of a flavourant on a dry weight basis. Even more preferably, the flavour material may up to 75 percent by weight of a flavourant on a dry weight basis.P / 90908.W001

[0114] - 17 - In certain preferred embodiments, the flavour material comprises from 20 percent by weight to 80 percent by weight of a flavourant on a dry weight basis, preferably from 25 percent by weight to 80 percent by weight of a flavourant on a dry weight basis, more preferably from 30 percent by weight to 80 percent by weight of a flavourant on a dry weight basis.

[0115] In other preferred embodiments, the flavour material comprises from 20 percent by weight to 75 percent by weight of a flavourant on a dry weight basis, preferably from 25 percent by weight to 75 percent by weight of a flavourant on a dry weight basis, more preferably from 30 percent by weight to 75 percent by weight of a flavourant on a dry weight basis.

[0116] Suitable flavourants for inclusion in the flavour formulation of a flavour material in accordance with the present invention include, but are not limited to:

[0117] Suitable flavourants for inclusion in the flavour formulation of a flavour material in accordance with the present invention include, but are not limited to, menthol, limonene, and eugenol.

[0118] Menthol is a monoterpenoid, which may be made synthetically or obtained from the oils of peppermint or other mints. It imparts minty, cool flavour notes.

[0119] Limonene is a cyclic monoterpene, and is typically found in the oil of citrus fruit peels. It is also a component of the aromatic resins of numerous coniferous and broadleaved trees. It imparts citrusy flavour notes.

[0120] Eugenol is an allyl chain-substituted guaiacol, and is commonly found in the essential oils of clove, nutmeg, cinnamon, basil and bay leaf. It imparts spicy, clove-like flavour notes.

[0121] The inventors have found that menthol and limonene can be fairly easily trapped and immobilised within the polysaccharide matrix, and so flavour materials containing a flavour formulation containing menthol, limonene or mixtures thereof exhibit very good stability.

[0122] In preferred embodiments, the flavourant formulation comprises menthol.

[0123] The flavour material may comprise at least 0.01 percent by weight of a menthol on a dry weight basis. Preferably, the flavour material comprises at least 1 percent by weight of a menthol on a dry weight basis. More preferably, the flavour material comprises at least 5 percent by weight of a menthol on a dry weight basis. Even more preferably, the flavour material comprises at least 10 percent by weight of a menthol on a dry weight basis.

[0124] In certain embodiments, the flavour material comprises at least 20 percent by weight of a menthol on a dry weight basis, preferably at least 25 percent by weight of a menthol on a dry weight basis, more preferably at least 30 percent by weight of a menthol on a dry weight basis.

[0125] The flavour material may up to 90 percent by weight of a menthol on a dry weight basis. Preferably, the flavour material may up to 85 percent by weight of a menthol on a dry weight basis. More preferably, the flavour material may up to 80 percent by weight of a menthol on a dryP / 90908.W001

[0126] - 18 -weight basis. Even more preferably, the flavour material may up to 75 percent by weight of a menthol on a dry weight basis.

[0127] In certain preferred embodiments, the flavour material comprises from 20 percent by weight to 80 percent by weight of a menthol on a dry weight basis, preferably from 25 percent by weight to 80 percent by weight of a menthol on a dry weight basis, more preferably from 30 percent by weight to 80 percent by weight of a menthol on a dry weight basis.

[0128] In other preferred embodiments, the flavour material comprises from 20 percent by weight to 75 percent by weight of a menthol on a dry weight basis, preferably from 25 percent by weight to 75 percent by weight of a menthol on a dry weight basis, more preferably from 30 percent by weight to 75 percent by weight of a menthol on a dry weight basis.

[0129] In some embodiments, the flavour material further comprises a polyol having the formula CnH2n+20n.

[0130] The term “polyol” is used herein to describe an organic compound comprising two or more hydroxyl groups. Polyols containing two, three, and four hydroxyl groups may also be referred to as diols, triols, and tetrols, respectively.

[0131] Preferred polyols for inclusion in a flavour material in accordance with the present invention include glycerol, sorbitol, xylitol, mannitol, and erythritol.

[0132] The incorporation of a polyol in the flavour material has a beneficial effect on its pliability. This may make the flavour material easier to handle and given a predetermined form, which may facilitate its incorporation into an aerosol-generating article.

[0133] Preferably, in embodiments where the flavour material comprises a polyol as described above, the polyol makes up from 0.01 percent by weight to 20 percent by weight of the flavour material on a dry weight basis. More preferably, the polyol makes up from 0.01 percent by weight to 15 percent by weight of the flavour material on a dry weight basis. Even more preferably, the polyol makes up from 0.01 percent by weight to 10 percent by weight of the flavour material on a dry weight basis.

[0134] In some embodiments, the flavour material comprises fibres, preferably cellulose fibres. The incorporation of fibres, especially cellulose fibres, may advantageously improve the tensile strength of the flavour material, particularly when it is provided in sheet form. This facilitates the manufacturing process, both of the flavour material itself and of an aerosol-generating article including the flavour material. The benefit is felt especially in those embodiments wherein the polysaccharide matrix trapping the flavourant formulation is not supported by a carrier material.

[0135] In embodiments of the flavour material comprising cellulose fibres, the cellulose fibres may make up at least 0.01 percent by weight of the flavour material on a dry weight basis. Preferably, the cellulose fibres make up at least 0.05 percent by weight of the flavour material on a dry weight basis. More preferably, the cellulose fibres make up at least 0.5 percent by weightP / 90908.W001

[0136] - 19 -of the flavour material on a dry weight basis. Even more preferably, the cellulose fibres make up at least 1.0 percent by weight of the flavour material on a dry weight basis. In particularly preferred embodiments, the cellulose fibres make up at least 2.0 percent by weight of the flavour material on a dry weight basis.

[0137] The cellulose fibres may make up 10 percent by weight or less of the flavour material on a dry weight basis. Preferably, the cellulose fibres make up 8.0 percent by weight or less of the flavour material on a dry weight basis. More preferably, the cellulose fibres make up 7.0 percent by weight or less of the flavour material on a dry weight basis. Even more preferably, the cellulose fibres make up 5.0 percent by weight or less of the flavour material on a dry weight basis.

[0138] In some embodiments, the fibres make up from 0.01 percent by weight to 10 percent by weight of the flavour material on a dry weight basis. Preferably, the fibres make up from 0.01 percent by weight to 8.0 percent by weight of the flavour material on a dry weight basis. More preferably, the fibres make up from 0.01 percent by weight to 7.0 percent by weight of the flavour material on a dry weight basis. Even more preferably, the fibres make up from 0.01 percent by weight to 5 percent by weight of the flavour material on a dry weight basis.

[0139] In other embodiments, the fibres make up from 1.0 percent by weight to 10 percent by weight of the flavour material on a dry weight basis. Preferably, the fibres make up from 1.0 percent by weight to 8.0 percent by weight of the flavour material on a dry weight basis. More preferably, the fibres make up from 1.0 percent by weight to 7.0 percent by weight of the flavour material on a dry weight basis. Even more preferably, the fibres make up from 1.0 percent by weight to 5 percent by weight of the flavour material on a dry weight basis.

[0140] In further embodiments, the fibres make up from 2.0 percent by weight to 10 percent by weight of the flavour material on a dry weight basis. Preferably, the fibres make up from 2.0 percent by weight to 8.0 percent by weight of the flavour material on a dry weight basis. More preferably, the fibres make up from 2.0 percent by weight to 7.0 percent by weight of the flavour material on a dry weight basis. Even more preferably, the fibres make up from 2.0 percent by weight to 5 percent by weight of the flavour material on a dry weight basis.

[0141] In some embodiments, a flavour material in accordance with the present invention may comprise a salt of calcium or a salt of magnesium or both, such as calcium chloride or calcium lactate.

[0142] In embodiments where the flavour material comprises a salt of calcium or a salt of magnesium or both, the salt or salts make up from 0.01 percent by weight to 10 percent by weight on a dry weight basis. Preferably, the salt or salts make up from 0.01 percent by weight to 5 percent by weight on a dry weight basis.P / 90908.W001

[0143] - 20 - In embodiments where the flavour material comprises a citrate salt, the citrate salt makes up from 0.01 percent by weight to 5 percent by weight on a dry weight basis. Preferably, the citrate salt makes up from 0.01 percent by weight to 1 percent by weight on a dry weight basis.

[0144] A flavour material in accordance with the present invention may generally comprise water. This is because the flavour material will generally be manufactured by combining the various compounds described above in an aqueous bath. After drying, the water content will be reduced, but may generally be non-null.

[0145] Thus, a flavour material in accordance with the present invention may comprise from 0.01 percent by weight to 10 percent by weight of water, preferably from 0.01 percent by weight to 8 percent by weight of water, more preferably from 0.01 percent by weight to 6 percent by weight of water, even more preferably from 0.01 percent by weight to 4 percent by weight of water.

[0146] In some embodiments, the flavour material comprises from 0.5 percent by weight to 10 percent by weight of water, preferably from 0.01 percent by weight to 8 percent by weight of water, more preferably from 0.5 percent by weight to 6 percent by weight of water, even more preferably from 0.5 percent by weight to 4 percent by weight of water.

[0147] In other embodiments, the flavour material comprises from 1.0 percent by weight to 10 percent by weight of water, preferably from 1.0 percent by weight to 8 percent by weight of water, more preferably from 1.0 percent by weight to 6 percent by weight of water, even more preferably from 1.0 percent by weight to 4 percent by weight of water.

