Aerosol-generating article with microencapsulated particles

Abstract

An aerosol-generating article (10) comprising: an aerosol-generating substrate (16) comprising aerosol-generating material and nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

Description

[0001] AEROSOL-GENERATING ARTICLE WITH MICROENCAPSULATED PARTICLES

[0002] The present disclosure relates to an aerosol-generating substrate for generating an inhalable aerosol upon heating. The present disclosure also relates to an aerosol-generating article comprising the aerosol-generating substrate. The present disclosure also relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device configured to heat the aerosol-generating article.

[0003] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobaccocontaining 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.

[0004] A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosolgenerating 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 a heated aerosol-generating 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 aerosol-generating substrate. Use of an aerosol-generating article in combination with an external heating system is also known. For example, WO 2020 / 115151 A1 describes the provision of an external heating element arranged around the periphery of the aerosol-generating article when the aerosol-generating article is received in a cavity of the aerosol-generating device. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor arranged within the aerosol-generating substrate have been proposed by WO 2015 / 176898 A1.

[0005] In some known aerosol-generating articles, flavourant is added to the aerosol-generating material of the aerosol-generating substrate. The aerosol-generating material may be tobacco. Upon heating of the aerosol-generating article during use, the flavourant is volatilised to provide the aerosol with a desired flavour. Flavourant used in aerosol-generating articles are typically highly volatile. Where the flavourant is not encapsulated, the flavourant is volatilised soon after initiation of the heating of the aerosol-generating substrate. This may be such that during the initial puffs by a user, the aerosol delivered to the user comprises high levels of flavourant. However, the flavourant may be quickly depleted during use of the aerosol-generating article such that there is undesirable drop in the level of flavourant in the aerosol delivered to the user during the later puffs, for example after six puffs.Nonencapsulated flavourant may migrate during storage of the aerosol-generating article from the aerosol-generating substrate to other components of the aerosol-generating article. This may result in a reduced amount of flavourant that is heated during use of the aerosol-generating article with an aerosol-generating device. Accordingly, the aerosol generated during use of the aerosol-generating article may have lower levels of flavourant than desired and some flavourant may be wasted.

[0006] It would be desirable to provide an aerosol-generating article in which the quality and consistency of aerosol delivered to a user is improved compared to known aerosol-generating articles. In particular, it would be desirable to provide an aerosol-generating article with a desired flavour delivery profile.

[0007] The present disclosure relates to an aerosol-generating article comprising an aerosolgenerating substrate. The aerosol-generating substrate may comprise aerosol-generating material. The aerosol-generating substrate may comprise nonencapsulated flavourant. The aerosol-generating article may comprise a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

[0008] A weight of the encapsulated flavourant may be at least 10 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the aerosol-generating article may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0009] According to a first aspect of the present disclosure, there is provided an aerosolgenerating article comprising: an aerosol-generating substrate comprising aerosol-generating material and nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

[0010] According to a second aspect of the present disclosure, there is provided an aerosolgenerating article comprising: an aerosol-generating substrate comprising nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant, wherein a total weight of encapsulated flavourant in the aerosol-generating article is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0011] The present disclosure also relates to an aerosol-generating system. The aerosolgenerating system may comprise an aerosol-generating article as described herein. The aerosolgenerating system may comprise an aerosol-generating device. The aerosol-generating device may be configured to heat the aerosol-generating substrate of the aerosol-generating article. The aerosol-generating device may comprise a housing. The housing may define a cavity. The cavity may be configured to receive the aerosol-generating article.

[0012] According to a third aspect of the present disclosure, there is provided an aerosolgenerating system comprising: an aerosol-generating article according to the first aspect of the present disclosure; and an aerosol-generating device configured to heat the aerosol-generatingsubstrate of the aerosol-generating article, wherein the aerosol-generating device comprises a housing defining a cavity configured to receive the aerosol-generating article.

[0013] The present disclosure also relates to an aerosol-generating substrate. The aerosolgenerating substrate may have any feature of the aerosol-generating substrate of the aerosolgenerating article described herein. The aerosol-generating substrate may comprise aerosolgenerating material. The aerosol-generating substrate may comprise nonencapsulated flavourant. The aerosol-generating substrate may comprise a plurality of microencapsulated flavourant particles comprising encapsulated flavourant. The plurality of microencapsulated flavourant particles of the aerosol-generating substrate may have any feature of the plurality of microencapsulated flavourant particles of the aerosol-generating article described herein.

[0014] The weight of the encapsulated flavourant may be at least 10 percent of the total weight of flavourant in the aerosol-generating substrate. The total weight of encapsulated flavourant in the aerosol-generating substrate may be at least 10 percent of the total weight of flavourant in the aerosol-generating substrate.

[0015] According to a fourth aspect of the present disclosure, there is provided an aerosolgenerating substrate comprising: aerosol-generating material and nonencapsulated flavourant and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

[0016] According to a fifth aspect of the present disclosure, there is provided an aerosolgenerating substrate comprising: nonencapsulated flavourant and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant, wherein a total weight of encapsulated flavourant in the aerosol-generating substrate is at least 10 percent of the total weight of flavourant in the aerosol-generating substrate.

[0017] The aerosol-generating substrate according to the fourth aspect or fifth aspect of the present disclosure may have any feature of the aerosol-generating substrate of the aerosolgenerating article according to the first aspect or second aspect of the present disclosure described herein. The plurality of microencapsulated flavourant particles of the aerosolgenerating substrate according to the fourth aspect or fifth aspect of the present disclosure may have any feature of the plurality of microencapsulated flavourant of the aerosol-generating article according to the first aspect or second aspect of the present disclosure described herein.

[0018] As used herein, 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.

[0019] As used herein, 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.

[0020] As used herein, 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 orsolid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0021] As used herein, the term “aerosol-generating device” is used to describe a device that interacts with the aerosol-generating substrate of the aerosol-generating article to generate an aerosol.

[0022] Aerosol-generating articles according to the present disclosure 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.

[0023] Aerosol-generating articles according to the present disclosure 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.

[0024] Components of aerosol-generating articles according to the present disclosure 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 aerosolgenerating article.

[0025] As used herein, 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.

[0026] As used herein, 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.

[0027] As used herein, 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.

[0028] As used herein, the term “width” denotes the maximum dimension of the aerosolgenerating article or a component of the aerosol-generating article in a transverse direction. Where the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating 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.

[0029] As used herein, the term “flavourant” is used to describe a material that can be used to deliver at least one of a gustatory sensation and an olfactory sensation to a consumer.A flavourant may comprise a material intended to deliver a gustatory sensation upon oral ingestion by the consumer. The gustatory sensation may comprise at least one of a taste sensation, a cooling or a warming sensation, a tingling sensation, a numbing sensation, effervescence, increased salivation, and combinations thereof.

[0030] Alternatively, a flavourant may comprise a material intended to deliver an olfactory sensation without oral ingestion by the consumer. Such flavourants may comprise at least one volatile compound that delivers an olfactory sensation at room temperature or upon heating.

[0031] Additionally, or alternatively, the flavourant may comprise one or more compounds intended to function as a deodorising agent to mask or remove odours, for example odours generated during smoking of the aerosol generating article.

[0032] As used herein, the term “microencapsulated flavourant particle” describes a small, discrete particle having a structure in which the flavourant is encapsulated within a shell such that the flavourant remains sealed and trapped within the shell until the shell material is ruptured or broken down during use. The microencapsulated flavourant particle may be of a reservoir or coreshell type, comprising an inner core of the flavourant contained within an outer shell. The microencapsulated flavourant particle may be of a matrix type, in which the flavourant material is dispersed within a shell matrix. In a microencapsulated flavourant particle of the matrix type, a plurality of droplets of the flavourant material may be trapped within the shell material. The matrix may have an open-cell structure or a closed-cell structure. The encapsulated flavourant may be irregularly dispersed within the shell matrix. The microencapsulated flavourant particle may be of a hybrid type, comprising an inner core contained within an outer shell, wherein the inner core comprises flavourant material dispersed within a shell matrix.

[0033] As used herein, the total weight of flavourant in the aerosol-generating article is the sum of the total weight of encapsulated flavourant in the aerosol-generating article and the total weight of nonencapsulated flavourant in the aerosol-generating article.

[0034] Aerosol-generating articles according to the first aspect of the present disclosure comprise: an aerosol-generating substrate comprising aerosol-generating material and nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

[0035] Aerosol-generating articles according to the second aspect of the present disclosure comprise: an aerosol-generating substrate comprising nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant, wherein a weight of the encapsulated flavourant is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0036] Upon heating of the aerosol-generating article during use, nonencapsulated flavourant may be preferentially volatilised during an initial period and delivered to a user during the initial puffs. The microencapsulated flavourant particles may be configured to release the encapsulatedflavourant when exposed to a minimum temperature. The microencapsulated flavourant particles may be configured to release the encapsulated flavourant after the initial heating period, and the released flavourant may be volatilised and delivered to the user through inhalation. This may help to minimise or avoid an undesirable drop in the level of flavourant being delivered to a user during use of the aerosol-generating article to provide a sustained flavour delivery profile.

[0037] The provision of a plurality of microencapsulated flavourant particles may simplify and provide flexibility in the distribution of flavourant in the aerosol-generating article. This may provide control over the amount of flavourant in the article and the location of the flavourant.

[0038] Microencapsulated flavourant particles may be less susceptible to migration within an aerosol-generating article compared to nonencapsulated flavourant particles. The provision of a plurality of microencapsulated flavourant particles may help to ensure that flavourant is retained at desired locations within the aerosol-generating article for optimised release and volatilisation of flavourant. This may help to provide the aerosol-generating article with a desired flavour delivery profile and reduce variation in the flavour delivery profile of one aerosol-generating article to another.

[0039] Providing flavourant in a plurality of microencapsulated flavourant particles may advantageously minimise loss of flavourant from the aerosol generating article during storage. This is particularly advantageous where the flavourant comprises one or more highly volatile compounds.

[0040] The plurality of microencapsulated flavourant particles may be stable and do not dissolve in, for example, propylene glycol. Accordingly, the plurality of microencapsulated flavourant particles may be applied to the aerosol-generating article using existing machinery and processes used to apply nonencapsulated flavourant to aerosol-generating material.

[0041] The provision of an aerosol-generating article according to the first aspect or second aspect of the present disclosure may advantageously provide the aerosol-generating article with a desired flavour delivery profile during use of the aerosol-generating article across the entire user experience, improve consistency in the flavour delivery profile of one aerosol-generating article to another, and may be simply and cost effectively manufactured.

[0042] The aerosol-generating material in the aerosol-generating substrate is in addition to the nonencapsulated flavourant. In other words, the nonencapsulated flavourant is exogenous and is added to the aerosol-generating material.

[0043] The aerosol-generating substrate may comprise aerosol-generating material and nonencapsulated flavourant dispersed one or both of within and between the aerosol-generating material.

[0044] The aerosol-generating substrate may comprise aerosol-generating material and nonencapsulated flavourant dispersed within the aerosol-generating material. The aerosolgenerating substrate may comprise aerosol-generating material and non-encapsulated flavourant dispersed between the aerosol-generating material.A total weight of encapsulated flavourant in the aerosol-generating article may be at least 10 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the aerosol-generating article may be at least 15 percent, at least 20 percent of the total weight of flavourant in the aerosol-generating article, or at least 30 percent of the total weight of flavourant in the aerosol-generating article.

[0045] A total weight of encapsulated flavourant in the aerosol-generating article may be less than or equal to 60 percent, less than or equal to 50 percent, less than or equal to 40 percent, or less than or equal to 30 percent of the total weight of flavourant in the aerosol-generating article.

[0046] A total weight of encapsulated flavourant in the aerosol-generating article may be between 10 percent and 60 percent, between 10 percent and 50 percent, between 10 percent and 40 percent, or between 10 percent and 30 percent of the total weight of flavourant in the aerosolgenerating article. A total weight of encapsulated flavourant in the aerosol-generating article may be between 15 percent and 60 percent, between 15 percent and 50 percent, between 15 percent and 40 percent, or between 15 percent and 30 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the aerosol-generating article may be between 20 percent and 60 percent, 20 percent and 50 percent, between 20 percent and 40 percent, or between 20 percent and 30 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the aerosol-generating article may be between 30 percent and 60 percent, 30 percent and 50 percent, or between 30 percent and 40 percent of the total weight of flavourant in the aerosol-generating article.

[0047] A majority of the flavourant in the aerosol-generating article may be provided in encapsulated form.

[0048] In some examples, a total weight of encapsulated flavourant in the aerosol-generating article may be at least 60 percent, or at least 70 percent of the total weight of flavourant in the aerosol-generating article. In some examples, a total weight of encapsulated flavourant in the aerosol-generating article may be less than or equal to 90 percent of the total weight of flavourant in the aerosol-generating article. In some examples, a total weight of encapsulated flavourant in the aerosol-generating article may be between 60 percent and 90 percent, or between 70 percent and 90 percent of the total weight of flavourant in the aerosol-generating article.

[0049] The proportion of flavourant that is provided in the aerosol-generating article in an encapsulated form discussed herein may provide a desired flavourant delivery profile. Increasing the amount and proportion of flavourant that is provided in encapsulated form may increase the amount and proportion of flavourant that is released during later puffs such that the aerosolgenerating article has a consistent and sustained flavour delivery profile throughout the entire user experience. However, increasing the amount and proportion of flavourant that is provided in encapsulated form may result in an increase in the total weight of the microencapsulated flavourant particles in the aerosol-generating article. The proportion of flavourant that is in an encapsulated form discussed herein may provide a desired balance between achieving a desiredflavourant delivery profile and a desired total weight of the encapsulated flavourant particles in the aerosol-generating article.

[0050] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 10 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 15 percent, at least 20 percent, or at least 30 percent of the total weight of flavourant in the aerosol-generating article.

[0051] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be less than or equal to 60 percent, less than or equal to 50 percent, less than or equal to 40 percent, or less than or equal to 30 percent of the total weight of flavourant in the aerosol-generating article.

[0052] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 10 percent and 60 percent, 10 percent and 50 percent, between 10 percent and 40 percent, or between 10 percent and 30 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 15 percent and 60 percent, 15 percent and 50 percent, between 15 percent and 40 percent, or between 15 percent and 30 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 20 percent and 60 percent, 20 percent and 50 percent, between 20 percent and 40 percent, or between 20 percent and 30 percent of the total weight of flavourant in the aerosol-generating article. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 30 percent and 60 percent, 30 percent and 50 percent, or between 30 percent and 40 percent of the total weight of flavourant in the aerosol-generating article.

[0053] In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 60 percent, or at least 70 percent of the total weight of flavourant in the aerosol-generating article. In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be less than or equal to 90 percent of the total weight of flavourant in the aerosol-generating article. In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 60 percent and 90 percent, or between 70 percent and 90 percent of the total weight of flavourant in the aerosol-generating article.

[0054] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 10 percent of the total weight of flavourant in the aerosol-generating substrate. A weight of the encapsulated flavourant may be at least 15 percent, at least 20 percent, or at least 30 percent of the total weight of flavourant in the aerosol-generating substrate.

[0055] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be less than or equal to 60 percent, less than or equal to 50 percent, less than orequal to 40 percent, or less than or equal to 30 percent of the total weight of flavourant in the aerosol-generating substrate.

[0056] A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 10 percent and 60 percent, between 10 percent and 50 percent, between 10 percent and 40 percent, or between 10 percent and 30 percent of the total weight of flavourant in the aerosol-generating substrate. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 15 percent and 60 percent, between 15 percent and 50 percent, between 15 percent and 40 percent, or between 15 percent and 30 percent of the total weight of flavourant in the aerosol-generating substrate. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 20 percent and 60 percent between 20 percent and 50 percent, between 20 percent and 40 percent, or between 20 percent and 30 percent of the total weight of flavourant in the aerosolgenerating substate. A total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 30 percent and 60 percent between 30 percent and 50 percent, or between 30 percent and 40 percent of the total weight of flavourant in the aerosol-generating substate.

[0057] In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 60 percent, or at least 70 percent of the total weight of flavourant in the aerosol-generating substate. In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be less than or equal to 90 percent of the total weight of flavourant in the aerosol-generating substate. In some examples, a total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 60 percent and 90 percent, or between 70 percent and 90 percent of the total weight of flavourant in the aerosol-generating substate.

[0058] The total weight of encapsulated flavourant in the aerosol-generating article may be at least 0.2 milligrams, at least 0.5 milligrams, or at least 0.8 milligrams.

[0059] The total weight of encapsulated flavourant in the aerosol-generating article may be less than or equal to 2.5 milligrams, less than or equal to 2 milligrams, or less than or equal to 1.5 milligrams.

[0060] The total weight of encapsulated flavourant in the aerosol-generating article may be between 0.2 milligrams and 2.5 milligrams, between 0.2 milligrams and 2 milligrams, or between 0.2 milligrams and 1.5 milligrams. The total weight of encapsulated flavourant in the aerosolgenerating article may be between 0.5 milligrams and 2.5 milligrams, between 0.5 milligrams and 2 milligrams, or between 0.5 milligrams and 1.5 milligrams. The total weight of encapsulated flavourant in the aerosol-generating article may be between 0.8 milligrams and 2.5 milligrams, between 0.8 milligrams and 2 milligrams, or between 0.8 milligrams and 1.5 milligrams.

[0061] The total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be at least 0.2 milligrams, at least 0.5 milligrams, or at least 0.8 milligrams.The total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be less than or equal to 2.5 milligrams, less than or equal to 2 milligrams, or less than or equal to 1.5 milligrams.

[0062] The total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 0.2 milligrams and 2.5 milligrams, between 0.2 milligrams and 2 milligrams, or between 0.2 milligrams and 1.5 milligrams. The total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 0.5 milligrams and 2.5 milligrams, between 0.5 milligrams and 2 milligrams, or between 0.5 milligrams and 1.5 milligrams. The total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles may be between 0.8 milligrams and 2.5 milligrams, between 0.8 milligrams and 2 milligrams, or between 0.8 milligrams and 1.5 milligrams.

[0063] All of the encapsulated flavourant in the aerosol-generating article may be provided in the plurality of microencapsulated flavourant particles.

[0064] The total weight of nonencapsulated flavourant in the aerosol-generating article may be at least 2 milligrams, at least 2.5 milligrams, or at least 3 milligrams.

[0065] The total weight of nonencapsulated flavourant in the aerosol-generating article may be less than or equal to 4.5 milligrams, less than or equal to 4 milligrams, or less than or equal to 3.5 milligrams.

[0066] The total weight of nonencapsulated flavourant in the aerosol-generating article may be between 2 milligrams and 4.5 milligrams, between 2 milligrams and 4 milligrams, or between 2 milligrams and 3.5 milligrams. The total weight of nonencapsulated flavourant in the aerosolgenerating article may be between 2.5 milligrams and 4.5 milligrams, between 2.5 milligrams and 4 milligrams, or between 2.5 milligrams and 3.5 milligrams. The total weight of nonencapsulated flavourant in the aerosol-generating article may be between 3 milligrams and 4.5 milligrams, between 3 milligrams and 4 milligrams, or between 3 milligrams and 3.5 milligrams.

[0067] The total weight of nonencapsulated flavourant in the aerosol-generating article discussed herein may apply to the total weight of nonencapsulated flavourant in the aerosol-generating substrate.

[0068] The total weight of flavourant in the aerosol-generating article may be at least 50 micrograms, or at least 100 micrograms. In particular, the total weight of flavourant in the aerosolgenerating article may be at least 2.5 milligrams, at least 3 milligrams, or at least 3.5 milligrams.

[0069] The total weight of flavourant in the aerosol-generating article may be less than or equal to 10 milligrams. In particular, the total weight of flavourant in the aerosol-generating article may be less than or equal to 6 milligrams, less than or equal to 5.5 milligrams, or less than or equal to 5 milligrams.

[0070] The total weight of flavourant in the aerosol-generating article may be between 2.5 milligrams and 10 milligrams, between 2.5 milligrams and 6 milligrams, between 2.5 milligrams and 5.5 milligrams, or between 2.5 milligrams and 5 milligrams. The total weight of flavourant inthe aerosol-generating article may be between 3 milligrams and 10 milligrams, between 3 milligrams and 6 milligrams, between 3 milligrams and 5.5 milligrams, or between 3 milligrams and 5 milligrams. The total weight of flavourant in the aerosol-generating article may be between 3 milligrams and 10 milligrams, between 3.5 milligrams and 6 milligrams, between 3.5 milligrams and 5.5 milligrams, or between 3.5 milligrams and 5 milligrams.

[0071] Where the aerosol-generating substrate comprises the plurality of microencapsulated flavourant particles, the total weight of flavourant in the aerosol-generating article discussed herein may apply to the total weight of flavourant in the aerosol-generating substrate.

[0072] The total weight of the microencapsulated flavourant particles in the aerosol-generating article may be at least 0.2 milligrams, or at least 0.5 milligrams. In particular, the total weight of the microencapsulated flavourant particles in the aerosol-generating article may be at least 1 milligram, at least 2 milligrams, or at least 3 milligrams.

[0073] The total weight of the microencapsulated flavourant particles in the aerosol-generating article may be less than or equal to 30 milligrams. In particular, the total weight of the microencapsulated flavourant particles in the aerosol-generating article may be less than or equal to 10 milligrams, less than or equal to 8 milligrams, less than or equal to 5 milligrams.

[0074] The total weight of the microencapsulated flavourant particles in the aerosol-generating article may be between 1 milligram and 30 milligrams, between 1 milligram and 10 milligrams, between 1 milligram and 8 milligrams, or between 1 milligram and 5 milligrams. The total weight of the microencapsulated flavourant particles in the aerosol-generating article may be between 2 milligrams and 30 milligrams, between 2 milligrams and 10 milligrams, between 2 milligrams and 8 milligrams, or between 2 milligrams and 5 milligrams. The total weight of the microencapsulated flavourant particles in the aerosol-generating article may be between 3 milligrams and 30 milligrams, between 3 milligrams and 10 milligrams, between 3 milligrams and 8 milligrams, or between 3 milligrams and 5 milligrams.

[0075] Increasing the total weight of the microencapsulated flavourant particles in the aerosolgenerating article may necessitate a reduction in the weight of another component or other components of the aerosol-generating article in order to maintain a desired total weight of the aerosol-generating article. In particular, where the plurality of microencapsulated flavourant particles are located within the aerosol-generating substrate, increasing the total weight of the microencapsulated flavourant particles may necessitate a reduction in the weight of the aerosolgenerating material in order to maintain a desired total weight of the aerosol-generating substrate. The total weight of the aerosol-generating substrate affects the density of the aerosol-generating substrate and may also affect the resistance to draw (RTD) of the aerosol-generating substrate.

[0076] The total weight of the microencapsulated flavourant particles in the aerosol-generating article discussed herein may provide a desired balance between the total weight of encapsulated flavourant and the weight of one or more other components of the aerosol-generating article. Accordingly, the total weight of the microencapsulated flavourant particles in the aerosol-generating article discussed herein may provide a desired balance between achieving a desired flavourant delivery profile and the density and resistance to draw of one or more other components of the aerosol-generating article and of the aerosol-generating article to provide an improved overall experience.

[0077] Where the aerosol-generating substrate comprises the plurality of microencapsulated flavourant particles, the total weight of the microencapsulated flavourant particles in the aerosolgenerating article discussed herein may apply to the total weight of the microencapsulated flavourant particles in the aerosol-generating substrate.

[0078] The aerosol-generating article may comprise at least 10, at least 50, or at least 100 microencapsulated flavourant particles.

[0079] The aerosol-generating article may comprise less than or equal to 1000, less than or equal to 500, or less than or equal to 300 microencapsulated flavourant particles.

[0080] The aerosol-generating article may comprise between 10 and 1000, between 10 and 500, or between 10 and 300 microencapsulated flavourant particles. The aerosol-generating article may comprise between 50 and 1000, between 50 and 500, or between 50 and 300 microencapsulated flavourant particles. The aerosol-generating article may comprise between 100 and 1000, between 100 and 500, or between 100 and 300 microencapsulated flavourant particles.

[0081] Where the aerosol-generating substrate comprises the plurality of microencapsulated flavourant particles, the number of microencapsulated flavourant particles in the aerosolgenerating article discussed herein may apply to the number of microencapsulated flavourant particles in the aerosol-generating substrate

[0082] The plurality of microencapsulated flavourant particles may have an average width of less than 500 micrometres. The plurality of microencapsulated flavourant particles may have an average width of less than or equal to 200 micrometres, less than or equal to 150 micrometres, or less than or equal to 100 micrometres.

[0083] The plurality of microencapsulated flavourant particles may have an average width of at least 1 micrometre, at least 10 micrometres, at least 20 micrometres, or at least 30 micrometres.

[0084] The plurality of microencapsulated flavourant particles may have an average width of between 1 micrometre and 500 micrometres, between 1 micrometre and 200 micrometres, between 1 micrometres and 150 micrometres, or between 1 micrometres and 100 micrometres. The plurality of microencapsulated flavourant particles may have an average width of between 10 micrometres and 500 micrometres, between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, or between 10 micrometres and 100 micrometres. The plurality of microencapsulated flavourant particles may have an average width of between 20 micrometres and 500 micrometres, between 20 micrometres and 200 micrometres, between 20 micrometres and 150 micrometres, or between 20 micrometres and 100 micrometres. The plurality of microencapsulated flavourant particles may have an average width of between 30micrometres and 500 micrometres, between 30 micrometres and 200 micrometres, between 30 micrometres and 150 micrometres, or between 30 micrometres and 100 micrometres.