[0148] In further embodiments, the flavour material comprises from 1.5 percent by weight to 10 percent by weight of water, preferably from 1.5 percent by weight to 8 percent by weight of water, more preferably from 1.5 percent by weight to 6 percent by weight of water, even more preferably from 1.5 percent by weight to 4 percent by weight of water.

[0149] As described briefly above, a flavour material in line with the foregoing description finds use, in particular, in aerosol-generating articles and systems.

[0150] An aerosol-generating article containing a flavour material in accordance with the present invention may be used in combination with an aerosol-generating device, such as a hand-held electrical heater configured to supply heat in a controlled manner to the aerosol-generating article. This is so, by heating the aerosol-generating substrate and the flavour material, a flavour-enriched aerosol can be delivered to a consumer.

[0151] Aerosol-generating articles according to the invention find particular application in aerosolgenerating systems comprising an aerosol-generating device having a heating chamber into which the aerosol-generating article is received such that heat can be supplied to the aerosolgenerating substrate.

[0152] To this purpose, the flavour material may be arranged at different locations within an aerosol-generating article.P / 90908.W001

[0153] - 21 - In certain embodiments, the aerosol-generating article comprises a rod of aerosolgenerating substrate extending along a longitudinal axis; a downstream section provided downstream of the rod of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article; optionally an upstream section provided upstream of the rod of aerosol-generating substrate and extending to a distal end of the aerosol-generating article. A flavour material in line with the foregoing description is provided in at least one of the rod of aerosol-generating substrate; the downstream section; and the optional upstream section.

[0154] In preferred embodiments, the flavour material is provided in the rod of aerosol-generating substrate, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.25 times a diameter of the rod of aerosol-generating substrate.

[0155] This is beneficial in that the flavour material and the aerosol-generating substrate may generally be in contact with each other, and so aerosol species released upon heating the flavour material and aerosol species released upon heating the aerosol-generating substrate may advantageously mix and blend with each other before the airflow carrying the aerosol species reaches a mouth end of the aerosol-generating article. Additionally, the inventors have found that locating the flavour material in an outer portion of the rod of aerosol-generating substrate facilitates the rapid supply of heat to the flavour material, so that at least some of the flavour formulation trapped within the polysaccharide matrix structure is released at the very beginning of a usage cycle, as soon as heat begins to be supplied to the aerosol-generating article by the heater element(s) of the aerosol-generating device.

[0156] Preferably, the radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.3 times a diameter of the rod of aerosolgenerating substrate. More preferably, the radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.35 times a diameter of the rod of aerosol-generating substrate. Even more preferably, the radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.40 times a diameter of the rod of aerosol-generating substrate. In particularly preferred example, the radial distance between the flavour material and the longitudinal axis of the rod of aerosolgenerating substrate is at least 0.45 times a diameter of the rod of aerosol-generating substrate.

[0157] A radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be up to 0.499 times a diameter of the rod of aerosol-generating substrate. Preferably, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be less than or equal to 0.495 times a diameter of the rod of aerosol-generating substrate. Even more preferably, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be lessP / 90908.W001

[0158] - 22 -than or equal to 0.49 times a diameter of the rod of aerosol-generating substrate. In particularly preferred examples, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be less than or equal to 0.48 times a diameter of the rod of aerosol-generating substrate.

[0159] For example, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be from 0.25 to 0.499 times a diameter of the rod of aerosol-generating substrate, preferably from 0.25 to 0.495 times a diameter of the rod of aerosolgenerating substrate, more preferably from 0.25 to 0.49 times a diameter of the rod of aerosolgenerating substrate, even more preferably from 0.25 to 0.48 times a diameter of the rod of aerosol-generating substrate.

[0160] In other examples, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be from 0.3 to 0.499 times a diameter of the rod of aerosol-generating substrate, preferably from 0.3 to 0.495 times a diameter of the rod of aerosol-generating substrate, more preferably from 0.3 to 0.49 times a diameter of the rod of aerosol-generating substrate, even more preferably from 0.3 to 0.48 times a diameter of the rod of aerosol-generating substrate.

[0161] In further examples, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be from 0.35 to 0.499 times a diameter of the rod of aerosol-generating substrate, preferably from 0.35 to 0.495 times a diameter of the rod of aerosol-generating substrate, more preferably from 0.35 to 0.49 times a diameter of the rod of aerosol-generating substrate, even more preferably from 0.35 to 0.48 times a diameter of the rod of aerosol-generating substrate.

[0162] In yet further examples, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate may be from 0.4 to 0.499 times a diameter of the rod of aerosol-generating substrate, preferably from 0.4 to 0.495 times a diameter of the rod of aerosol-generating substrate, more preferably from 0.4 to 0.49 times a diameter of the rod of aerosol-generating substrate, even more preferably from 0.4 to 0.48 times a diameter of the rod of aerosol-generating substrate.

[0163] Without wishing to be bound by theory, the inventors believe that positioning a flavour material wherein a flavourant formulation immobilised within a polysaccharide matrix structurally coupled with an elongate susceptor element in the form of a metal fibre element or a metal wire element or a metal thread element or a metal rod element at a location within the rod of aerosolgenerating substrate described above facilitates a prompt and quick heating of the elongate susceptor during the very first phase of a usage cycle. As a result, at least some of the immobilised flavourant formulation is released during the first one or two puffs, and this is perceived as an intense burst of flavour by the consumer.P / 90908.W001

[0164] - 23 - In addition, because the flavour material can easily be kept at a temperature sufficient to promote further release of the remaining flavourant formulation, a particularly consistent release and delivery of aerosol species can be attained, leading to an overall flavour delivery profile that is recognisably distinguished from a flavour delivery profile obtainable with an aerosol-generating not incorporating a flavour material in accordance with the present disclosure.

[0165] Preferably, the aerosol-generating article further comprises a primary susceptor element located within the aerosol-generating substrate, and the aerosol-generating device comprises an inductor for producing an alternating or fluctuating electromagnetic field. The primary susceptor element is arranged in thermal contact with the aerosol-generating substrate. Thus, when the susceptor heats up, the aerosol-generating substrate is heated by the susceptor to generate an aerosol. The susceptor may be arranged in direct physical contact with the aerosol-generating substrate.

[0166] When the aerosol-generating article engages with the aerosol-generating device, the fluctuating electromagnetic field produced by the inductor induces a current in the primary susceptor element as well as in the elongate susceptor element coupled with the immobilised flavourant formulation, causing both the primary susceptor element and the elongate susceptor elements to heat up.

[0167] The electrically-operated aerosol-generating device may be capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of between 1 and 5 kilo amperes per metre (kA m), preferably between 2 and 3 kA / m, for example about 2.5 kA / m.

[0168] The primary susceptor may extend from the downstream end of the rod of aerosolgenerating substrate towards the upstream end of the rod of aerosol-generating substrate.

[0169] The primary susceptor may extend from the upstream end of the rod of aerosol-generating substrate towards the downstream end of the rod of aerosol-generating substrate.

[0170] The primary susceptor may extends from the upstream end of the rod of aerosolgenerating substrate to the downstream end of the rod of aerosol-generating substrate. That is, the primary susceptor may extend along the entire length of the rod of aerosol-generating substrate.

[0171] The length of the primary susceptor may be substantially the same as the length of the rod of aerosol-generating substrate.

[0172] The primary susceptor may extend part way along the length of the rod of aerosolgenerating substrate.

[0173] The primary susceptor may be spaced apart from the downstream end of the aerosolgenerating substrate.P / 90908.W001

[0174] - 24 - The primary susceptor may be spaced apart from the upstream end of the rod of aerosolgenerating substrate.

[0175] The primary susceptor may be spaced apart from both a downstream end and an upstream end of the rod of aerosol-generating substrate.

[0176] The length of the primary susceptor may be less than the length of the rod of aerosolgenerating substrate.

[0177] The primary susceptor may be entirely enclosed within the aerosol-generating substrate. That is, the aerosol-generating substrate may completely surround the primary susceptor.

[0178] The primary susceptor may be in the form of a pin, rod, strip or blade.

[0179] The primary susceptor may have a length of at least about 5 millimetres, at least about 6 millimetres, or at least about 8 millimetres.

[0180] The primary susceptor may have a length of less than or equal to about 15 millimetres, less than or equal to about 12 millimetres, or less than or equal to about 10 millimetres.

[0181] The primary susceptor may have a length of between about 5 millimetres and about 15 millimetres, between about 5 millimetres and about 12 millimetres, or between about 5 millimetres and about 10 millimetres.

[0182] The primary susceptor may have a length of between about 6 millimetres and about 15 millimetres, between about 6 millimetres and about 12 millimetres, or between about 6 millimetres and about 10 millimetres.

[0183] The primary susceptor may have a length of between about 8 millimetres and about 15 millimetres, between about 8 millimetres and about 12 millimetres, or between about 8 millimetres and about 10 millimetres.

[0184] The primary susceptor may have a width of at least about 1 millimetre.

[0185] The primary susceptor may have width of less than or equal to about 5 millimetres.

[0186] The primary susceptor may have a width of between about 1 millimetre and about 5 millimetres.

[0187] The primary susceptor may have a thickness of at least about 0.01 millimetres, or at least about 0.5 millimetres.

[0188] The primary susceptor may have a thickness of less than or equal to about 2 millimetres, less than or equal to about 500 micrometres, or less than or equal to about 100 micrometres.

[0189] The primary susceptor may have a thickness of between about 10 micrometres and about 2 millimetres, between about 10 micrometres and about 500 micrometres, or between about 10 micrometres and about 100 micrometres.

[0190] The primary susceptor may have a thickness of between about 0.5 millimetres and about 2 millimetres.

[0191] The primary susceptor may have a substantially circular cross-section.P / 90908.W001

[0192] - 25 - The primary susceptor may have a substantially constant cross-section along the length of the primary susceptor.

[0193] If the primary susceptor has the form of a strip or blade, the strip or blade may have a rectangular shape having a width of between about 2 millimetres to about 8 millimetres, or between about 3 millimetres to about 5 millimetres. By way of example, a primary susceptor in the form of a strip of blade may have a width of about 4 millimetres.

[0194] If the primary susceptor has the form of a strip or blade, the strip or blade may have a rectangular shape and a thickness of between about 0.03 millimetres to about 0.15 millimetres, or between about 0.05 millimetres to about 0.09 millimetres. By way of example, a primary susceptor in the form of a strip of blade may have a thickness of about 0.07 millimetres, or about 0.06 millimetres.

[0195] The primary susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. For example, the primary susceptor may comprise a metal or carbon.

[0196] The primary susceptor may comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. A suitable primary susceptor may be, or comprise, aluminium. The primary susceptor may be formed from 400 series stainless steels, for example grade 410, or grade 420, or grade 430 stainless steel. Different materials will dissipate different amounts of energy when positioned within electromagnetic fields having similar values of frequency and field strength.

[0197] Thus, parameters of the primary susceptor such as material type, length, width, and thickness may all be altered to provide a desired power dissipation within a known electromagnetic field. The primary susceptor may be heated to a temperature in excess of 250 degrees Celsius.

[0198] Suitable primary susceptors may comprise a non-metallic core with a metal layer disposed on the non-metallic core, for example metallic tracks formed on a surface of a ceramic core. A primary susceptor may have a protective external layer, for example a protective ceramic layer or protective glass layer encapsulating the primary susceptor. The primary susceptor may comprise a protective coating formed by a glass, a ceramic, or an inert metal, formed over a core of primary susceptor material.

[0199] The primary susceptor may be a multi-material primary susceptor and may comprise a first primary susceptor material and a second primary susceptor material.

[0200] As described briefly above, an aerosol-generating article in accordance with the present invention may comprise a rod of aerosol-generating substrate, preferably circumscribed by a wrapper, and a downstream section located downstream of the rod. The aerosol-generating article may optionally comprise an upstream section located upstream of the rod.P / 90908.W001

[0201] - 26 - Preferably, the downstream section may be provided immediately downstream of the rod, so that it extends from a downstream end of the rod to a downstream end of the aerosolgenerating article. The upstream section may be provided immediately upstream of the rod, so that it extends from an upstream end of the rod to an upstream end of the aerosol-generating article.

[0202] In some embodiments, the downstream section comprises a hollow tubular element provided immediately downstream of the rod of aerosol-generating substrate. An upstream end of the hollow tubular element abuts a downstream end of the rod of aerosol-generating substrate, and the flavour material is provided in the hollow tubular element.

[0203] In other embodiments, the downstream section comprises a hollow tubular element provided downstream of the rod of aerosol-generating substrate, and the flavour material is provided between a downstream end of the rod of aerosol-generating substrate and an upstream end of the hollow tubular element. For example, the flavour material is sandwiched between the rod of aerosol-generating substrate and the hollow tubular element.

[0204] In some embodiments, the upstream section comprises an upstream element provided immediately upstream of the rod of aerosol-generating substrate. A downstream end of the upstream element abuts an upstream end of the rod of aerosol-generating substrate, and the flavour material is provided in the upstream element.

[0205] In other embodiments, the upstream section comprises an upstream element provided upstream of the rod of aerosol-generating substrate, and the flavour material is provided between an upstream end of the rod of aerosol-generating substrate and a downstream end of the upstream element.

[0206] For example, the flavour material is sandwiched between the rod of aerosol-generating substrate and the upstream element.

[0207] The downstream section may further include one or more components downstream of the hollow tubular element. For example, the aerosol-generating article may include a mouthpiece element extending all the way to and defining a proximal end of the aerosol-generating article. The aerosol-generating article may additionally include an aerosol-cooling element provided between the hollow tubular element and the mouthpiece element. The hollow tubular element and the one or more additional components provided downstream of the hollow tubular element form a downstream section of the aerosol-generating article.

[0208] The upstream element may have a length of at least about 2 millimetres, at least about 3 millimetres, or at least about 4 millimetres.

[0209] The upstream element may have a length of less than or equal to about 10 millimetres, less than or equal to about 8 millimetres, or less than or equal to about 6 millimetres.P / 90908.W001

[0210] - 27 - The upstream element may have a length of between about 2 millimetres and about 10 millimetres, between about 2 millimetres and about 8 millimetres, or between about 2 millimetres and about 6 millimetres.

[0211] The upstream element may have a length of between about 3 millimetres and about 10 millimetres, between about 3 millimetres and about 8 millimetres, or between about 3 millimetres and about 6 millimetres.

[0212] The upstream element may have a length of between about 4 millimetres and about 10 millimetres, between about 4 millimetres and about 8 millimetres, or between about 4 millimetres and about 6 millimetres.

[0213] For example, the upstream element may have a length of about 5 millimetres.

[0214] The length of the upstream element may be selected based on a desired balance between the ability of the upstream element to prevent or restrict upstream movement of aerosolgenerating material from the rod of aerosol-generating substrate and the RTD (resistance to draw) of the upstream element.

[0215] The length of the upstream element may be selected based on a desired total length of the aerosol-generating article.

[0216] The ratio of the length of the upstream element to the total length of the aerosol-generating article may be at least about 0.03, at least about 0.05, or at least about 0.07.

[0217] The ratio of the length of the upstream element to the total length of the aerosol-generating article may be less than or equal to about 0.25, less than or equal to about 0.2, or less than or equal to about 0.15.

[0218] Preferably, the upstream element has a substantially circular cross-section.

[0219] The upstream element may have an external diameter of at least about 5 millimetres, about 6 millimetres, or about 7 millimetres.

[0220] The upstream element may have an external diameter of less than or equal to 12 millimetres, less than or equal to about 10 millimetres, or less than or equal to about 8 millimetres.

[0221] The upstream element may have an external diameter of between about 5 millimetres and about 12 millimetres, between about 5 millimetres and about 10 millimetres, or between about 5 millimetres and about 8 millimetres.

[0222] The upstream element may have an external diameter of between about 6 millimetres and about 12 millimetres, between about 6 millimetres and about 10 millimetres, or between about 6 millimetres and about 8 millimetres.

[0223] The upstream element may have an external diameter of between about 7 millimetres and about 12 millimetres, between about 7 millimetres and about 10 millimetres, or between about 7 millimetres and about 8 millimetres.P / 90908.W001

[0224] - 28 - For example, the upstream element may have an external diameter of about 7.1 millimetres.

[0225] Preferably, the external diameter of the upstream element is substantially the same as the external diameter of the rod of aerosol-generating substrate.

[0226] Preferably, the external diameter of the upstream element is substantially the same as the external diameter of the aerosol-generating article.

[0227] As described above, the upstream element is upstream of the rod of aerosol-generating substrate and may abut the rod of aerosol-generating substrate. This may advantageously improve the ability of the upstream element to prevent or restrict upstream movement of aerosolgenerating substrate from the rod of aerosol-generating substrate.

[0228] The upstream element may be at the upstream end of the aerosol-generating article. The aerosol-generating article may comprise an additional element upstream of the upstream element. For example, an additional element upstream of the upstream element may act as a cap or cover to help avoid damage to the upstream element.

[0229] Preferably, the majority of aerosol generated by the aerosol-generating article is generated by the aerosol-generating substrate. The entirety of aerosol generated by the aerosolgenerating article may be generated by the aerosol-generating substrate.

[0230] As described above, the rod of aerosol-generating substrate comprises aerosolgenerating substrate in the form of a rod. As used herein with reference to the invention, the term “rod” is used to denote a generally cylindrical element having a substantially circular, oval or elliptical cross-section.

[0231] The rod of aerosol-generating substrate may have a length of at least about 8 millimetres, at least about 9 millimetres, or at least about 10 millimetres.

[0232] The rod of aerosol-generating substrate may have a length of less than or equal to about 16 millimetres, less than or equal to about 15 millimetres, or less than or equal to about 14 millimetres.

[0233] The rod of aerosol-generating substrate may have a length of between about 8 millimetres and about 16 millimetres, between about 8 millimetres and about 15 millimetres, or between about 8 millimetres and about 14 millimetres.

[0234] The rod of aerosol-generating substrate may have a length of between about 9 millimetres and about 16 millimetres, between about 9 millimetres and about 15 millimetres, or between about 9 millimetres and about 14 millimetres.

[0235] The rod of aerosol-generating substrate may have a length of between about 10 millimetres and about 16 millimetres, between about 10 millimetres and about 15 millimetres, or between about 10 millimetres and about 14 millimetres.P / 90908.W001

[0236] - 29 - For example, the rod of aerosol-generating substrate may have a length of about 12 millimetres.