[0085] As used herein, the average width of the plurality of microencapsulated flavourant particles is the arithmetic mean of the width of each of the microencapsulated flavourant particles.

[0086] The inclusion of flavourant in the aerosol-generating article in the form of microencapsulated flavourant particles having the widths discussed herein may advantageously simplify incorporation of the encapsulated flavourant in the aerosol-generating article. For example, the plurality of microencapsulated flavourant particles may be applied to aerosolgenerating material and distributed in the aerosol-generating substrate using existing machinery used to apply liquid flavourant to aerosol-generating material. The plurality of microencapsulated flavourant particles may be applied to aerosol generating material in the same process as the nonencapsulated flavourant is applied to the aerosol-generating material.

[0087] The microencapsulated flavourant particles may be characterised by a particle size distribution. The particle size distribution may have number D10, D50 and D90 particle sizes. The number D10 particle size is defined such that 10% of the particles have a particle size less than or equal to the number D10 particle size. Similarly, the number D50 particle size is defined such that 50% of the particles have a particle size less than or equal to the number D50 particle size. Thus, the number D50 particle size may be referred to as a median particle size. The number D90 particle size is defined such that 90% of the particles have a particles size less than or equal to the number D90 particle size. Thus, if there were 1,000 particles in the distribution and the particles were order by ascending particle size, one would expect the number D10 particle size to be roughly equal to the particle size of the 100th particle, the number D50 particle size to be roughly equal to the particle size of the 500th particle, and the number D90 particle size to be roughly equal to the particle size of the 900th particle.

[0088] Unless otherwise stated, the particle size distributions, such as D10, D50, D90, Dv10, Dv50 and Dv90, is measured using laser diffraction in accordance with IS013320:2020. With this technique, particles are dispersed in air or in liquid and illuminated by a laser beam. The resulting diffraction pattern is measured and converted into a particle size distribution using Mie or Fraunhofer optical models. The microencapsulated flavourant particles may have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is less than or equal to 200 micrometres, less than or equal to 150 micrometres, or less than or equal to 100 micrometres.

[0089] The microencapsulated flavourant particles may have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is at least 10 micrometres, at least 20 micrometres, or at least 30 micrometres

[0090] The microencapsulated flavourant particles may have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, or between 10 micrometresand 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is between 20 micrometres and 200 micrometres, between 20 micrometres and 150 micrometres, or between 20 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D10 particle size, wherein the number D10 particle size is between 30 micrometres and 200 micrometres, between 30 micrometres and 150 micrometres, or between 30 micrometres and 100 micrometres.

[0091] The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is less than or equal to 200 micrometres, less than or equal to 150 micrometres, or less than or equal to 100 micrometres.

[0092] The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is at least 10 micrometres, at least 20 micrometres, or at least 30 micrometres

[0093] The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, or between 10 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is between 20 micrometres and 200 micrometres, between 20 micrometres and 150 micrometres, or between 20 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D50 particle size is between 30 micrometres and 200 micrometres, between 30 micrometres and 150 micrometres, or between 30 micrometres and 100 micrometres.

[0094] The microencapsulated flavourant particles may have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is less than or equal to 200 micrometres, less than or equal to 150 micrometres, or less than or equal to 100 micrometres.

[0095] The microencapsulated flavourant particles may have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is at least 10 micrometres, at least 20 micrometres, or at least 30 micrometres

[0096] The microencapsulated flavourant particles may have a particle size distribution having a number D50 particle size, wherein the number D90 particle size is between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, or between 10 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D90 particle size, wherein the number D90 particle size is between 20 micrometres and 200 micrometres, between 20 micrometres and 150 micrometres, or between 20 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a number D90 particle size, wherein the number D90 particle sizeis between 30 micrometres and 200 micrometres, between 30 micrometres and 150 micrometres, or between 30 micrometres and 100 micrometres.

[0097] The particle size distribution may have Dv10, Dv50 and Dv90 particle sizes. The Dv10 particle size is defined such that 10% of the volume of the particles have a particle size less than or equal to the Dv10 particle size. Similarly, the Dv50 particle size is defined such that 50% of the volume of the particles have a particle size less than or equal to the Dv50 particle size. Thus, the Dv50 particle size may be referred to as a median particle size by volume. The Dv90 particle size is defined such that 90% of the volume of the particles have a particles size less than or equal to the Dv90 particle size.

[0098] The microencapsulated flavourant particles may have a particle size distribution having a Dv10 particle size of at least 10 micrometres, or at least 20 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv10 particle size of less than or equal to 200 micrometres, or less than or equal to 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv10 particle size between 10 micrometres and 200 micrometres, between 10 micrometres and 100 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv10 particle size between 20 micrometres and 200 micrometres, between 20 micrometres and 100 micrometres.

[0099] The microencapsulated flavourant particles may have a particle size distribution having a Dv50 particle size of at least 20 micrometres, or at least 40 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv50 particle size of less than or equal to 400 micrometres, or less than or equal to 200 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv50 particle size between 20 micrometres and 400 micrometres, between 20 micrometres and 200 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv50 particle size between 40 micrometres and 400 micrometres, between 40 micrometres and 200 micrometres.

[0100] The microencapsulated flavourant particles may have a particle size distribution having a Dv90 particle size of at least 40 micrometres, or at least 60 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv90 particle size of less than or equal to 500 micrometres, or less than or equal to 350 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv90 particle size between 40 micrometres and 500 micrometres, between 40 micrometres and 350 micrometres. The microencapsulated flavourant particles may have a particle size distribution having a Dv90 particle size between 60 micrometres and 500 micrometres, between 60 micrometres and 350 micrometres.

[0101] Each of the microencapsulated flavourant particles may have a width of less than 500 micrometres. Each of the microencapsulated flavourant particles may have a width of less thanor equal to 200 micrometres, less than or equal to 150 micrometres, or less than or equal to 100 micrometres.

[0102] Each of the microencapsulated flavourant particles may have a width of at least 1 micrometre, at least 10 micrometres, at least 20 micrometres, or at least 30 micrometres.

[0103] Each of the microencapsulated flavourant particles may have a width between 1 micrometre and 500 micrometres, between 1 micrometre and 200 micrometres, between 1 micrometres and 150 micrometres, or between 1 micrometres and 100 micrometres. Each of the microencapsulated flavourant particles may have a width of between 10 micrometres and 500 micrometres, between 10 micrometres and 200 micrometres, between 10 micrometres and 150 micrometres, or between 10 micrometres and 100 micrometres. Each of the microencapsulated flavourant particles may have a width of between 20 micrometres and 500 micrometres, between 20 micrometres and 200 micrometres, between 20 micrometres and 150 micrometres, or between 20 micrometres and 100 micrometres. Each of the microencapsulated flavourant particles may have a width of between 30 micrometres and 500 micrometres, between 30 micrometres and 200 micrometres, between 30 micrometres and 150 micrometres, or between 30 micrometres and 100 micrometres.

[0104] Each of the microencapsulated flavourant particles comprise a shell material and the encapsulated flavourant.

[0105] Each of the microencapsulated flavourant particles may comprise an inner core comprising the encapsulated flavourant contained within an outer shell of shell material. The outer shell may not comprise flavourant.

[0106] Each of the microencapsulated flavourant particles may comprise the encapsulated flavourant dispersed within a shell matrix of shell material. The encapsulated flavourant may be dispersed within the shell matrix in a plurality of vesicles. The shell matrix may have an open-cell or a closed-shell structure. The encapsulated flavourant may be irregularly dispersed within the shell matrix. The encapsulated flavourant may be provided in a plurality of vesicles. The vesicles may be of different sizes. The vesicles may have different shapes. The vesicles may have an irregular shape.

[0107] Each of the microencapsulated flavourant particles may comprise an inner core contained within an outer shell, and wherein the inner core comprises the encapsulated flavourant dispersed within a shell matrix. The structure of such microencapsulated flavourant particle may be referred to as a hybrid structure. The encapsulated flavourant may be dispersed within the shell matrix in a plurality of vesicles. The outer shell may not comprise flavourant. The shell material of the outer shell may be the same or different to the shell material of the shell matrix.

[0108] The outer shell entirely encloses the inner core.

[0109] The outer shell may have a laminate structure. This may be the case, for example, where a particle having a core-shell structure is further coated with another layer.

[0110] The microencapsulated flavourant particles may have an irregular shape.The plurality of microencapsulated flavourant particles may be formed using a spray drying, coacervation, interfacial polymerization, spray granulation, or spray coating process.

[0111] Preferably, the plurality of microencapsulated flavourant particles are formed using a coacervation. Particles formed using an electrostatic spray drying process may have a core-shell structure.

[0112] Where the plurality of microencapsulated flavourant particles are formed using a spray drying process, the spray drying process is an electrostatic spray drying process. A spray drying process typically involves spraying a liquid composition comprising a solvent and a solute or a suspension into a drying chamber, wherein the solvent is rapidly evaporated in the drying chamber to leave the solute or suspension in the form of microparticles. Forming the plurality of microencapsulated flavourant particles using a spray drying process may be a convenient and cost-effective process for forming the particles. Spray drying processes suitable for forming the microencapsulated flavourant particles according to the present disclosure are known within the food industry, for example, and the skilled person can select a suitable spray drying process depending on the particular materials used to form the microencapsulated flavourant particles. Particles formed using a spray drying process may have a matrix-type structure. An electrostatic spray drying process typically involves applying a high voltage electric field to induce a phase separation between polar molecules and non-polar molecules. Nonpolar molecules are pushed inwards while polar molecules migrate to the outside of the particle. The shell material are typically polar and may be aqueous-based. The flavourant may be non-polar. Electrostatic spray drying processes may be carried out at lower temperatures compared to conventional spray drying processes. Electrostatic spray drying processes may be particularly advantageous for the microencapsulated flavourant particles according to the present disclosure since the flavourant used for aerosol-generating articles are typically highly volatile. Carrying out the encapsulation process at a lower temperature may advantageously minimise or avoid loss of flavourant. A suitable machine for electrostatic spray drying is commercially available from Fluid Air under the name PolarDry®. Particles formed using an electrostatic spray drying process may have a coreshell structure. The core may have a matrix-type structure.

[0113] Preferably, the plurality of microencapsulated flavourant particles is formed using a spray coating process, such as a spouted bed spray coating process. This may be in addition to a spray drying, coacervation, interfacial polymerization, or spray granulation process.

[0114] The plurality of microencapsulated flavourant particles have preferably undergone a drying process.

[0115] The plurality of microencapsulated flavourant particles may have a water activity (Aw) of less than or equal to 0.6, less than or equal to 0.5, or less than or equal to 0.4.

[0116] The plurality of microencapsulated flavourant particles may be referred to as a plurality of microencapsulated flavourant powder particles.Preferably, each of the microencapsulated flavourant particles comprises an outer shell enclosing an inner core containing flavourant. Compared to microencapsulated flavourant particles having a matrix-type structure without an outer shell, encapsulated flavourant in microencapsulated flavourant particles having an outer shell may be located further away from the external surface of the microencapsulated flavourant particles. The provision of each of the microencapsulated flavourant particles with an outer shell may advantageously facilitate delayed release of the encapsulated flavourant for sustained and consistent flavour delivery profile.

[0117] The inner core may be a liquid inner core or the inner core may have a matrix-type structure in which the flavourant is dispersed within a shell matrix.

[0118] As discussed above, the microencapsulated flavourant particles may have an outer shell enclosing an inner core, wherein the inner core comprises the flavourant dispersed within a shell matrix, where the microencapsulated flavourant particles are formed from an electrostatic spray drying process. This may also be the case where a matrix-type particle is coated with shell material. Accordingly, a central region of the microencapsulated flavourant particle may comprise a majority of the flavourant in the particle.

[0119] Each of the microencapsulated flavourant particles may comprise a central region containing at least 90 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle. In other words, each of the microencapsulated flavourant particles may comprise a central region comprising the encapsulated flavourant, wherein the encapsulated flavourant in the central region has a weight of at least 90 percent of the total weight of the encapsulated flavourant in the entire microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle.

[0120] Each of the microencapsulated flavourant particles may comprise a central region containing at least 95 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle.

[0121] Each of the microencapsulated flavourant particles may comprise a central region containing at least 90 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 70 percent of the volume of the microencapsulated flavourant particle.