[0237] The ratio between the length of the rod of aerosol-generating substrate to the total length of the aerosol-generating article may be at least about 0.10, at least about 0.15, or at least about 0.20.

[0238] The ratio between the length of the rod of aerosol-generating substrate to the total length of the aerosol-generating article may be less than or equal to about 0.40, less than or equal to about 0.35, or less than or equal to about 0.3.

[0239] The ratio between the length of the rod of aerosol-generating substrate to the total length of the aerosol-generating article may be between about 0.10 and about 0.40, between about 0.10 and about 0.35, or between about 0.10 and about 0.30.

[0240] The ratio between the length of the rod of aerosol-generating substrate to the total length of the aerosol-generating article may be between about 0.15 and about 0.40, between about 0.15 and about 0.35, or between about 0.15 and about 0.30.

[0241] The ratio between the length of the rod of aerosol-generating substrate to the total length of the aerosol-generating article may be between about 0.20 and about 0.40, between about 0.20 and about 0.35, or between about 0.20 and about 0.30.

[0242] Preferably, the rod of aerosol-generating substrate has a substantially circular crosssection.

[0243] The rod of aerosol-generating substrate may have an external diameter of at least about 5 millimetres, about 6 millimetres, or about 7 millimetres.

[0244] The rod of aerosol-generating substrate may have an external diameter of less than or equal to 12 millimetres, less than or equal to about 10 millimetres, or less than or equal to about 8 millimetres.

[0245] The rod of aerosol-generating substrate may have an external diameter of between about 5 millimetres and about 12 millimetres, between about 5 millimetres and about 10 millimetres, or between about 5 millimetres and about 8 millimetres.

[0246] The rod of aerosol-generating substrate may have an external diameter of between about 6 millimetres and about 12 millimetres, between about 6 millimetres and about 10 millimetres, or between about 6 millimetres and about 8 millimetres.

[0247] The rod of aerosol-generating substrate may have an external diameter of between about 7 millimetres and about 12 millimetres, between about 7 millimetres and about 10 millimetres, or between about 7 millimetres and about 8 millimetres.

[0248] For example, the rod of aerosol-generating substrate may have an external diameter of about 7.1 millimetres.P / 90908.W001

[0249] - 30 - The aerosol-generating substrate may have a density of at least about 150 milligrams per cubic centimetre, at least about 175 milligrams per cubic centimetre, at least about 200 milligrams per cubic centimetre, or at least about 250 milligrams per cubic centimetre.

[0250] The aerosol-generating substrate may have a density of less than or equal to about 500 milligrams per cubic centimetre, less than or equal to about 450 milligrams per cubic centimetre, less than or equal to about 400 milligrams per cubic centimetre, or less than or equal to about 350 milligrams per cubic centimetre.

[0251] The aerosol-generating substrate may have a density of between about 150 milligrams per cubic centimetre and about 500 milligrams per cubic centimetre, between about 150 milligrams per cubic centimetre and about 450 milligrams per cubic centimetre, between about 150 milligrams per cubic centimetre and about 400 milligrams per cubic centimetre, or between about 150 milligrams per cubic centimetre and about 350 milligrams per cubic centimetre.

[0252] The aerosol-generating substrate may have a density of between about 175 milligrams per cubic centimetre and about 500 milligrams per cubic centimetre, between about 175 milligrams per cubic centimetre and about 450 milligrams per cubic centimetre, between about 175 milligrams per cubic centimetre and about 400 milligrams per cubic centimetre, or between about 175 milligrams per cubic centimetre and about 350 milligrams per cubic centimetre.

[0253] The aerosol-generating substrate may have a density of between about 200 milligrams per cubic centimetre and about 500 milligrams per cubic centimetre, between about 200 milligrams per cubic centimetre and about 450 milligrams per cubic centimetre, between about 200 milligrams per cubic centimetre and about 400 milligrams per cubic centimetre, or between about 200 milligrams per cubic centimetre and about 350 milligrams per cubic centimetre.

[0254] The aerosol-generating substrate may have a density of between about 250 milligrams per cubic centimetre and about 500 milligrams per cubic centimetre, between about 250 milligrams per cubic centimetre and about 450 milligrams per cubic centimetre, between about 250 milligrams per cubic centimetre and about 400 milligrams per cubic centimetre, or between about 250 milligrams per cubic centimetre and about 350 milligrams per cubic centimetre.

[0255] For example, the aerosol-generating substrate may have a density of about 300 milligrams per cubic centimetre.

[0256] The RTD of the rod of aerosol-generating substrate may be at least about 4 millimetres H2O, at least about 5 millimetres H2O, or at least about 6 millimetres H2O.P / 90908.W001

[0257] - 31 - The RTD of the rod of aerosol-generating substrate may be less than or equal to about 10 millimetres H2O, less than or equal to about 9 millimetres H2O, or less than or equal to about 8 millimetres H2O.

[0258] The RTD of the rod of aerosol-generating substrate may be between about 4 millimetres H2O and about 10 millimetres H2O, between about 4 millimetres H2O and about 9 millimetres H2O, or between about 4 millimetres H2O and about 8 millimetres H2O.

[0259] The RTD of the rod of aerosol-generating substrate may be between about 5 millimetres H2O and about 10 millimetres H2O, between about 5 millimetres H2O and about 9 millimetres H2O, or between about 5 millimetres H2O and about 8 millimetres H2O.

[0260] The RTD of the rod of aerosol-generating substrate may be between about 6 millimetres H2O and about 10 millimetres H2O, between about 6 millimetres H2O and about 9 millimetres H2O, or between about 6 millimetres H2O and about 8 millimetres H2O.

[0261] The aerosol-generating substrate may be a solid aerosol-generating substrate. The aerosol-generating substrate preferably comprises an aerosol former.

[0262] The aerosol former may be any suitable known compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol. The aerosol former may be facilitating that the aerosol is substantially resistant to thermal degradation at temperatures typically applied during use of the aerosol-generating article. Suitable aerosol formers are for example: polyhydric alcohols such as, for example, triethylene glycol, 1,3-butanediol, propylene glycol and glycerine; esters of polyhydric alcohols such as, for example, glycerol mono-, di- or triacetate; aliphatic esters of mono-, di- or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0263] Preferably, the aerosol former comprises one or more of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0264] The aerosol-generating substrate may comprise at least about 5 percent, at least about 10 percent, or at least about 12 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0265] The aerosol-generating substrate may comprise less than or equal to about 30 percent, less than or equal to about 25 percent, or less than or equal to about 20 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0266] The aerosol-generating substrate may comprise between about 5 percent and about 30 percent, between about 5 percent and about 25 percent, or between about 5 percent and about 20 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0267] The aerosol-generating substrate may comprise between about 10 percent and about 30 percent, between about 10 percent and about 25 percent, or between about 10 percent andP / 90908.W001

[0268] - 32 -about 20 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0269] The aerosol-generating substrate may comprise between about 12 percent and about 30 percent, between about 12 percent and about 25 percent, or between about 12 percent and about 20 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0270] The aerosol-generating substrate may comprise a plurality of shreds of tobacco material. The aerosol-generating substrate may comprise a plurality of shreds of homogenised tobacco material.

[0271] As used herein with reference to the invention, the term “shred” denotes an element having a length substantially greater than a width and a thickness thereof.

[0272] As used herein with reference to the invention, the term “homogenised tobacco material” is used to describe material formed by agglomerating particulate tobacco material.

[0273] Shreds of homogenised tobacco material may be formed from a sheet of homogenised tobacco material, for example, by cutting or shredding. Shreds of homogenised tobacco material may be formed by other methods, for example, by extrusion.

[0274] The shreds of tobacco material may have a width of at least about 0.3 millimetres, at least about 0.5 millimetres, or at least about 0.6 millimetres.

[0275] The shreds of tobacco material may have a width of less than or equal to about 2 millimetres, less than or equal to about 1.2 millimetres, or less than about 0.9 millimetres.

[0276] The shreds of tobacco material may have a width of between about 0.3 millimetres and about 2 millimetres, between about 0.3 millimetres and about 1.2 millimetres, or between about 0.3 millimetres and about 0.9 millimetres.

[0277] The shreds of tobacco material may have a width of between about 0.5 millimetres and about 2 millimetres, between about 0.5 millimetres and about 1.2 millimetres, or between about 0.5 millimetres and about 0.9 millimetres.

[0278] The shreds of tobacco material may have a width of between about 0.6 millimetres and about 2 millimetres, between about 0.6 millimetres and about 1.2 millimetres, or between about 0.6 millimetres and about 0.9 millimetres.

[0279] The shreds of tobacco material may have a length of at least about 10 millimetres.

[0280] The shreds of tobacco material may have a length of less than or equal to about 40 millimetres.

[0281] The shreds of tobacco material may have a length of between about 10 millimetres and about 40 millimetres.

[0282] At least about 20 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may extend along the entire length of the aerosol-generating substrate. At leastP / 90908.W001

[0283] - 33 -about 20 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may have a length substantially the same as the length of the aerosol-generating substrate.

[0284] Less than or equal to about 60 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may extend along the entire length of the aerosol-generating substrate. Less than or equal to about 60 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may have a length substantially the same as the length of the aerosol-generating substrate.

[0285] Between about 20 percent and 60 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may extend along the entire length of the aerosol-generating substrate. Between about 20 percent and 60 percent by weight of the plurality of shreds of tobacco material on a dry weight basis may have a length substantially the same as the length of the aerosol-generating substrate.

[0286] The size of the aerosol-generating material of the aerosol-generating substrate, such as a plurality of shreds of tobacco material, may play a role in the distribution of heat inside the aerosol-generating substrate. Also, the size of the aerosol-generating material may play a role in the resistance to draw of the article. In addition, the size of the aerosol-generating material may affect the ability of the upstream element to prevent or restrict movement of the aerosolgenerating material into the longitudinally extending channels of the upstream element. The size of the aerosol-generating material may also affect the ability of the upstream element to prevent or restrict upstream movement of the aerosol-generating material along the longitudinally extending channels and out of the upstream element.

[0287] The aerosol-generating substrate may comprise a plurality of pellets or granules of tobacco material. The aerosol-generating substrate may comprise a plurality of pellets or granules of homogenised tobacco material.

[0288] At least about 60 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimetre, at least about 70 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimetre, or at least about 80 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimetre.

[0289] Where the homogenised plant material is in the form of a plurality of pellets or granules, at least about 70 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 0.5 millimetres, at least about 80 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 0.5 millimetres, or at least about 90 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 0.5 millimetres.P / 90908.W001

[0290] - 34 - For example, at least about 80 percent by weight of the plurality of pellets or granules may have a largest dimension greater than about 1 millimetre and at least about 90% by weight of the plurality of pellets or granules may have a largest dimension greater than about 0.5 millimetres.

[0291] The aerosol-generating substrate may comprise one or more sheets of tobacco material. The aerosol-generating substrate may comprise one or more sheets of homogenised tobacco material.

[0292] The one or sheets of tobacco material may each individually have a thickness of at least about 100 micrometres, at least about 150 micrometres, or at least about 300 micrometres.

[0293] As used herein with reference to the invention, individual thickness refers to the thickness of the individual sheet of tobacco material, whereas combined thickness refers to the total thickness of all sheets of tobacco material that make up the aerosol-generating substrate. For example, if the aerosol-generating substrate is formed from two individual sheets of tobacco material, then the combined thickness is the sum of the thickness of the two individual sheets of tobacco material or the measured thickness of the two sheets of tobacco material where the two sheets of tobacco material are stacked in the aerosol-generating substrate.

[0294] The one or more sheets of tobacco material may each individually have a thickness of less than or equal to about 600 micrometres, less than or equal to about 300 micrometres, or less than or equal to about 250 micrometres.

[0295] The one or more sheets of tobacco material may each individually have a thickness of between about 100 micrometres and about 600 micrometres, between about 100 micrometres and about 300 micrometres, or between about 100 micrometres and about 250 micrometres.

[0296] The one or more sheets of tobacco material may each individually have a thickness of between about 150 micrometres and about 600 micrometres, between about 150 micrometres and about 300 micrometres, or between about 150 micrometres and about 250 micrometres.

[0297] The one or more sheets of tobacco material may each individually have a thickness of between about 250 micrometres and about 600 micrometres, between about 250 micrometres and about 300 micrometres, or between about 250 micrometres and about 250 micrometres.

[0298] The one or more sheets of tobacco material may each individually have a length substantially the same as the length of the aerosol-generating substrate.

[0299] The one or more sheets of tobacco material may have been one or more of crimped, folded, gathered, and pleated.

[0300] Crimping, folding, gathering, or pleating of the one or more sheets of tobacco material may cause splitting of the one or more sheets of tobacco material to form shreds of tobacco material. For example, the one or more sheets of tobacco material may be crimped to such an extent that the integrity of the one or more sheets of tobacco material becomes disrupted at theP / 90908.W001

[0301] - 35 -plurality of parallel ridges or corrugations causing separation of the material, and results in the formation of shreds of tobacco material.

[0302] In the context of the present invention, a “hollow tubular element” provides an unrestricted flow channel. This means that the hollow tubular element provides a negligible level of resistance to draw (RTD). As used herein with reference to the invention, the term “negligible level of RTD” is used to describe an RTD of less than 1 mm H2O per 10 millimetres of length of the hollow tubular substrate element, less than 0.4 mm H2O per 10 millimetres of length of the hollow tubular substrate element, or less than 0.1 mm H2O per 10 millimetres of length of the hollow tubular substrate element. The flow channel should therefore be free from any components that would obstruct the flow of air in a longitudinal direction. Preferably, the flow channel is substantially empty.

[0303] The hollow tubular element may have a total length of at least about 10 millimetres, at least about 12 millimetres, or at least about 15 millimetres.

[0304] The hollow tubular element may have a total length of less than or equal to about 30 millimetres, less than or equal to about 25 millimetres, or less than or equal to about 23 millimetres.

[0305] The hollow tubular element may have a total length of between about 10 millimetres and about 30 millimetres, between about 10 millimetres and about 25 millimetres, or between about 10 millimetres and about 23 millimetres.

[0306] The hollow tubular element may have a total length of between about 12 millimetres and about 30 millimetres, between about 12 millimetres and about 25 millimetres, or between about 12 millimetres and about 23 millimetres.

[0307] The hollow tubular element may have a total length of between about 12 millimetres and about 30 millimetres, between about 12 millimetres and about 25 millimetres, or between about 12 millimetres and about 23 millimetres.

[0308] The total length of the hollow tubular element may be selected based on a desired total length of the aerosol-generating article.

[0309] The hollow tubular element may be formed from any suitable material or combination of materials. For example, the hollow tubular element may be formed from one or more materials selected from the group consisting of: cellulose acetate; a paper based material such as paper or cardboard; and polymeric materials, such as low density polyethylene (LDPE). Other suitable materials include polyhydroxyalkanoate (PHA) fibres.

[0310] In some embodiments, a ventilation zone may be provided at a location downstream of the rod of aerosol-generating substrate. A satisfactory cooling of the stream of aerosol generated upon heating the aerosol-generating substrate and drawn through the hollow tubular element may be achieved by providing for the hollow tubular element itself to comprise a ventilation zone or forP / 90908.W001

[0311] - 36 -an intermediate element provided between the hollow tubular element and the mouthpiece to comprise a ventilation zone. One such intermediate element may also be described as an aerosol-cooling element. One such intermediate element may also be provided in the form of a hollow tubular element. Without wishing to be bound by theory, the temperature drop caused by the admission of cooler, external air into the aerosol-generating article downstream of the rod of aerosol-generating substrate via the ventilation zone may have an advantageous effect on the nucleation and growth of aerosol particles.

[0312] The ventilation zone may comprise a plurality of perforations through a tubular wall of the hollow tubular element. The ventilation zone may comprise at least one circumferential row of perforations. The ventilation zone may comprise two circumferential rows of perforations. For example, the perforations may be formed online during manufacturing of the aerosol-generating article. Each circumferential row of perforations may comprise from 8 to 30 perforations.

[0313] As mentioned above, the aerosol-generating article may comprise a mouthpiece element located downstream of the aerosol-generating substrate and at the downstream end or mouth end or proximal end of the aerosol-generating article.

[0314] The mouthpiece element may be a mouthpiece filter element. The mouthpiece element may comprise at least one filter segment for filtering aerosol generated upon heating the aerosolgenerating substrate. For example, the mouthpiece element may comprise one or more segments of a fibrous filtration material. Suitable fibrous filtration materials are known in the art. For example, the at least one mouthpiece filter segment may comprise a cellulose acetate filter segment formed of cellulose acetate tow.

[0315] The mouthpiece element may consist of a single filter segment. The mouthpiece element may include two or more filter segments axially aligned in an abutting end to end relationship with each other.

[0316] Parameters or characteristics described herein in relation to the mouthpiece element as a whole may equally be applied to a filter segment of the mouthpiece element.

[0317] The mouthpiece element may have a low particulate filtration efficiency.

[0318] The mouthpiece element may have an RTD of less than or equal to about 25 millimetres H2O, less than or equal to about 20 millimetres H2O, or less than or equal to about 15 millimetres H2O.

[0319] The mouthpiece element may have an RTD of at least about 10 millimetres H2O.

[0320] The mouthpiece element may have an RTD of between about 10 millimetres H2O and to about 25 millimetres H2O, between about 10 millimetres H2O and to about 20 millimetres H2O, or of between about 10 millimetres H2O and to about 15 millimetres H2O.

[0321] Preferably, the mouthpiece element has a substantially circular cross-section.P / 90908.W001

[0322] - 37 - Preferably, the mouthpiece element has an external diameter that is substantially the same as the external diameter of the aerosol-generating article.

[0323] The mouthpiece element may have a length of at least about 3 millimetres, or at least about 5 millimetres.

[0324] The length of the mouthpiece element may be less than or equal to about 11 millimetres, or less than or equal to about 9 millimetres.

[0325] The length of the mouthpiece element may be between about 3 millimetres and about 11 millimetres, or between about 3 millimetres and about 9 millimetres.

[0326] The length of the mouthpiece element may be between about 5 millimetres and about 11 millimetres, or between about 5 millimetres and about 9 millimetres.

[0327] For example, the length of the mouthpiece element may be about 7 millimetres.

[0328] The length of the mouthpiece element may be selected based on a desired total length of the aerosol-generating article.

[0329] The mouthpiece element may be circumscribed by a plug wrap.

[0330] The mouthpiece element may be unventilated such that air does not enter the aerosolgenerating article along the mouthpiece element.

[0331] The mouthpiece element may be connected to one or more adjacent components of the aerosol-generating article by means of a tipping wrapper.