[0122] Each of the microencapsulated flavourant particles may comprise a central region containing at least 95 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 70 percent of the volume of the microencapsulated flavourant particle.The plurality of microencapsulated flavourant particles may comprise at least 5 percent, at least 10 percent, at least 15 percent, or at least 20 percent by weight of flavourant on a dry weight basis.

[0123] The plurality of microencapsulated flavourant particles may comprise less than or equal to 50 percent, less than or equal to 45 percent, less than or equal to 40 percent, less than or equal to 35 percent, or less than or equal to 30 percent by weight of flavourant on a dry weight basis.

[0124] The plurality of microencapsulated flavourant particles may comprise between 5 percent and 50 percent, between 5 percent and 45 percent, between 5 percent and 35 percent, or between 5 percent and 30 percent by weight of flavourant on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 10 percent and 50 percent, between 10 percent and 45 percent, between 10 percent and 40 percent, between 10 percent and 35 percent, or between 10 percent and 30 percent by weight of flavourant on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 15 percent and 50 percent, between 15 percent and 45 percent, between 15 percent and 40 percent, between 15 percent and 35 percent, or between 15 percent and 30 percent by weight of flavourant on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 20 percent and 50 percent, between 20 percent and 45 percent, between 20 percent and 40 percent, between 20 percent and 35 percent, or between 20 percent and 30 percent by weight of flavourant on a dry weight basis.

[0125] The proportion of encapsulated flavourant in the plurality of microencapsulated flavourant particles described herein may provide a controlled release of a desired amount of flavourant at a desired temperature to achieve a sustained flavour delivery profile.

[0126] The plurality of microencapsulated flavourant particles may comprise at least 15 percent, at least 20 percent, or at least 25 percent by weight of shell material on a dry weight basis.

[0127] The plurality of microencapsulated flavourant particles may comprise less than or equal to 45 percent, less than or equal to 40 percent, or less than or equal to 35 percent by weight of shell material on a dry weight basis. This may particularly be applicable to microencapsulated flavourant particles comprising an inner core comprising encapsulated flavourant contained within an outer shell. Such microencapsulated flavourant particles may comprise a solvent for solubilising the flavourant. The microencapsulated flavourant particles may comprise a lipophilic phase comprising the solvent and the flavourant.

[0128] The plurality of microencapsulated flavourant particles may comprise between 15 percent and 45 percent, between 15 percent and 40 percent, or between 15 percent and 35 percent by weight of shell material. The plurality of microencapsulated flavourant particles may comprise between 20 percent and 45 percent, between 20 percent and 40 percent, or between 20 percent and 35 percent by weight of shell material on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 25 percent and 45 percent,between 25 percent and 40 percent, or between 25 percent and 35 percent by weight of shell material.

[0129] The plurality of microencapsulated flavourant particles may comprise at least 50 percent, at least 60 percent, or at least 70 percent by weight of shell material. This may particularly be applicable to microencapsulated flavourant particles comprising encapsulated flavourant dispersed within a shell matrix.

[0130] The plurality of microencapsulated flavourant particles may comprise less than or equal to 90 percent, less than or equal to 85 percent, or less than or equal to 80 percent by weight of shell material on a dry weight basis.

[0131] The plurality of microencapsulated flavourant particles may comprise between 50 percent and 90 percent, between 50 percent and 85 percent, or between 50 percent and 80 percent by weight of shell material on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 60 percent and 90 percent, between 60 percent and 85 percent, or between 60 percent and 80 percent by weight of shell material on a dry weight basis. The plurality of microencapsulated flavourant particles may comprise between 70 percent and 90 percent, between 70 percent and 85 percent, or between 70 percent and 80 percent by weight of shell material on a dry weight basis.

[0132] Each of the microencapsulated flavourant particles may be thermally stable at temperatures up to 100 degrees Celsius, up to 120 degrees Celsius, or up to 150 degrees Celsius. Each of the microencapsulated flavourant particles may be configured to retain the encapsulated flavourant at temperatures up to 100 degrees Celsius, up to 120 degrees Celsius, or up to 150 degrees Celsius. Retention of the encapsulated flavourant until the microencapsulated flavourant particles reach at least the specific temperatures discussed herein may avoid release of the encapsulated flavourant during early puffs when nonencapsulated flavourant are being volatilised and delivered to a user. The encapsulated flavourant may be released and volatilised at a later stage when the level of nonencapsulated flavourant in the aerosol-generating article and the level of nonencapsulated flavourant being delivered to a user through a puff have dropped. This may advantageously result in a sustained delivery of flavourant to a user to provide a desired user experience throughout the entire user experience.

[0133] Each of the microencapsulated flavourant particles may be configured to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature above 100 degrees Celsius, above 120 degrees Celsius, or above 150 degrees Celsius. Release of the encapsulated flavourant when the microencapsulated flavourant particles reach the specific temperatures discussed herein may avoid release of the encapsulated flavourant during early puffs when nonencapsulated flavourant are being volatilised and delivered to a user. Instead, release of the encapsulated flavourant at the specific temperatures discussed herein may result in release and volatilisation of the encapsulated flavourant during later puffs when the levels of nonencapsulated flavourant being delivered to a user has decreased. This may advantageouslyresult in a sustained delivery of flavourant to a user to provide a desired user experience throughout the entire user experience.

[0134] Each of the microencapsulated flavourant particles may be configured to retain the encapsulated flavourant at temperatures up to 100 degrees Celsius and to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature above 100 degrees Celsius. Each of the microencapsulated flavourant particles may be configured to retain the encapsulated flavourant at temperatures up to 120 degrees Celsius and to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature of above 120 degrees Celsius. Each of the microencapsulated flavourant particles may be configured to retain the encapsulated flavourant at temperatures up to 150 degrees Celsius and to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature above 150 degrees Celsius.

[0135] Each of the microencapsulated flavourant particles may be configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes when the microencapsulated flavourant particle is at a temperature of at least 100 degrees Celsius. Each of the microencapsulated flavourant particles may be configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes when the microencapsulated flavourant particle is at a temperature of at least 120 degrees Celsius. Each of the microencapsulated flavourant particles may be configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes when the microencapsulated flavourant particle is at a temperature of at least 150 degrees Celsius. Retention of the encapsulated flavourant when the microencapsulated flavourant particles are at the specific temperatures discussed herein for at least three minutes may result in delayed release of the encapsulated flavourant such that the aerosol-generating article has a sustained flavourant delivery profile.

[0136] The plurality of microencapsulated flavourant particles may be configured to release the encapsulated flavourant at temperatures usually reached by an aerosol-generating article that is configured to be heated and not burned to generate an inhalable aerosol. Each of the microencapsulated flavourant particles may be configured to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature below 300 degrees Celsius, below 280 degrees Celsius, or below 250 degrees Celsius.

[0137] The plurality of microencapsulated flavourant particles may be configured to release the encapsulated flavourant through melting, rupturing and decomposition of the shell material upon heating of the microencapsulated flavourant particles. For example, the plurality of microencapsulated flavourant particles may comprise an inner core comprising encapsulated flavourant and an outer shell, wherein the inner core is configured to expand more than the outer shell upon heating of the microencapsulated flavourant particles such that the outer shell ruptures to release the encapsulated flavourant.Each of the microencapsulated flavourant particles may comprise shell material having a melting point of at least 100 degrees Celsius, at least 120 degrees Celsius, or at least 150 degrees Celsius.

[0138] Each of the microencapsulated flavourant particles may comprise shell material having a melting point of less than or equal to 300 degrees Celsius, less than or equal to 280 degrees Celsius, or less than or equal to 250 degrees Celsius.

[0139] Each of the microencapsulated flavourant particles may comprise shell material having a melting point of between 100 degrees Celsius and 300 degrees Celsius, between 100 degrees Celsius and 280 degrees Celsius, or between 100 degrees Celsius and 250 degrees Celsius.

[0140] The melting points of the shell material discussed herein may advantageously result in a desired flavourant delivery profile during use of the aerosol-generating article.

[0141] The shell material may comprise: a polysaccharide-based material, such as starch, a modified starch such as Hi-cap® 100, alginate, pectin, or maltodextrin; hydroxylpropylcellulose (HPC), hydroxypropylmethylcellulose (HPMC); Gum Arabic; guar gum; gelatin; waxes, such as a paraffin wax, carnauba wax; or combinations thereof.

[0142] The shell material may be selected such that it has biocompatibility suitable for inclusion in aerosol-generating articles.

[0143] The shell material may be insoluble in one or both of propylene glycol and glycerine. Preferably, the shell material is insoluble in propylene glycol.

[0144] The nonencapsulated flavourant may comprise: menthol, limonene, linalool, geraniol, vanillin, ethyl acetate, acetaldehyde, or combinations thereof.

[0145] The encapsulated flavourant may comprise: menthol, limonene, linalool, geraniol, vanillin, ethyl acetate, acetaldehyde, or combinations thereof. Preferably, the encapsulated flavourant comprises limonene, linalool, geraniol, or combinations thereof. Limonene, linalool, geraniol are highly volatile and therefore encapsulation may advantageously avoid or reduce loss of these flavourants during storage of the aerosol-generating article and depletion of these flavourants soon after initiation of heating of the aerosol-generating article.

[0146] The nonencapsulated flavourant may be a non-tobacco nonencapsulated flavourant. In other words, the nonencapsulated flavourant may not comprise tobacco and any tobacco in the aerosol-generating substrate is provided as a separate component to the nonencapsulated flavourant.

[0147] The nonencapsulated flavourant may not comprise tobacco particles. The nonencapsulated flavourant may not comprise tobacco extract. The nonencapsulated flavourant may not comprise tobacco particles or tobacco extract.

[0148] The encapsulated flavourant may not comprise tobacco particles. The encapsulated flavourant may not comprise tobacco extract. The nonencapsulated flavourant may not comprise tobacco particles or tobacco extract.The nonencapsulated flavourant may be the same or different to the encapsulated flavourant.

[0149] Each of the microencapsulated flavourant particles may comprise a single encapsulated flavourant or two or more different encapsulated flavourants. Preferably, each of the microencapsulated flavourant particles comprise less than or equal to 10 encapsulated flavourants, less than or equal to 8 encapsulated flavourants, or less than or equal to 6 encapsulated flavourants. Minimising the number of encapsulated flavourants may facilitate manufacture of the microencapsulated flavourant particles. For example, it may be easier to solubilise all of the encapsulated flavourants.

[0150] The aerosol-generating article may comprise less than or equal to 10 encapsulated flavourants, less than or equal to 8 encapsulated flavourants, or less than or equal to 6 encapsulated flavourants.

[0151] The nonencapsulated flavourant may be a liquid nonencapsulated flavourant. The encapsulated flavourant may be a liquid encapsulated flavourant.

[0152] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a boiling point of less than or equal to 300 degrees Celsius, less than or equal to 280 degrees Celsius, or less than or equal to 250 degrees Celsius. These boiling points may be particularly applicable to the encapsulated flavourant.

[0153] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a boiling point of at least 30 degrees Celsius, at least 90 degrees Celsius, or at least 150 degrees Celsius. These boiling points may be particularly applicable to the encapsulated flavourant.

[0154] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a boiling point of between 30 degrees Celsius and 300 degrees Celsius, between 30 degrees Celsius and 280 degrees Celsius, or between 30 degrees Celsius and 250 degrees Celsius. One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a boiling point of between 90 degrees Celsius and 300 degrees Celsius, between 90 degrees Celsius and 280 degrees Celsius, or between 90 degrees Celsius and 250 degrees Celsius. One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a boiling point of between 120 degrees Celsius and 300 degrees Celsius, between 120 degrees Celsius and 280 degrees Celsius, or between 120 degrees Celsius and 250 degrees Celsius.

[0155] The total weight of flavourant in the aerosol-generating article having a boiling point as described above may be at least 10 percent of the total weight of flavourant in the aerosolgenerating article.

[0156] When one or both of the nonencapsulated flavourant and the encapsulated flavourant has a boiling point as described above, the total weight of flavourant in the aerosol-generating article having the same boiling point may be at least 10 percent of the total weight of flavourant in the aerosol-generating articleThe encapsulated flavourant may have a boiling point of less than or equal to 250 degrees Celsius, less than or equal to 200 degrees Celsius, or less than or equal to 190 degrees Celsius.

[0157] The encapsulated flavourant may have a boiling point of at least 40 degrees Celsius, at least 50 degrees Celsius, or at least 60 degrees Celsius.