[0332] The aerosol-generating article may comprise a mouth end cavity at the downstream end of the aerosol-generating article. The mouth end cavity may be downstream of the mouthpiece element, where present.

[0333] The mouth end cavity may be defined by a hollow tubular element provided at the downstream end of the mouthpiece. Alternatively, the mouth end cavity may be defined by an outer wrapper of the mouthpiece element, wherein the outer wrapper extends in a downstream direction from the mouthpiece element.

[0334] The aerosol-generating article may have a total length of at least about 35 millimetres, at least about 38 millimetres, at least about 40 millimetres, or at least about 42 millimetres.

[0335] The aerosol-generating article may have a total length of less than or equal to about 100 millimetres, less than or equal to about 70 millimetres, less than or equal to about 60 millimetres, or less than or equal to 50 millimetres.

[0336] The aerosol-generating article may have a total length of between about 35 millimetres and about 100 millimetres, between about 35 millimetres and about 70 millimetres, between about 35 millimetres and about 60 millimetres, or between about 35 millimetres and about 50 millimetres.

[0337] The aerosol-generating article may have a total length of between about 38 millimetres and about 100 millimetres, between about 38 millimetres and about 70 millimetres, between aboutP / 90908.W001

[0338] - 38 - 38 millimetres and about 60 millimetres, or between about 38 millimetres and about 50 millimetres.

[0339] The aerosol-generating article may have a total length of between about 40 millimetres and about 100 millimetres, between about 40 millimetres and about 70 millimetres, between about 40 millimetres and about 60 millimetres, or between about 40 millimetres and about 50 millimetres.

[0340] The aerosol-generating article may have a total length of between about 42 millimetres and about 100 millimetres, between about 42 millimetres and about 70 millimetres, between about 42 millimetres and about 60 millimetres, or between about 42 millimetres and about 50 millimetres.

[0341] For example, the aerosol-generating article may have a total length of about 45 millimetres.

[0342] Preferably, the aerosol-generating article has a substantially circular cross-section.

[0343] The aerosol-generating article may have an external diameter of at least about 5 millimetres, at least about 6 millimetres, or at least about 7 millimetres.

[0344] The aerosol-generating article may have an external diameter of less than or equal to about 12 millimetres, less than or equal to about 10 millimetres, or less than or equal to about 8 millimetres.

[0345] The aerosol-generating article may have an external diameter of between about 5 millimetres and about 12 millimetres, between about 5 millimetres and about 10 millimetres, or between about 5 millimetres and about 8 millimetres.

[0346] The aerosol-generating article may have an external diameter of between about 6 millimetres and about 12 millimetres, between about 6 millimetres and about 10 millimetres, or between about 6 millimetres and about 8 millimetres.

[0347] The aerosol-generating article may have an external diameter of between about 7 millimetres and about 12 millimetres, between about 7 millimetres and about 10 millimetres, or between about 7 millimetres and about 8 millimetres.

[0348] For example, the aerosol-generating article may have an external diameter of about 7.1 millimetres.

[0349] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0350] Example Ex1: A flavour material for use in an aerosol-generating article, the flavour material comprising: a polysaccharide matrix structure; a flavourant formulation dispersed within the polysaccharide matrix structure, wherein the flavourant formulation is at least partly trappedP / 90908.W001

[0351] - 39 -within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavour material; and an elongate susceptor element structurally coupled with the polysaccharide matrix structure and the flavourant formulation, wherein the elongate susceptor element is a metal fibre element or a metal wire element or a metal thread element.

[0352] Example Ex2: A flavour material according to Example Ex1, wherein the metal wire is at least partly enveloped by the polysaccharide matrix structure.

[0353] Example Ex3: A flavour material according to Example Ex1 further comprising a carrier sheet material, wherein the polysaccharide matrix structure and the flavourant formulation are supported by the carrier sheet material and the metal wire is embedded within or secured to the carrier sheet material.

[0354] Example Ex4: A flavour material according to Example Ex3, wherein the carrier material is preferably a sheet of homogenised tobacco material or a sheet of plug paper wrapper material.

[0355] Example Ex5: A flavour material according to Example Ex1, the flavour material being in the form of a flavour sheet comprising the polysaccharide matrix structure and the flavourant formulation, wherein the metal wire is secured to the flavour sheet.

[0356] Example Ex6: A flavour material according to any one of Examples Ex1 to Ex5, wherein the elongate susceptor element has a diameter of at least 5 micrometres.

[0357] Example Ex7: A flavour material according to any one of Examples Ex1 to Ex6, wherein the elongate susceptor element has a diameter of less than or equal to 100 micrometres.

[0358] Example Ex8: A flavour material according to any one of Examples Ex1 to Ex7, wherein the elongate susceptor element has a length of at least 100 micrometres.

[0359] Example Ex9: A flavour material according to any one of Examples Ex1 to Ex8, wherein the polysaccharide matrix structure comprises gellan gum and emulsifier.

[0360] Example Ex10: A flavour material according to any one of Examples Ex1 to Ex9, wherein the emulsifier is lecithin.

[0361] Example Ex11: A flavour material according to Example Ex9 or Example Ex10, wherein the polysaccharide matrix structure comprises gellan gum as the sole polysaccharide or gellan gum in combination with at least a further polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethyl cellulose, and hydroxypropyl methyl cellulose, wherein the gellan gum makes up from 5 percent by weight to 99.9 percent by weight of the flavour material on a dry weight basis.

[0362] Example Ex12: A flavour material according to any one of Examples Ex1 to Ex11, the flavour material further comprising a polyol having the formula CnH2n+2On, wherein the polyol is preferably selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol or wherein the polyol makes up 0.01 percent by weight to 20 percent by weight of the flavour material on a dry weight basis or both.P / 90908.W001

[0363] - 40 - Example Ex13: A flavour material according to any one of Examples Ex1 to Ex12, the flavour material further comprising fibres, wherein the fibres preferably make up from 0.01 percent by weight to 10 percent by weight of the flavour material on a dry weight basis.

[0364] Example Ex14: An aerosol-generating article comprising a flavour material according to any one of Examples Ex1 to Ex13.

[0365] Example Ex15: An aerosol-generating article according to Example Ex14, the aerosolgenerating article comprising: a rod of aerosol-generating substrate extending along a longitudinal axis; a downstream section provided downstream of the rod of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article; optionally an upstream section provided upstream of the rod of aerosol-generating substrate and extending to a distal end of the aerosol-generating article; wherein the flavour material is provided in at least one of the rod of aerosol-generating substrate; the downstream section; and the optional upstream section.

[0366] Example Ex16: An aerosol-generating article according to Example Ex15, wherein the flavour material is provided in the rod of aerosol-generating substrate, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.25 times a diameter of the rod of aerosol-generating substrate.

[0367] Example Ex17: An aerosol-generating article according to Example Ex15, wherein the radial distance between the flavour material and the longitudinal axis of the rod of aerosolgenerating substrate is at least 0.35 times a diameter of the rod of aerosol-generating substrate.

[0368] Example Ex18: An aerosol-generating article according to any one of Examples Ex15 to Ex17, wherein the radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is less than or equal to 0.45 times a diameter of the rod of aerosolgenerating substrate.

[0369] Example Ex19: An aerosol-generating article according to any one of Examples Ex15 to Ex18, wherein the aerosol-generating article comprises a ventilation zone at a location along the downstream section.

[0370] Example Ex20: An aerosol-generating article according to any one of Examples Ex15 to Ex19, wherein the aerosol-generating substrate comprises a tobacco material.

[0371] Example Ex21: An aerosol-generating article according to Example Ex20, wherein the tobacco material comprises a sheet of homogenised tobacco material or one or more of tobacco cut filler, cut reconstituted tobacco, and cut homogenised tobacco material.

[0372] Example Ex22: An aerosol-generating system comprising: an aerosol-generating article according to any one of Examples Ex15 to Ex21; and an aerosol-generating device configured to heat the aerosol-generating substrate of the aerosol-generating article, wherein the aerosolgenerating device comprises a housing defining a cavity configured to receive the aerosolgenerating article.P / 90908.W001

[0373] - 41 - Example Ex23: An aerosol-generating system according to Example Ex22, wherein the aerosol-generating article comprises a susceptor element provided at a location within the rod of aerosol-generating substrate; and wherein the aerosol-generating device comprises an inductor coil positioned on or within the housing, and a power supply connected to the inductor coil and configured to provide a high frequency oscillating current to the inductor coil.

[0374] Examples will now be further described with reference to the figures in which:

[0375] Figure 1 shows a schematic side cross-sectional view of an aerosol-generating article comprising a flavour material in accordance with the present invention;

[0376] Figure 2 shows a schematic side cross-sectional view of another aerosol-generating article comprising a flavour material in accordance with the present invention.

[0377] An aerosol-generating article 10 in accordance with the present invention is shown in Figure 1. The aerosol-generating article 10 shown in Figure 1 comprises a rod 12 of aerosol-generating substrate and a downstream section 14 at a location downstream of the rod 12 of aerosolgenerating substrate. Further, the aerosol-generating article 10 comprises an upstream section 16 at a location upstream of the rod 12 of aerosol-generating substrate.

[0378] The aerosol-generating article 10 extends along a longitudinal axis 102, which is also a longitudinal axis of the rod 12 of aerosol-generating substrate.