[0158] The encapsulated flavourant may have a boiling point of between 40 degrees Celsius and 250 degrees Celsius, between 40 degrees Celsius and 200 degrees Celsius, or preferably between 40 degrees Celsius and 190 degrees Celsius. The encapsulated flavourant may have a boiling point of between 50 degrees Celsius and 250 degrees Celsius, between 50 degrees Celsius and 200 degrees Celsius, or preferably between 50 degrees Celsius and 190 degrees Celsius. The encapsulated flavourant may have a boiling point of between 60 degrees Celsius and 250 degrees Celsius, between 60 degrees Celsius and 200 degrees Celsius, or preferably between 60 degrees Celsius and 190 degrees Celsius.

[0159] The total weight of flavourant in the aerosol-generating article having a boiling point as described above may be at least 10 percent of the total weight of flavourant in the aerosolgenerating article.

[0160] When the encapsulated flavourant has a boiling point as described above, the total weight of flavourant in the aerosol-generating article having the same boiling point may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0161] For example, when the encapsulated flavourant has a boiling point of at least 40 degrees Celsius, a total weight of flavourant having a boiling point of at least 40 degrees Celsius may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0162] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a vapour pressure of at least 0.05 mmHg at 20 degrees Celsius, at least 0.1 mmHg at 20 degrees Celsius, or at least 0.15 mmHg at 20 degrees Celsius, or at least 0.5 mmHg at 20 degrees Celsius. These vapour pressures may be particularly applicable to the encapsulated flavourant.

[0163] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a vapour pressure of less than or equal to 1000 mmHg at 20 degrees Celsius, less than or equal to 500 mmHg at 20 degrees Celsius, or less than or equal to 100 mmHg at 20 degrees Celsius. These vapour pressures may be particularly applicable to the encapsulated flavourant.

[0164] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a vapour pressure of between 0.05 mmHg and 1000 mmHg at 20 degrees Celsius, between 0.1 mmHg and 1000 mmHg at 20 degrees Celsius, between 0.15 mmHg and 1000 mmHg at 20 degrees Celsius, or between 0.5 mmHg and 1000 mmHg at 20 degrees Celsius.

[0165] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a vapour pressure of between 0.05 mmHg and 500 mmHg at 20 degrees Celsius, between 0.1 mmHg and 500 mmHg at 20 degrees Celsius, between 0.15 mmHg and 500 mmHg at 20 degrees Celsius, or between 0.5 mmHg and 500 mmHg at 20 degrees Celsius.One or both of the nonencapsulated flavourant and the encapsulated flavourant may have a vapour pressure of between 0.05 mmHg and 100 mmHg at 20 degrees Celsius, between 0.1 mmHg and 100 mmHg at 20 degrees Celsius, between 0.15 mmHg and 100 mmHg at 20 degrees Celsius, or between 0.5 mmHg and 100 mmHg at 20 degrees Celsius.

[0166] The total weight of flavourant in the aerosol-generating article having a vapour pressure as described above may be at least 10 percent of the total weight of flavourant in the aerosolgenerating article.

[0167] When one or both of the nonencapsulated flavourant and the encapsulated flavourant has a vapour pressure as described above, the total weight of flavourant in the aerosol-generating article having the same vapour pressure may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0168] The encapsulated flavourant may have a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius, at least 0.75 mmHg at 20 degrees Celsius, or at least 0.85 mmHg at 20 degrees Celsius, or at least 1 mmHg at 20 degrees Celsius.

[0169] The encapsulated flavourant may have a vapour pressure of less than or equal to 100 mmHg at 75 degrees Celsius, less than or equal to 50 mmHg at 20 degrees Celsius, or less than or equal to 20 mmHg at 20 degrees Celsius.

[0170] The encapsulated flavourant may have a vapour pressure of between 0.5 mmHg and 100 mmHg at 20 degrees Celsius, between 0.75 mmHg and 100 mmHg at 20 degrees Celsius, between 0.85 mmHg and 100 mmHg at 20 degrees Celsius, or between 1 mmHg and 100 mmHg at 20 degrees Celsius.

[0171] The encapsulated flavourant may have a vapour pressure of between 0.5 mmHg and 75 mmHg at 20 degrees Celsius, between 0.75 mmHg and 75 mmHg at 20 degrees Celsius, between 0.85 mmHg and 75 mmHg at 20 degrees Celsius, or between 1 mmHg and 75 mmHg at 20 degrees Celsius.

[0172] The encapsulated flavourant may have a vapour pressure of between 0.5 mmHg and 50 mmHg at 20 degrees Celsius, between 0.75 mmHg and 50 mmHg at 20 degrees Celsius, between 0.85 mmHg and 50 mmHg at 20 degrees Celsius, or between 1 mmHg and 50 mmHg at 20 degrees Celsius.

[0173] The encapsulated flavourant may have a vapour pressure of between 0.5 mmHg and 20 mmHg at 20 degrees Celsius, between 0.75 mmHg and 20 mmHg at 20 degrees Celsius, between 0.85 mmHg and 20 mmHg at 20 degrees Celsius, or between 1 mmHg and 20 mmHg at 20 degrees Celsius.

[0174] The encapsulated flavourant may have a vapour pressure greater than the vapour pressure of the nonencapsulated flavourant. The encapsulated flavourant may have a vapour pressure at 20 degrees Celsius greater than the vapour pressure of the nonencapsulated flavourant at 20 degrees Celsus.The total weight of flavourant in the aerosol-generating article having a vapour pressure as described above may be at least 10 percent of the total weight of flavourant in the aerosolgenerating article.

[0175] When the encapsulated flavourant has a vapour pressure as described above, the total weight of flavourant in the aerosol-generating article having the same vapour pressure may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0176] For example, when the encapsulated flavourant has a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius, a total weight of flavourant having a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0177] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have an enthalpy of vaporization of less than or equal to 150 kilojoules per mole, less than or equal to 120 kilojoules per mole, or less than or equal to 100 kilojoules per mole. These enthalpy of vaporizations may be particularly applicable to the encapsulated flavourant.

[0178] One or both of the nonencapsulated flavourant and the encapsulated flavourant may have an enthalpy of vaporization of at least 5 kilojoules per mole, at least 8 kilojoules per mole, or at least 10 kilojoules per mole. These enthalpy of vaporizations may be particularly applicable to the encapsulated flavourant.

[0179] One or both of the nonencapsulated flavourant and the encapsulated flavourant may may have an enthalpy of vaporization of between 5 kilojoules per mole and 150 kilojoules per mole, between 5 kilojoules per mole and 120 kilojoules per mole, or between 5 kilojoules per mole and 100 kilojoules per mole. One or both of the nonencapsulated flavourant and the encapsulated flavourant may may have an enthalpy of vaporization of between 8 kilojoules per mole and 150 kilojoules per mole, between 8 kilojoules per mole and 120 kilojoules per mole, or between 8 kilojoules per mole and 100 kilojoules per mole. One or both of the nonencapsulated flavourant and the encapsulated flavourant may may have an enthalpy of vaporization of between 10 kilojoules per mole and 150 kilojoules per mole, between 10 kilojoules per mole and 120 kilojoules per mole, or between 10 kilojoules per mole and 100 kilojoules per mole.

[0180] The total weight of flavourant in the aerosol-generating article having an enthalpy of vaporization as described above may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0181] When one or both of the nonencapsulated flavourant and the encapsulated flavourant has an enthalpy of vaporization as described above, the total weight of flavourant in the aerosolgenerating article having the same an enthalpy of vaporization may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.The encapsulated flavourant may have an enthalpy of vaporization of less than or equal to 100 kilojoules per mole, less than or equal to 85 kilojoules per mole, or less than or equal to 70 kilojoules per mole.

[0182] The encapsulated flavourant may have an enthalpy of vaporization of at least 10 kilojoules per mole, at least 20 kilojoules per mole, or at least 25 kilojoules per mole.

[0183] The encapsulated flavourant may may have an enthalpy of vaporization of between 10 kilojoules per mole and 100 kilojoules per mole, between 10 kilojoules per mole and 85 kilojoules per mole, or between 10 kilojoules per mole and 70 kilojoules per mole.

[0184] The encapsulated flavourant may may have an enthalpy of vaporization of between 20 kilojoules per mole and 100 kilojoules per mole, between 20 kilojoules per mole and 85 kilojoules per mole, or between 20 kilojoules per mole and 70 kilojoules per mole.

[0185] The encapsulated flavourant may may have an enthalpy of vaporization of between 25 kilojoules per mole and 100 kilojoules per mole, between 25 kilojoules per mole and 85 kilojoules per mole, or between 25 kilojoules per mole and 70 kilojoules per mole.

[0186] The enthalpy of vaporization of the encapsulated flavourant may be less than the enthalpy of vaporization of the nonencapsulated flavourant.

[0187] The total weight of flavourant in the aerosol-generating article having an enthalpy of vaporization as described above may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0188] When the encapsulated flavourant has an enthalpy of vaporization as described above, the total weight of flavourant in the aerosol-generating article having the same an enthalpy of vaporization may be at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0189] For example, when the encapsulated flavourant has an enthalpy of vaporization of at least 10 kilojoules per mole, a total weight of flavourant having an enthalpy of vaporization of at least 10 kilojoules per mole may be at least 10 percent of the total weight of flavourant in the aerosolgenerating article.

[0190] One or both of the nonencapsulated flavourant and the encapsulated flavourant may be lipophilic. Preferably, the encapsulated flavourant is lipophilic.

[0191] The encapsulated flavourant may be in a solution. This may be particularly useful where the encapsulated flavourant has a relatively high melting point. In particular, this may be useful where the encapsulated flavourant is solid at room temperature. As used herein, the term “room temperature” is used to describe a temperature between 20 degrees Celsius and 30 degrees Celsius. The encapsulated flavourant being in a solution may be particularly useful where the encapsulated flavourant is vanillin.

[0192] Each of the microencapsulated flavourant particles may comprise one or more encapsulated flavourants in a solution.The solution may comprise a homogenisation solvent. The encapsulated flavourant may be dissolved in the homogenisation solvent. Where the plurality of microencapsulated flavourant particles comprise a plurality of encapsulated flavourants, at least two, but preferably all, of the encapsulated flavourants are dissolved in the homogenisation solvent. Each of the plurality of microencapsulated flavourant particles may comprise one or more encapsulated flavourants dissolved in the homogenisation solvent.

[0193] Preferably, the homogenisation solvent is lipophilic.

[0194] The solution may be lipophilic. Such a solution may be referred to as a lipophilic phase of the microencapsulated flavourant particle. Each of the microencapsulated flavourant particles may comprise a lipophilic phase comprising the encapsulated flavourant. This may particularly be the case where each of the plurality of microencapsulated flavourant particles comprise an inner core comprising the flavourant contained within an outer shell. The inner core may be formed of the lipophilic phase. For example, each of the microencapsulated flavourant particles may comprise an inner core of a lipophilic phase contained within an outer shell, wherein the lipophilic phase comprises the flavourant.

[0195] Each of the plurality of microencapsulated flavourant particles may comprise the encapsulated flavourant in a solution in a lipophilic phase. Each of the plurality of microencapsulated flavourant particles may comprise one or more encapsulated flavourants in a solution in a lipophilic phase.

[0196] The lipophilic phase may comprise the homogenisation solvent. The encapsulated flavourant may be dissolved in the homogenisation solvent. Where the plurality of microencapsulated flavourant particles comprise a plurality of encapsulated flavourants, at least two, but preferably all, of the encapsulated flavourants are dissolved in the homogenisation solvent. Each of the plurality of microencapsulated flavourant particles may comprise one or more encapsulated flavourants dissolved in the homogenisation solvent.

[0197] The homogenisation solvent may be an alcohol, such as propylene glycol and benzyl alcohol.

[0198] The homogenisation solvent may be selected such that it has biocompatibility suitable for inclusion in aerosol-generating articles. The homogenisation solvent may not be or comprise medium chain triglycerides (MCT). The plurality of microencapsulated flavourant particles may not comprise medium chain triglycerides. The aerosol-generating article may not comprise medium chain triglycerides.

[0199] Where each of the microencapsulated flavourant particles comprise a plurality of encapsulated flavourants, one or more of the encapsulated flavourants may act as a homogenisation solvent. This may particularly be the case where each of the microencapsulated flavourant particles comprise at least one of menthol and limonene. Menthol and limonene can serve as both flavourant and solvent. Each of the microencapsulated flavourant particles may comprise an encapsulated flavourant dissolved in at least one of menthol and limonene. Whereeach of the microencapsulated flavourant particles comprise menthol and one or more encapsulated flavourants in a solution, the solution may comprise at least 50 percent, or at least 60 percent, or at least 70 percent by weight of menthol. Where each of the microencapsulated flavourant particles comprise limonene and one or more encapsulated flavourants in a solution, the solution may comprise at least 50 percent, or at least 60 percent, or at least 70 percent by weight of limonene.