[0379] A ventilation zone 60 is provided downstream of the rod 12 of aerosol-generating substrate. In more detail, in the embodiment of Figure 1, the downstream section 14 comprises a mouthpiece element 18 and a hollow section 20. The hollow section 20 comprises an aerosolcooling element 22 comprising a hollow tubular element and the ventilation zone 60, which comprises a plurality of openings formed through a wall of the hollow tubular element. The aerosol-cooling element 22 is positioned immediately downstream of the rod 12 of aerosolgenerating substrate. As shown in the drawing of Figure 1, an upstream end of the aerosolcooling element 22 abuts a downstream end of the rod 12 of aerosol-generating substrate. The mouthpiece element 18 is positioned immediately downstream of the aerosol-cooling element 22. As shown in the drawing of Figure 1, an upstream end of the mouthpiece element 18 abuts a downstream end of the aerosol-cooling element 22. The mouthpiece element 18 comprises a plug 24 of low-density filtration material.

[0380] The rod 12 comprises an aerosol-generating substrate in the form of a gathered sheet of homogenised tobacco material. However, other types of tobacco-containing substrate, such as a tobacco cut filler, may replace the gathered sheet of homogenised tobacco material. The aerosol-generating article further comprises a primary susceptor element 60 arranged within and thermally coupled with the aerosol-generating substrate. The primary susceptor element is in the form of a metal blade having the same length as the rod 12.P / 90908.W001

[0381] - 42 - The upstream section 16 comprises a cylindrical plug 26 of compressed and plasticised cellulose acetate circumscribed by a wrapper 28. The plug 26 of the upstream section 16 has a length of about 5 millimetres.

[0382] Further, the aerosol-generating article comprises a flavour material 50. In more detail, a plurality of pieces of a flavour material in sheet form are dispersed within the rod 12. A radial distance between the pieces of flavour material 50 and a longitudinal axis of the aerosolgenerating article is larger than 0.25 times a diameter of the rod of aerosol-generating substrate.

[0383] The flavour material 50 is of the type described in detail above. Each piece of flavour material 50 comprises an elongate susceptor element in the form of a predetermined length of metal wire element (not shown).

[0384] Examples of suitable formulations for the flavour material 50 and processes for forming the flavour material 50 are set out below.

[0385] Another aerosol-generating article 100 in accordance with the present invention is shown in Figure 2. The aerosol-generating article 100 shown in Figure 2 has substantially the same structure and geometry of the aerosol-generating 10 shown in Figure 1, and will be described below only insofar as it differs from the aerosol-generating 10 shown in Figure 1.

[0386] In the aerosol-generating article 100, the aerosol-generating substrate 121 is in the form of shreds of a homogenised tobacco material. However, other types of tobacco-containing substrate, such as a tobacco cut filler or a gathered sheet of homogenised tobacco material can replace the shreds of homogenised tobacco material. The aerosol-generating article further comprises a primary susceptor element 60 arranged within and thermally coupled with the aerosol-generating substrate. The primary susceptor element is in the form of a metal blade having the same length as the rod 12.

[0387] Further, in the aerosol-generating article 100 the flavour material 50 is provided dispersed among the shreds of homogenised tobacco material. A radial distance between the pieces of flavour material 50 and a longitudinal axis of the aerosol-generating article is larger than 0.25 times a diameter of the rod of aerosol-generating substrate.

[0388] The flavour material 50 is of the type described in detail above. Each piece of flavour material 50 comprises an elongate susceptor element in the form of a predetermined length of metal wire element (not shown).P / 90908.W001

[0389] - 43 - Preparation A - Flavour delivery material comprising a menthol formulation trapped in a matrix + carrier sheet material with embedded

[0390] element

[0391] 100 g of water are heated to about 60 degrees Celsius and 3.0 g of gellan gum are added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range from 80 to 85 degrees Celsius and kept at this temperature for 5 minutes. The mixture is subsequently cooled down to a temperature in the range from 70 to 75 degrees Celsius and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavour-containing mixture is homogenized for 3 minutes. Subsequently, the resulting aqueous composition is cast on a plug wrap paper containing lengths of Iron / Nickel (Ni36, Ni 42, permalloy wire having a diameter from 5 micrometres to 100 micrometres and a length from 100 micrometres to 15 millimetres), which has previously been laid out on a metallic tray. The cast aqueous composition is left to jellify and dried in a still oven at 75 degrees Celsius. A layer having a thickness of 10 to 150 micrometres of an additive-enriched flavour material supported by a sheet carrier form is obtained, wherein a plurality of elongate susceptor elements are embedded in the sheet carrier. From this, pieces of flavour material according to the present invention are cut.

[0392] Preparation B - Flavour delivery material comprising a menthol formulation trapped in a matrix + carrier sheet material with embedded

[0393] element

[0394] 100 g of water are heated to about 60 degrees Celsius and 3.0 g of gellan gum are added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range from 80 to 85 degrees Celsius and kept at this temperature for 5 minutes. The mixture is subsequently cooled down to a temperature in the range from 70 to 75 degrees Celsius and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavour-containing mixture is homogenized for 3 minutes. Subsequently, the resulting aqueous composition is cast on a plug wrap paper containing lengths of Iron / Nickel (Ni36, Ni 42, permalloy wire having a diameter from 5 micrometres to 100 micrometres and a length from 100 micrometres to 15 millimetres), which has previously been laid out on a metallic tray. The cast aqueous composition is left to jellify and dried in a still oven at 75 degrees Celsius. A layer having a thickness of 10 to 150 micrometres of additive-enriched flavour material supported by a sheet carrier form is obtained, wherein a plurality of elongate susceptor elements are embedded in the sheet carrier. From this, pieces of flavour material according to the present invention are cut.P / 90908.W001

[0395] - - Preparation C - Flavour delivery material comprising a menthol formulation trapped in a matrix + carrier sheet material with embedded

[0396] element

[0397] 100 g of water are heated to about 60 degrees Celsius and 2.0 g of gellan gum and 0.5 grams of alginate are added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range from 90 to 95 degrees Celsius and kept at this temperature for 5 minutes. The mixture is subsequently cooled down to a temperature in the range from 70 to 75 degrees Celsius and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavourcontaining mixture is homogenized for 3 minutes. Subsequently, the resulting aqueous composition is cast on a plug wrap paper containing lengths of Iron / Nickel (Ni36, Ni 42, permalloy wire having a diameter from 5 micrometres to 100 micrometres and a length from 100 micrometres to 15 millimetres), which has previously been laid out on a metallic tray. The cast aqueous composition is left to jellify and dried in a still oven at 75 degrees Celsius. A layer having a thickness of 10 to 150 micrometres of an additive-enriched flavour material supported by a sheet carrier form is obtained, wherein a plurality of elongate susceptor elements are embedded in the sheet carrier. From this, pieces of flavour material according to the present invention are cut.

[0398] Comparative Preparation - Flavour delivery material comprising a menthol formulation ed in a qellan qum polysaccharide matrix + carrier sheet material with embedded elongate susceptor element

[0399] 100 g of water are heated to about 60 degrees Celsius and 3.0 g of gellan gum are added to the water bath. The resulting mixture is homogenized and heated to a temperature in the range from 80 to 85 degrees Celsius and kept at this temperature for 5 minutes. The mixture is subsequently cooled down to a temperature in the range from 70 to 75 degrees Celsius and 0.1 g of lecithin and 8.0 g of menthol are added to the mixture. The flavour-containing mixture is homogenized for 3 minutes. Subsequently, the resulting aqueous composition is cast on a metallic tray. The cast aqueous composition is left to jellify and dried in a still oven at 75 degrees Celsius. A layer having a thickness of 10 to 150 micrometres of an additive-enriched flavour material is obtained. From this, pieces of flavour material suitable for inclusion in an aerosolgenerating article are obtained.

[0400] Assessment of flavour delivery - aerosol-generating articles

[0401] Smoking tests were carried out to assess the release and delivery of flavour species from flavour materials in accordance with the present invention. To this purpose, the following aerosolgenerating articles were prepared and subjected to a smoking test.P / 90908.W001

[0402] - 45 - Aerosol-generating article 1

[0403] An aerosol-generating article in accordance with the present invention, having the structure and dimensions described with reference to the drawing of Figure 1 was prepared. 12 mg of a flavour material prepared in accordance with Preparation A described above were introduced in the peripheral portion of the rod of aerosol-generating substrate, so that a radial distance between the pieces of flavour material and the longitudinal axis of the rod of aerosol-generating substrate was greater than 0.25 times a diameter of the rod of aerosol-generating substrate.

[0404] Reference aerosol-generating article

[0405] An aerosol-generating article in accordance with the present invention, having the structure and dimensions described with reference to the drawing of Figure 1 was prepared. 15 mg of a flavour material prepared in accordance with the Comparative Preparation described above were introduced in the central portion of the rod of aerosol-generating substrate.

[0406] Comparative aerosol-generating article 1

[0407] An aerosol-generating article in accordance with the present invention, having the structure and dimensions described with reference to the drawing of Figure 1 was prepared. 15 mg of a flavour material prepared in accordance with the Comparative Preparation described above were introduced in the central portion of the rod of aerosol-generating substrate, so that a radial distance between the pieces of flavour material and the longitudinal axis of the rod of aerosolgenerating substrate was less than 0.15 times a diameter of the rod of aerosol-generating substrate. In contrast to the Reference aerosol-generating article, in the Comparative aerosolgenerating article 1 the rod of aerosol-generating substrate further comprised 7.6 percent by weight on a dry weight basis of graphite particles dispersed throughout the rod of aerosolgenerating substrate.