[0200] One or more encapsulated flavourants acting as a homogenisation solvent may advantageously avoid the need for a non-flavourant homogenisation solvent. This may advantageously increase the concentration of flavourants in the plurality of microencapsulated flavourant particles and reduce the average size and the total weight of the plurality of microencapsulated flavourant particles.

[0201] The plurality of microencapsulated flavourant particles may be located within the aerosolgenerating substrate. Typically, the heating element of an aerosol-generating device is configured to be aligned with the aerosol-generating substrate of the aerosol-generating article when the aerosol-generating article is inserted into the aerosol-generating device during use of the aerosolarticle. Placement of the plurality of microencapsulated flavourant particles within the aerosolgenerating substrate may advantageously simplify optimisation of the release and delivery profile of the encapsulated flavourant. Incorporation of the plurality of microencapsulated flavourant particles within the aerosol-generating substrate may be through a process already being carried out to form the aerosol-generating substrate, such as a spraying process to include aerosol former in the aerosol-generating substrate. This may simplify manufacturing of the aerosol-generating article.

[0202] Preferably, the plurality of microencapsulated flavourant particles is dispersed within the aerosol-generating substrate.

[0203] The plurality of microencapsulated flavourant particles may be located along substantially the entire length of the aerosol-generating substrate.

[0204] The plurality of microencapsulated flavourant particles may be dispersed substantially evenly within the aerosol-generating substrate.

[0205] The plurality of microencapsulated flavourant particles may be dispersed within the aerosol-generating substrate using existing machinery used to apply liquid flavourant to aerosolgenerating material. The plurality of microencapsulated flavourant particles may be applied to aerosol-generating material using existing machinery used to apply liquid flavourant to aerosolgenerating material. The plurality of microencapsulated flavourant particles may be applied to the aerosol-generating material using the same machinery used to apply the nonencapsulated flavourant to the aerosol-generating material.

[0206] The plurality of microencapsulated flavourant particles may be dispersed within the aerosol-generating substrate using existing machinery used to apply aerosol former to aerosolgenerating material. The plurality of microencapsulated flavourant particles may be applied toaerosol-generating material using existing machinery used to apply aerosol former to aerosolgenerating material.

[0207] The plurality of microencapsulated flavourant particles may be dispersed in one or more aerosol formers for applying, such as by spraying, onto aerosol-generating material, such as homogenised tobacco material. The provision of flavourant in encapsulated form through the plurality of microencapsulated flavourant particles may advantageously avoid dissolution of the encapsulated flavourant in the one or more aerosol formers. Preferably, the plurality of microencapsulated flavourant particles may be dispersed in propylene glycol, and optionally glycerine, for spraying onto aerosol-generating material, such as homogenised tobacco material.

[0208] The plurality of microencapsulated flavourant particles may be dispersed in one or more aerosol formers for spraying onto one or more sheets of aerosol-generating material, such as one or more sheets of tobacco material. The one or more sheets of aerosol-generating material may have been crimped.

[0209] The aerosol-generating article may comprise the plurality of microencapsulated flavourant particles dispersed in one or more aerosol formers within the aerosol-generating substrate. Preferably, the one or more aerosol formers comprise propylene glycol. The one or more aerosol formers may comprise glycerine. The one or more aerosol formers may comprise both propylene glycol and glycerine.

[0210] Each of the microencapsulated flavourant particles may have one or more aerosol formers disposed on at least a part of the external surface of the microencapsulated flavourant particle. Each of the microencapsulated flavourant particles may have one or more aerosol formers disposed on a majority of the external surface of the microencapsulated flavourant particle. The one or more aerosol formers may be disposed on the entirety of the external surface of the microencapsulated flavourant particle. Preferably, the one or more aerosol formers comprise propylene glycol. The one or more aerosol formers may comprise glycerine. The one or more aerosol formers may comprise both propylene glycol and glycerine.

[0211] The plurality of microencapsulated flavourant particles may be dispersed in a solution comprising one or more aerosol formers and a binder for applying, such as by spraying, onto aerosol-generating material, such as homogenised tobacco material. The binder may advantageously enhance adhesion of the plurality of microencapsulated flavourant particles to the aerosol-generating material.

[0212] Each of the of the microencapsulated flavourant particles may have a binder disposed on at least a part of the external surface of the microencapsulated flavourant particle. The aerosol former may be disposed on the entirety of the external surface of the microencapsulated flavourant particle.

[0213] Each of the microencapsulated flavourant particles may be adhered to the aerosolgenerating material. Each of the microencapsulated flavourant particles may be adhered to the aerosol-generating material by a binder.The aerosol-generating substrate comprises aerosol-generating material in addition to nonencapsulated flavourant.

[0214] The nonencapsulated flavourant may be in the form of a liquid. For example, the aerosolgenerating substrate may comprise solid aerosol-generating material and liquid nonencapsulated flavourant.

[0215] The aerosol-generating substrate may be in the form of a rod. As used herein, the term “rod” is used to denote a generally cylindrical element having a substantially circular, oval or elliptical cross-section.

[0216] The aerosol-generating substrate may comprise aerosol-generating material circumscribed by a wrapper, such as a plug wrap. For example, the aerosol-generating substrate may comprise aerosol-generating material circumscribed by a wrapper to form a rod.

[0217] The aerosol-generating substrate may have a length of at least 8 millimetres, at least 9 millimetres, or at least 10 millimetres. The aerosol-generating substrate may have a length of less than or equal to 16 millimetres, less than or equal to 15 millimetres, or less than or equal to 14 millimetres.

[0218] Preferably, the aerosol-generating substrate has a substantially circular cross-section. The aerosol-generating substrate may have an external diameter of at least 5 millimetres, 6 millimetres, or 7 millimetres. The aerosol-generating substrate may have an external diameter of less than or equal to 12 millimetres, less than or equal to 10 millimetres, or less than or equal to 8 millimetres.

[0219] The resistance to draw (RTD) of the aerosol-generating substrate may be at least 4 millimetres H2O, at least 5 millimetres H2O, or at least 6 millimetres H2O. The RTD of the aerosolgenerating substrate may be less than or equal to 10 millimetres H2O, less than or equal to 9 millimetres H2O, or less than or equal to 8 millimetres H2O.

[0220] 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 or downstream 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%.

[0221] The aerosol-generating substrate may comprise solid aerosol-generating material. The aerosol-generating substrate may be a solid aerosol-generating substrate.

[0222] The aerosol-generating substrate preferably comprises an aerosol former.

[0223] 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 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 ofmono-, di- or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0224] 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.

[0225] The aerosol-generating substrate may comprise at least 5 percent, at least 10 percent, or at least 12 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate. The aerosol-generating substrate may comprise less than or equal to 30 percent, less than or equal to 25 percent, or less than or equal to 20 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate.

[0226] The aerosol-generating substrate preferably comprises nicotine.

[0227] The aerosol-generating material of the aerosol-generating substrate may be tobacco material. Accordingly, the aerosol-generating substrate may comprise tobacco material. The tobacco material may be homogenised tobacco material. As used herein, the term “homogenised tobacco material” is used to describe material formed by agglomerating particulate tobacco material.

[0228] The aerosol-generating substrate may comprise a plurality of shreds of tobacco material, such as homogenised tobacco material. As used herein, the term “shred” denotes an element having a length substantially greater than a width and a thickness thereof. 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.

[0229] The shreds of tobacco material may have a width of at least 0.3 millimetres, at least 0.5 millimetres, or at least 0.6 millimetres. The shreds of tobacco material may have a width of less than or equal to 2 millimetres, less than or equal to 1.2 millimetres, or less than 0.9 millimetres.

[0230] The shreds of tobacco material may have a length of at least 10 millimetres.

[0231] The shreds of tobacco material may have a length of less than or equal to 40 millimetres. 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.

[0232] The aerosol-generating substrate may comprise a plurality of pellets or granules of tobacco material, such as homogenised tobacco material.

[0233] The aerosol-generating substrate may comprise one or more sheets of tobacco material, such as homogenised tobacco material. The one or more sheets of tobacco material may have been one or more of crimped, folded, gathered, and pleated. 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 moresheets of tobacco material becomes disrupted at the plurality of parallel ridges or corrugations causing separation of the material, and results in the formation of shreds of tobacco material.

[0234] The aerosol-generating substrate may comprise at least 150 milligrams, at least 200 milligrams, or at least 250 milligrams of aerosol-generating material, such as tobacco material.

[0235] The aerosol-generating substrate may comprise less than or equal to 400 milligrams, less than or equal to 350 milligrams, less than or equal to 300 milligrams of aerosol-generating material, such as tobacco material.

[0236] The aerosol-generating substrate may comprise between 150 milligrams and 400 milligrams, between 150 milligrams and 350 milligrams, or between 150 milligrams and 300 milligrams of aerosol-generating material, such as tobacco material. The aerosol-generating substrate may comprise between 200 milligrams and 400 milligrams, between 200 milligrams and 350 milligrams, or between 200 milligrams and 300 milligrams of aerosol-generating material. The aerosol-generating substrate may comprise between 250 milligrams and 400 milligrams, between 250 milligrams and 350 milligrams, or between 250 milligrams and 300 milligrams of aerosolgenerating material, such as tobacco material.

[0237] The amount of encapsulated flavourant and nonencapsulated described herein with an aerosol-generating substrate having the amount of aerosol-generating material described above may advantageously provide a desired sensory profile.

[0238] The aerosol-generating article may comprise a susceptor. As used herein, 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.

[0239] The susceptor 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 aerosolgenerating substrate.

[0240] The susceptor may be arranged within the aerosol-generating substrate.

[0241] The 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 susceptor may comprise a metal or carbon. The 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 susceptor may be, or comprise, aluminium.

[0242] The aerosol-generating article may comprise a downstream section located downstream of the aerosol-generating substrate. The downstream section may extend from the downstream end of the aerosol-generating substrate to the downstream end of the aerosol-generating article.

[0243] A length of the downstream section may be at least 20 millimetres, or at least 25 millimetres, or at least 30 millimetres. A length of the downstream section may be less than orequal to 70 millimetres, or less than or equal to 60 millimetres, or less than or equal to 50 millimetres.

[0244] The aerosol-generating article may comprise one or more elements provided downstream of the aerosol-generating substrate. Where present, the one or more elements located downstream of the aerosol-generating substrate may form the downstream section of the aerosolgenerating article. The one or more elements may be in an abutting end to end relationship with each other.

[0245] The aerosol-generating article may comprise a mouthpiece element located downstream of the aerosol-generating substrate. The mouthpiece element may be located at the downstream end or mouth end of the aerosol-generating article.

[0246] The mouthpiece element may be a mouthpiece filter element. The mouthpiece element may comprises 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.

[0247] Each of the at least one filter segments may be a solid plug. That is, each of the at least one filter segment may be non-tubular.

[0248] 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.

[0249] The mouthpiece element may comprise a flavourant, which may be provided in any suitable form. For example, the mouthpiece element may comprise one or more capsules, beads or granules of a flavourant, or one or more flavour loaded threads or filaments.

[0250] 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.

[0251] The mouthpiece element may have an RTD of at least 10 millimetres H2O. The mouthpiece element may have an RTD of less than or equal to 25 millimetres H2O, less than or equal to 20 millimetres H2O, or less than or equal to 15 millimetres H2O.

[0252] The mouthpiece element may have a length of at least 3 millimetres, or at least 5 millimetres. The length of the mouthpiece element may be less than or equal to 15 millimetres, less than or equal to 12 millimetres, or less than or equal to 9 millimetres. The length of the mouthpiece element may be selected based on a desired total length of the aerosol-generating article.

[0253] Preferably, the mouthpiece element has a substantially circular cross-section.

[0254] Preferably, the mouthpiece element has an external diameter that is substantially the same as the external diameter of the aerosol-generating substrate.

[0255] The mouthpiece element may be circumscribed by a plug wrap.The mouthpiece element may be unventilated such that air does not enter the aerosolgenerating article along the mouthpiece element.

[0256] The mouthpiece element may be connected to one or more adjacent components of the aerosol-generating article by means of a tipping wrapper.

[0257] 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.

[0258] 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.

[0259] The aerosol-generating article may comprise one or more intermediate elements between the aerosol-generating substrate and the mouthpiece element. The one or more intermediate elements may be in an abutting end to end relationship with each other.

[0260] One of the one or more intermediate elements may abut the downstream end of the aerosol-generating substrate. One of the one or more intermediate elements may abut the upstream end of the mouthpiece element. For example, where there is a single intermediate element, the single intermediate element may abut both the downstream end of the aerosolgenerating substrate and the upstream end of the mouthpiece element. For example, where there are a plurality of intermediate elements, one intermediate element may abut the downstream end of the aerosol-generating substrate and another intermediate element may abut the upstream end of the mouthpiece element.

[0261] At least one of the one or more intermediate elements may be a hollow tubular element. The one or more intermediate elements may be one or more hollow tubular elements.

[0262] As used herein, the term "hollow tubular element" is used to denote a generally cylindrical element having a lumen along a longitudinal axis thereof. The hollow tubular element 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 hollow tubular element.

[0263] In the context of the present disclosure, 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, 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 element, less than 0.4 mm H2O per 10 millimetres of length of the hollow tubular element, or less than 0.1 mm H2O per 10 millimetres of length of the hollow tubular element. The flow channel should therefore be free fromany components that would obstruct the flow of air in a longitudinal direction. Preferably, the flow channel is substantially empty.

[0264] The one or more intermediate elements may have a total length of at least 10 millimetres, at least 12 millimetres, or at least 15 millimetres. The one or more intermediate elements may have a total length of less than or equal to 30 millimetres, less than or equal to 25 millimetres, or less than or equal to 23 millimetres. The total length of the one or more intermediate elements may be selected based on a desired total length of the aerosol-generating article.

[0265] Where the aerosol-generating article comprises a single intermediate element, the total length of the one or more intermediate elements is the length of the single intermediate element. Where the aerosol-generating article comprises a plurality of intermediate elements, the total length of the one or more intermediate elements is the sum of the lengths of each of the plurality of intermediate elements.

[0266] Preferably, each of the one or more intermediate elements has a substantially circular cross-section. Preferably, the external diameter of each of the one or more intermediate elements is substantially the same as the external diameter of the aerosol-generating substrate.

[0267] The one or more intermediate elements may be formed from any suitable material or combination of materials. For example, at least one of the one or more intermediate elements 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.

[0268] The aerosol-generating article may comprise a ventilation zone. The aerosol-generating article may comprise a downstream section and a ventilation zone at location along the downstream section.

[0269] A ventilation zone may be provided at a location along the one or more intermediate elements. A satisfactory cooling of the stream of aerosol generated upon heating the aerosolgenerating substrate and drawn through the one or more intermediate elements may be achieved by providing a ventilation zone at a location along the one or more intermediate elements. Without wishing to be bound by theory, the temperature drop caused by the admission of cooler, external air into the one or more intermediate elements via the ventilation zone may have an advantageous effect on the nucleation and growth of aerosol particles.

[0270] A ventilation zone may be provided at a location along at least one of the one or more intermediate elements.

[0271] 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.Where the one or more intermediate elements are one or more hollow tubular elements, the ventilation zone may comprise a plurality of perforations through a tubular wall of at least one of the one or more hollow tubular elements.

[0272] The aerosol-generating article may comprise an upstream section upstream of the aerosol-generating substrate. The upstream section may extend from the upstream end of the aerosol-generating article to the upstream end of the aerosol-generating substrate.

[0273] The upstream section may comprise an upstream element. The provision of an upstream element upstream of the aerosol-generating substrate may advantageously prevent or reduce aerosol-generating material from being dislodged from the aerosol-generating substrate. Where the plurality of microencapsulated flavourant particles are located in the aerosol-generating substrate, the upstream element may advantageously prevent or reduce dislodgement of the microencapsulated flavourant particles.

[0274] The upstream element may be a solid plug. That is, the upstream element may be nontubular.

[0275] The upstream section may have a length of at least 3 millimetres, or at least 5 millimetres. The length of the upstream section may be less than or equal to 15 millimetres, less than or equal to 12 millimetres, or less than or equal to 9 millimetres. The length of the upstream section may be selected based on a desired total length of the aerosol-generating article.

[0276] The upstream section may comprise an upstream element. The upstream element may extend from the upstream end of the aerosol-generating article to the upstream end of the aerosolgenerating substrate.

[0277] The upstream element may have a length of at least 3 millimetres, or at least 5 millimetres. The length of the upstream element may be less than or equal to 15 millimetres, less than or equal to 12 millimetres, or less than or equal to 9 millimetres. The length of the upstream element may be selected based on a desired total length of the aerosol-generating article.

[0278] Preferably, the upstream element has a substantially circular cross-section.

[0279] Preferably, the upstream element has an external diameter that is substantially the same as the external diameter of the aerosol-generating substrate.

[0280] The upstream element may have a length of at least about 2 millimetres, or at least about 3 millimetres, or at least about 5 millimetres.

[0281] The upstream element may have a length of up to about 15 millimetres, or up to about 12 millimetres, or up to about 10 millimetres.

[0282] The aerosol-generating article may have a total length of at least 35 millimetres, at least 38 millimetres, at least 40 millimetres, or at least 42 millimetres. The aerosol-generating article may have a total length of less than or equal to 100 millimetres, less than or equal to 70 millimetres, less than or equal to 60 millimetres, or less than or equal to 50 millimetres.

[0283] Preferably, the aerosol-generating article has a substantially circular cross-section.The aerosol-generating article may have an external diameter of at least 5 millimetres, at least 6 millimetres, or at least 7 millimetres. The aerosol-generating article may have an external diameter of less than or equal to 12 millimetres, less than or equal to 10 millimetres, or less than or equal to 8 millimetres.

[0284] According to the third aspect of the present disclosure, there is provided an aerosolgenerating system comprising: an aerosol-generating article as described herein; and an aerosolgenerating 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. The aerosol-generating device may be configured to heat the plurality of microencapsulated flavourant particles of the aerosol-generating article.

[0285] The aerosol-generating device may be a handheld aerosol-generating device.

[0286] The aerosol-generating device may be an electrically-operated aerosol-generating device. The aerosol-generating device may comprise a power supply and control electronics. The aerosol-generating device may comprise a battery and control electronics.

[0287] The aerosol-generating device may be configured to externally heat the aerosolgenerating substrate of the aerosol-generating article. That is, the aerosol-generating device may be configured to heat the aerosol-generating substrate of the aerosol-generating article from an exterior of the aerosol-generating substrate of the aerosol-generating article.

[0288] The aerosol-generating device may comprise a heating element, for example an external heating element. The heating element may be located about a perimeter of the cavity.

[0289] The heating element may have substantially the same length as the aerosol-generating substrate of the aerosol-generating article. The aerosol-generating device may be configured such that when the aerosol-generating article is received within the cavity of the aerosolgenerating device, the aerosol-generating substrate of the aerosol-generating article is substantially aligned with the heating element of the aerosol-generating device.

[0290] The heating element may be one or both of a resistive heating element and an inductive heating element.

[0291] The aerosol-generating device may comprise a mouthpiece.

[0292] Each of the microencapsulated flavourant particles of the aerosol-generating article may be configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes from activation of the heating element of the aerosol-generating device.

[0293] Each of the microencapsulated flavourant particles of the aerosol-generating article may be configured to retain at least 60 percent by weight of the encapsulated flavourant until at least the fifth puff, preferably the sixth puff, on the aerosol-generating article.

[0294] 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, or embodiment, or aspect described herein.Example 1: An aerosol-generating article comprising: an aerosol-generating substrate comprising nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

[0295] Example 2: An aerosol-generating article according to example 1, wherein a total weight of encapsulated flavourant in the aerosol-generating article is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0296] Example 3: An aerosol-generating article according to example 1 or 2, wherein a weight of the encapsulated flavourant is less than or equal to 60 percent of the total weight of flavourant in the aerosol-generating article.

[0297] Example 4: An aerosol-generating article according to any preceding example, wherein the total weight of encapsulated flavourant in the aerosol-generating article is at least 0.2 milligrams.

[0298] Example 5: An aerosol-generating article according to any preceding example, wherein the total weight of encapsulated flavourant in the aerosol-generating article is less than or equal to 2.5 milligrams.

[0299] Example 6: An aerosol-generating article according to any preceding example, wherein the total weight of nonencapsulated flavourant in the aerosol-generating article is at least 2 milligrams.

[0300] Example 7: An aerosol-generating article according to any preceding example, wherein the total weight of nonencapsulated flavourant in the aerosol-generating article is less than or equal to 4.5 milligrams.

[0301] Example 8: An aerosol-generating article according to any preceding example, wherein the total weight of flavourant in the aerosol-generating article is at least 2.5 milligrams.

[0302] Example 9: An aerosol-generating article according to any preceding example, wherein the total weight of flavourant in the aerosol-generating article is less than or equal to 10 milligrams.

[0303] Example 10: An aerosol-generating article according to any preceding example, wherein the total weight of the microencapsulated flavourant particles in the aerosol-generating article is at least 1 milligram.

[0304] Example 11: An aerosol-generating article according to any preceding example, wherein the total weight of the microencapsulated flavourant particles in the aerosol-generating article is less than or equal to 30 milligrams.

[0305] Example 12: An aerosol-generating article according to any preceding example, wherein the aerosol-generating article comprises at least 10 microencapsulated flavourant particles.

[0306] Example 13: An aerosol-generating article according to any preceding example, wherein the aerosol-generating article may comprise less than or equal to 1000 microencapsulated flavourant particles.Example 14: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles has an average width of less than or equal to 500 micrometres.

[0307] Example 15: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles has an average width of at least 1 micrometre.

[0308] Example 16: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles have a width of less than or equal to 500 micrometres.

[0309] Example 17: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles have a width of at least 1 micrometre.

[0310] Example 18: An aerosol-generating article according to any preceding example, each of the microencapsulated flavourant particles comprises an inner core comprising the encapsulated flavourant contained within an outer shell of shell material.

[0311] Example 19: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprises the encapsulated flavourant dispersed within a shell matrix of shell material.

[0312] Example 20: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprises an inner core contained within an outer shell, wherein the inner core comprises the encapsulated flavourant dispersed within a shell matrix.

[0313] Example 20: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles are formed using a spray drying, coacervation, interfacial polymerization, spray granulation, or spray coating process.

[0314] Example 21: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles are formed using a coacervation process or an electrostatic spray drying process.

[0315] Example 22: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles have a water activity (Aw) of less than or equal to 0.5

[0316] Example 23: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprises a central region containing at least 90 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle.

[0317] Example 24: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprise at least 5 percent by weight of flavourant on a dry weight basis.Example 25: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprises less than or equal to 50 percent by weight of flavourant on a dry weight basis.

[0318] Example 26: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprises at least 10 percent by weight of shell material on a dry weight basis.

[0319] Example 27: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprises less than or equal to 35 percent by weight of shell material on a dry weight basis.

[0320] Example 28: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprises at least 50 percent by weight of shell material.

[0321] Example 29: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles comprises less than or equal to 90 percent by weight of shell material on a dry weight basis.

[0322] Example 30: An aerosol-generating article according to any preceding example, each of the microencapsulated flavourant particles is configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes when the microencapsulated flavourant particle is at a temperature of at least 100 degrees Celsius.

[0323] Example 31: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles is configured to release the encapsulated flavourant when the microencapsulated flavourant particle reaches a temperature above 100 degrees Celsius.

[0324] Example 32: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprises shell material having a melting point of at least 100 degrees Celsius.

[0325] Example 33: An aerosol-generating article according to any preceding example, wherein one or both of the nonencapsulated flavourant comprises: menthol, limonene, linalool, geraniol, vanillin, ethyl acetate, acetaldehyde, or combinations thereof.

[0326] Example 34: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprise less than or equal to 10 encapsulated flavourants.

[0327] Example 35: An aerosol-generating article according to any preceding example, wherein one or both of the nonencapsulated flavourant and the encapsulated flavourant have a boiling point of less than or equal to 300 degrees Celsius

[0328] Example 36: An aerosol-generating article according to any preceding example, wherein one or both of the nonencapsulated flavourant and the encapsulated flavourant have a vapour pressure of at least 0.05 mmHg at 20 degrees Celsius.Example 37: An aerosol-generating article according to any preceding example, wherein one or both of the nonencapsulated flavourant and the encapsulated flavourant have an enthalpy of vaporization of less than or equal to 150 kilojoules per mole.

[0329] Example 38: An aerosol-generating article according to any preceding example, wherein the encapsulated flavourant is in a solution.

[0330] Example 39: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles do not comprise medium chain triglycerides.

[0331] Example 40: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprises menthol and one or more encapsulated flavourants in a solution, and wherein the solution comprises at least 50 percent by weight of menthol.

[0332] Example 41: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles comprise limonene and one or more encapsulated flavourants in a solution, and wherein the solution comprises at least 50 percent by weight of menthol.

[0333] Example 42: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles are located within the aerosol-generating substrate.

[0334] Example 43: An aerosol-generating article according to any preceding example, wherein the plurality of microencapsulated flavourant particles is dispersed within the aerosol-generating substrate.

[0335] Example 44: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles have one or more aerosol formers disposed on at least a part of the external surface of the microencapsulated flavourant particle.

[0336] Example 45: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles have propylene glycol disposed on at least a part of the external surface of the microencapsulated flavourant particle.