[0408] The aerosol-generating article in accordance with the present invention (Aerosol-generating article 1), the Comparative aerosol-generating article 1, and the Reference aerosol-generating article were heated in a commercially available aerosol-generating device IQOS 4 (IQOS lluma Prime) and air was drawn through the aerosol-generating articles to simulate a consumer’s puffs.

[0409] The concentration of menthol in the airflow delivered at the mouth end of the aerosolgenerating articles tested was measured and tracked over time, so as to associate a value of concentration of menthol to each puff. In more detail, the menthol delivery was assessed on a puff-by-puff basis by determining the concentration of menthol in the airflow delivered at the mouth end of an aerosol-generating article using headspace (HS) gas chromatography (GC) coupled to time of flight (TOF) mass spectroscopy (MS).P / 90908.W001

[0410] - 46 - The values of menthol concentration detected for Aerosol-generating article 1 and Comparative aerosol-generating article 1 were compared with the values of menthol concentration detected for the Reference aerosol-generating article 1.

[0411] This was to compare the performance of Aerosol-generating article 1 - wherein, in the pieces of flavour material, the immobilised flavourant formulation is structurally coupled with elongate susceptor material elements - with the performance of the Reference aerosolgenerating article - wherein the flavour material is not coupled with any material that can act as a susceptor other than the primary susceptor provided in the rod of aerosol-generating substrate as described above.

[0412] Further, this was to compare the performance of Comparative aerosol-generating article 1 , wherein the pieces of flavour material are functionally, but not structurally, coupled with particles of graphite dispersed within the rod of aerosol-generating substrate - which are understood to enhance heat transfer across the rod of aerosol-generating substrate and to the immobilised flavourant formulation - with the performance of the Reference aerosol-generating article, wherein the flavour material is not coupled with any other material that can act as a susceptor other than the primary susceptor provided in the rod of aerosol-generating substrate as described above.

[0413] The values contained in the following Table 1 refer to a percent variation between a value of menthol concentration detected at the mouth end of Aerosol-generating article 1 and a value of menthol concentration detected at the mouth end of the Reference aerosol-generating article 1 assessed on a puff by puff basis during a usage cycle.

[0414] Table 1

[0415]

[0416] P / 90908.W001

[0417] - 47 -

[0418]

[0419] It is apparent that with an aerosol-generating article in accordance with the present invention, a much more significant release and delivery of menthol is observed in connection with the first three puffs, the very first puff in the usage cycle being in particular associated with a much more intense menthol release and delivery. Although the variation diminishes progressively, the aerosol-generating article in accordance with the present invention remains associated with an increased release and delivery of menthol throughout the usage cycle compared with the Reference aerosol-generating article. Without wishing to be bound by theory, it is hypothesised that release and delivery of menthol trapped within the polysaccharide matrix is initiated much sooner and more intensely because the elongate susceptor element structurally coupled with the immobilised flavourant formulation is capable of supplying heat in a concentrated manner and with minimum delay. Data would appear to suggest that, throughout the usage cycle, heat is supplied generally more efficiently, and so it is easier to maintain the immobilised menthol at a temperature sufficient to volatilise it and release it into the airflow.

[0420] The values contained in the following Table 2 refer to a percent variation between a value of menthol concentration detected at the mouth end of Comparative aerosol-generating article 1 and a value of menthol concentration detected at the mouth end of the Reference aerosolgenerating article assessed on a puff by puff basis during a usage cycle.

[0421] Table 2

[0422]

[0423] P / 90908.W001

[0424] - 48 -

[0425]

[0426] In an aerosol-generating article wherein heat transfer within the rod of aerosol-generating substrate is generally enhanced by the presence of graphite particles, the release and delivery of menthol may be increased throughout the usage cycle. However, the intensity of the increase stays relatively the same during the first 7 puffs, only to oscillate over the remainder of the usage cycle.

[0427] Thus, Comparative aerosol-generating article 1 consistently delivers more menthol to the consumers compared to the Reference aerosol-generating article, yet the increase in the menthol concentration remains roughly the same for the majority of the usage cycle. Accordingly, a consumer may generally perceive an enhanced menthol flavour sensation, yet the entity of the flavour boost may generally be perceived as remaining constant over the first part of the usage cycle.

[0428] By contrast, an aerosol-generating article in accordance with the present invention (Aerosolgenerating article 1) provides a noticeably different flavour delivery profile, with a sudden burst of menthol released and delivered over the very first puffs of the usage cycle, compared with the reference article. This may generally be perceived by the consumer as an intense flavour burst associated with the beginning of the usage cycle, in a way that mimics what could have been obtained in conventional smoking articles comprising a breakable capsule if the user ruptured the capsule before the first puff.

[0429] Accordingly, these data suggest that incorporating a material capable of enhancing heat transfer generally throughout the rod of aerosol-generating substrate does not have the same effect on flavour release and delivery that is achieved instead by the present invention, according to which elongate susceptor elements in the form of metal fibres, metal wires, metal threads or metal rods are structurally coupled with the immobilised flavour formulation. The flavour material and aerosol-generating article of the present invention appear in fact to be associated with a clearly distinguished flavour release and delivery profile.

[0430] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, mayP / 90908.W001

[0431] - 49 -deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

P / 90908.W001- 50 - CLAIMS1. A flavour material for use in an aerosol-generating article, the flavour material comprising:a polysaccharide matrix structure;a flavourant formulation dispersed within the polysaccharide matrix structure, wherein the flavourant formulation is at least partly trapped within the polysaccharide matrix structure and releasable from the polysaccharide matrix structure upon heating of the flavour material; and an elongate susceptor element structurally coupled with the polysaccharide matrix structure and the flavourant formulation, wherein the elongate susceptor element is a metal fibre element or a metal wire element or a metal thread element.

2. A flavour material according to claim 1 , wherein the metal wire is at least partly enveloped by the polysaccharide matrix structure.

3. A flavour material according to claim 1 further comprising a carrier sheet material, wherein the polysaccharide matrix structure and the flavourant formulation are supported by the carrier sheet material and the metal wire is embedded within or secured to the carrier sheet material.

4. A flavour material according to claim 3, wherein the carrier material is preferably a sheet of homogenised tobacco material or a sheet of plug paper wrapper material.

5. A flavour material according to claim 1 in the form of a flavour sheet comprising the polysaccharide matrix structure and the flavourant formulation, wherein the metal wire is secured to the flavour sheet.

6. A flavour material according to any one of claims 1 to 5, wherein the elongate susceptor element has a diameter of at least 5 micrometres or a diameter of less than or equal to 100 micrometres or a diameter from 5 micrometres to 100 micrometres.

7. A flavour material according to any one of claims 1 to 6, wherein the elongate susceptor element has a length of at least 100 micrometres.

8. A flavour material according to any one of claims 1 to 8, wherein the polysaccharide matrix structure comprises gellan gum and emulsifier.

9. A flavour material according to claim 8, wherein the emulsifier is lecithin.P / 90908.W001- 51 -10. A flavour material according to claim 8 or 9, wherein the polysaccharide matrix structure comprises gellan gum as the sole polysaccharide or gellan gum in combination with at least a further polysaccharide selected from the group consisting of guar, tamarind gum, sodium alginate, xanthan gum, sodium carboxymethyl cellulose, and hydroxypropyl methyl cellulose, wherein the gellan gum makes up from 5 percent by weight to 99.9 percent by weight of the flavour material on a dry weight basis.

11. A flavour material according to any one of claims 1 to 10, further comprising a polyol having the formula CnH2n+2On, wherein the polyol is preferably selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, and erythritol or wherein the polyol makes up 0.01 percent by weight to 20 percent by weight of the flavour material on a dry weight basis or both.

12. An aerosol-generating article comprising a flavour material according to any one of claims 1 to 11.

13. An aerosol-generating article according to claim 12 comprising: a rod of aerosolgenerating substrate extending along a longitudinal axis; a downstream section provided downstream of the rod of aerosol-generating substrate and extending to a mouth end of the aerosol-generating article; optionally an upstream section provided upstream of the rod of aerosol-generating substrate and extending to a distal end of the aerosol-generating article; wherein the flavour material is provided in at least one of the rod of aerosol-generating substrate; the downstream section; and the optional upstream section.

14. An aerosol-generating article according to claim 13, wherein the flavour material is provided in the rod of aerosol-generating substrate, a radial distance between the flavour material and the longitudinal axis of the rod of aerosol-generating substrate is at least 0.25 times a diameter of the rod of aerosol-generating substrate or less than or equal to 0.45 times a diameter of the rod of aerosol-generating substrate or from 0.25 to 0.45 times a diameter of the rod of aerosol-generating substrate.

15. An aerosol-generating system comprising: an aerosol-generating article according to claim 13 or claim 14; and an aerosol-generating device configured to heat the aerosol-generating substrate of the aerosol-generating article, wherein the aerosol-generating device comprises a housing defining a cavity configured to receive the aerosol-generating article, wherein the aerosol-generating article preferably comprises a susceptor element provided at a location withinP / 90908.W001- 52 -the rod of aerosol-generating substrate; and wherein the aerosol-generating device preferably comprises an inductor coil positioned on or within the housing, and a power supply connected to the inductor coil and configured to provide a high frequency oscillating current to the inductor coil.

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