[0337] Example 46: An aerosol-generating article according to any preceding example, comprising an upstream element located upstream of the aerosol-generating substrate.

[0338] Example 47: An aerosol-generating article according to any preceding example, wherein the aerosol-generating substrate comprises aerosol-generating material.

[0339] Example 48: An aerosol-generating article according to example 47, wherein the aerosolgenerating material comprises tobacco material, such as homogenised tobacco material.

[0340] Example 49: An aerosol-generating article according to any preceding example, wherein the nonencapsulated flavourant is a non-tobacco nonencapsulated flavourant.Example 50: An aerosol-generating article according to any preceding example, wherein a total weight of encapsulated flavourant in the aerosol-generating article is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0341] Example 51 : An aerosol-generating article according to any preceding example, wherein the encapsulated flavourant has a boiling point of at least 40 degrees Celsius, and wherein a total weight of flavourant having a boiling point of at least 40 degrees Celsius is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0342] Example 52: An aerosol-generating article according to any preceding example, wherein the encapsulated flavourant has a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius, and wherein a total weight of flavourant having a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0343] Example 53: An aerosol-generating article according to any preceding example, wherein the encapsulated flavourant has an enthalpy of vaporization of at least 10 kilojoules per mole, and wherein a total weight of flavourant having an enthalpy of vaporization of at least 10 kilojoules per mole is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

[0344] Example 54: An aerosol-generating article according to any preceding example, wherein each of the microencapsulated flavourant particles has a width of less than or equal to 500 micrometres.

[0345] Example 55: An aerosol-generating system comprising: an aerosol-generating article according to any preceding example; and an aerosol-generating device configured to heat the aerosol-generating substrate of the aerosol-generating article.

[0346] Example 56: An aerosol-generating system according to example 55, wherein the device comprises a heating element, and wherein each of the microencapsulated flavourant particles of the aerosol-generating article is configured to retain at least 60 percent by weight of the encapsulated flavourant for at least three minutes from activation of the heating element of the aerosol-generating device.

[0347] The present disclosure will be further described, by way of example only, with reference to the accompanying drawings in which:

[0348] Figure 1 shows a schematic side-sectional view of an aerosol-generating article; and Figures 2A, 2B, 2C, and 2D show a schematic sectional view of different examples of microencapsulated flavourant particles.

[0349] Figure 1 shows an aerosol-generating article 10 having an upstream end 12 and a downstream end 14. The aerosol-generating article 10 comprises an aerosol-generating substrate 16 and an upstream element 18 located upstream of the aerosol-generating substrate 16. As shown in Figure 1, a downstream end of the upstream element 18 abuts an upstream end of the aerosol-generating substrate 16. The aerosol-generating article 10 further comprises a hollow tubular element 20 located downstream of the aerosol-generating substrate 16, and amouthpiece element 22 downstream of the hollow tubular element 20. The upstream end 12 of the aerosol-generating article 10 corresponds to the upstream end of the upstream element 18. The downstream end 14 of the aerosol-generating article 10 corresponds to a downstream end of the mouthpiece element 22.

[0350] The aerosol-generating article 10 has a total length of about 45 millimetres and an external diameter of about 7.1 millimetres.

[0351] The aerosol-generating substrate 16 comprises one or more sheets of homogenised tobacco material and propylene glycol. The aerosol-generating substrate 16 also comprises nonencapsulated flavourant applied to the one or more sheets of homogenised tobacco material. The aerosol-generating substrate 16 also comprises a plurality of microencapsulated flavourant particles comprising encapsulated flavourant, wherein the plurality of microencapsulated flavourant particles is dispersed within the aerosol-generating substrate.

[0352] In this example, a ratio of the weight of the encapsulated flavourant to the total weight of flavourant in the aerosol-generating article is at least 10 percent on a dry weight basis.

[0353] Each of the microencapsulated flavourant particles has a width or diameter of less than or equal to 200 micrometres.

[0354] Both the nonencapsulated flavourant and the plurality of microencapsulated flavourant particles were applied to the one or more sheets of homogenised tobacco material with propylene glycol in a spraying process prior to combining of the one or more sheets of homogenised tobacco material to form the aerosol-generating substrate. The nonencapsulated flavourant was dissolved in the propylene glycol, and the plurality of microencapsulated flavourant was in a suspension with the propylene glycol, and the combination of the propylene glycol, nonencapsulated flavourant and plurality of microencapsulated flavourant was applied to the one or more sheets of homogenised tobacco material.

[0355] Each of the plurality of microencapsulated flavourant particles has propylene glycol disposed on at least a part of the external surface of the microencapsulated flavourant particle.

[0356] The hollow tubular element 20 is a hollow cylindrical tube made of cardboard. The hollow cylindrical tube defines an internal cavity that extends from an upstream end of the hollow tubular element 20 to a downstream end of the hollow tubular element 20. The internal cavity of the hollow tubular element 20 is substantially empty, and so substantially unrestricted airflow is enabled along the internal cavity of the hollow tubular element 20. The hollow tubular element 20 does not substantially contribute to the overall RTD of the aerosol-generating article 10.

[0357] The hollow tubular element 20 has a length of about 21 millimetres, an external diameter of about 7.1 millimetres, and an internal diameter of about 6.7 millimetres. Thus, a thickness of a tubular wall of the hollow tubular element 20 is about 0.2 millimetres.

[0358] The aerosol-generating article 10 comprises a ventilation zone at a location along the hollow tubular element. The ventilation zone comprises a circumferential row of perforations 24 extending through the tubular wall of the hollow tubular element 20, in order to allow air flow intothe internal cavity of the hollow tubular element 20 from the exterior of the aerosol-generating article 10.

[0359] An upstream end of the mouthpiece element 22 abuts from a downstream end of the hollow tubular element 20. The mouthpiece element 22 has a length of about 7 mm and an external diameter of about 7.1 mm. The mouthpiece element 22 comprises a segment of low-density, cellulose acetate tow circumscribed by a plug wrap (not shown).

[0360] As shown in Figure 1, the aerosol-generating article 10 comprises an upstream wrapper 26 circumscribing the upstream element 18, the aerosol-generating substrate 16 and the hollow tubular element 20. The ventilation zone comprises a circumferential row of perforations 28 extending through the upstream wrapper 26. The circumferential row of perforations 28 extending through the upstream wrapper 26 overlies the circumferential row of perforations 24 extending through the tubular wall of the hollow tubular element 20.

[0361] The aerosol-generating article 10 further comprises a downstream tipping wrapper 30 circumscribing the hollow tubular element 20 and the mouthpiece element 22. The tipping wrapper 30 overlies the portion of the upstream wrapper 26 that overlies the hollow tubular element 20. This way the tipping wrapper 30 effectively joins the mouthpiece element 22 to the other components of the aerosol-generating article 10. The ventilation zone may comprise a circumferential row of perforations (not shown) extending through the tipping wrapper 30. The circumferential row of perforations extending through the tipping wrapper 30 may overlie the circumferential row of perforations 28 extending through the upstream wrapper 26 and the circumferential row of perforations 24 extending through the tubular wall of the hollow tubular element 20.

[0362] In Figure 1, the upstream wrapper 26 and the downstream tipping wrapper 30 of the aerosol-generating article 10 are shown partially unwrapped in order to show the upstream element 18, the aerosol-generating substrate 16 and the hollow tubular element 20 of the aerosolgenerating article 10.

[0363] Each of the plurality of microencapsulated flavourant particles may have the structure of one of the microencapsulated flavourant particles shown in Figures 2A to 2D.

[0364] Figure 2A shows a microencapsulated flavourant particle 40 having a core-shell structure. The microencapsulated flavourant particle 40 comprises an outer shell 42 enclosing an inner core 46. The inner core 46 comprises the encapsulated flavourant in a solution.

[0365] Figure 2B shows a microencapsulated flavourant particle 50 having a matrix-type structure. The microencapsulated flavourant particle 50 comprises a shell matrix 54 and a plurality of vesicles 56 comprising the encapsulated flavourant.

[0366] Figure 2C shows a microencapsulated flavourant particle670 having a hybrid structure. The microencapsulated flavourant particle 60 has an outer shell 62 enclosing an inner core 63. The inner core 63 comprises a shell matrix 64 and a plurality of vesicles 66 comprising the encapsulated flavourant. The shell matrix 64 and the outer shell 62 are formed from the sameshell material. The microencapsulated flavourant particle 60 has a central region containing at least 90 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle 60, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle 60. The microencapsulated flavourant particle 60 shown in Figure 2C may have been formed by a electrostatic spray drying process.

[0367] Figure 2D shows a microencapsulated flavourant particle 70 having a hybrid structure. The microencapsulated flavourant particle 70 has an outer shell 72 enclosing an inner core 74. The inner core 74 has the same structure as the microencapsulated flavourant particle 50 shown in Figure 2B. The microencapsulated particle 70 may have been formed by applying a coating, such as through a spray coating process, to the microencapsulated flavourant particle 50 shown in Figure 2B.

[0368] Figure 2E shows a microencapsulated flavourant particle 80 having a hybrid structure. The microencapsulated flavourant particle 80 has an outer shell 82 enclosing an inner core 84. The inner core 84 has a matrix-type structure and comprises a shell matrix 85 and a plurality of vesicles 86 dispersed and trapped within the shell matrix 85. The microencapsulated flavourant particle 80 has an irregular shape. The vesicles 86 may have different shapes and sizes.

[0369] The specific embodiments and examples described above illustrate, but do not limit, the invention. It is to be understood that other embodiments of the invention may be made and the specific embodiments and examples described herein are not exhaustive.

Claims

CLAIMS:

1. An aerosol-generating article comprising: an aerosol-generating substrate comprising aerosol-generating material and nonencapsulated flavourant; and a plurality of microencapsulated flavourant particles comprising encapsulated flavourant.

2. An aerosol-generating article according to claim 1, wherein the plurality of microencapsulated flavourant particles are dispersed within the aerosol-generating substrate.

3. An aerosol-generating article according to claim 1 or 2, wherein a total weight of encapsulated flavourant in the aerosol-generating article is less than or equal to 60 percent of the total weight of flavourant in the aerosol-generating article.

4. An aerosol-generating article according to any preceding claim, wherein the plurality of the microencapsulated flavourant particles have an average width of less than or equal to 500 micrometres.

5. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises an inner core comprising the encapsulated flavourant contained within an outer shell.

6. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises the encapsulated flavourant dispersed within a shell matrix.

7. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises an inner core contained within an outer shell, and wherein the inner core comprises the encapsulated flavourant dispersed within a shell matrix.

8. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises a central region containing at least 90 percent by weight of the encapsulated flavourant in the microencapsulated flavourant particle, wherein the central region has a volume of less than or equal to 80 percent of the volume of the microencapsulated flavourant particle,9. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises shell material, and wherein the shell material has a melting point of at least 100 degrees Celsius.

10. An aerosol-generating article according to any preceding claim, wherein the total weight of encapsulated flavourant in the plurality of microencapsulated flavourant particles is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

11. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles have one or more aerosol formers disposed on at least a part of the external surface of the microencapsulated flavourant particle.

12. An aerosol-generating article according to any preceding claim, wherein the encapsulated flavourant has a boiling point of less than or equal to 300 degrees Celsius.

13. An aerosol-generating article according to preceding claim, wherein the encapsulated flavourant has a vapour pressure of at least 0.05 mmHg at 20 degrees Celsius.

14. An aerosol-generating article according to any preceding claim, wherein the encapsulated flavourant has an enthalpy of vaporization of less than or equal to 150 kilojoules per mole.

15. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles comprises menthol and one or more encapsulated flavourants in a solution, and wherein the solution comprises at least 50 percent by weight of menthol.

16. An aerosol-generating article according to any preceding claim, wherein a total weight of encapsulated flavourant in the aerosol-generating article is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

17. An aerosol-generating article according to any preceding claim, wherein the encapsulated flavourant has a boiling point of at least 40 degrees Celsius, and wherein a total weight of flavourant having a boiling point of at least 40 degrees Celsius is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

18. An aerosol-generating article according to any preceding claim, wherein the encapsulated flavourant has a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius, and wherein a total weight of flavourant having a vapour pressure of at least 0.5 mmHg at 20 degrees Celsius is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

19. An aerosol-generating article according to any preceding claim, wherein the encapsulated flavourant has an enthalpy of vaporization of at least 10 kilojoules per mole, and wherein a total weight of flavourant having an enthalpy of vaporization of at least 10 kilojoules per mole is at least 10 percent of the total weight of flavourant in the aerosol-generating article.

20. An aerosol-generating article according to any preceding claim, wherein each of the microencapsulated flavourant particles has a width of less than or equal to 500 micrometres.

Images